High-speed transformer winding machine

       In power transmission and power supply systems such as power plants and substations, voltage transformers are an indispensable electrical appliance. The voltage transformer for measurement specifies the accuracy level of the voltage transformer according to the error generated when the voltage is changed. Voltage transformers of level 0. 2 and above are generally called precision voltage transformers, which are mainly used in the laboratory to expand the measurement limit with the standard meter for precise measurement of voltage, power and electrical energy; or as a standard to check low standards, Low-accuracy voltage transformer; it can also be used with standard meters to test the corresponding meters.

       With the rapid development of science and technology and electronic application technology, the requirements for technical indicators such as the rated primary voltage and accuracy of voltage transformers are getting higher and higher, and the demand for various types of voltage transformers is increasing. In the past, voltage transformers were mostly manually wound with annular iron cores and thick enameled wires. The products were large and heavy. In the daily winding, processing and production process, the degree of mechanization was not high, the labor intensity of workers was high, and the production efficiency was low. It is necessary to improve the voltage transformer design process and develop a new type of mechanical equipment for winding the voltage transformer.

 REPOSAL® precision winding machine

Precision C-shaped coil winding machine

Precision large torque winding machine:

       With the continuous improvement of the technical level, people have more and more stringent requirements on the winding of transformer coils, hoping that each enameled wire can be like

The ideal sorted arrangement has the following benefits.

       First, in the case of neat arrangement, the enameled wire with limited space accounts for a much larger proportion than the irregular arrangement

       The second is the wire saving.To achieve the same energy density, less neatly arranged copper wire is consumed than if it is neatly arranged.

        The third is the consistency of the product, because the neat wiring, so the copper consumed by each coil is more consistent.

        Of course, there are advantages of heat dissipation and high temperature resistance.

        Despite the above advantages, but for a long time, it was thought that the equipment manufacturers were powerless, and it was difficult for people to do it smoothly with machines.When there is such a requirement, people usually use manual processing.

        Wire the cable by hand, hit an irregular place, stop, handle it manually, and then slowly wind it.For a long time, people have done this.

        Now all this has changed. We have successfully developed a  precision large torque winding machine . Through control and mechanical optimization, we have done so.

        It takes a long time, but now only a simple training is required.The precision large torque winding machine makes what was impossible before possible.

      This article introduces the test of designing tension control system to minimize the change of tension. Perform theoretical analysis on simulation. The simulation results show that the tension of the enameled wire is frequently fluctuated due to the length change caused by the speed change. The model's tension sensor verifies the prediction. The key to successful design is to eliminate changes in tension. We added a tension system that includes a high-speed cylinder to replace the traditional wool felt and spring mechanism. The simulation results showed that the new prototype system almost doubled the winding speed and the ability to withstand tension fluctuations.

Keywords: tension control, winding machine, rectangular coil, precision winding machine.

One. introduction

      Countless transformers are produced every year. Together with power plants, substations and power lines, distribution transformers provide electricity for businesses and residential buildings across the country. Transformer manufacturing involves the production of winding coils. These coils are usually made of an insulating paper layer sandwiched between a pair of copper wires. They are usually round or rectangular.

      A consistent tension must be maintained on the coil windings. The shape of the coil has a major influence on the tension applied by the tension. For a circular coil, the tension does not change significantly, but a rectangular coil is different. As a rectangular coil, the tension changes sharply with the position of the drop point. As shown in the figure, this change in speed is caused by the changing length of the line. In the case of a round coil, this is not a problem, because the contact points of the wires on the coil are fixed.

Precision hollow coil winding machine