Distribution Transformer Foil Winding Machine

(1) Scope of application
It is a kind of multifunctional automatic winding equipment specially for the winding of amorphous triangular coiling core transformer. It is suitable for the production of 50KVA-630KVA amorphous (silicon steel) triangular coiling core transformer low-voltage foil coil and high-voltage coil, and can also be wound flat high-low voltage coil through simple assembly, so as to achieve a multi-purpose machine.
(2) The integrated machine technology innovation for the characteristics of amorphous three-dimensional coil core uses amorphous alloys with outstanding magnetic permeability to be used as core materials for the manufacture of transformers, and ultimately can obtain very low loss values. However, it has many characteristics, which must be guaranteed and considered in the design and manufacturing, and a very key point is that amorphous alloys are very sensitive to mechanical stress. Compared with the silicon steel three-dimensional coil core has a clear difference, it is necessary to have new breakthroughs in key equipment.

Non-contact core winding technology
In the structural design, the traditional design scheme with iron core as the main bearing structure must be avoided. The conventional low-pressure foil coil is based on the iron core as the skeleton, and the slide rail of the winding gear die is bolted to the iron core, so that the iron core can fully withstand the mechanical stress generated in the winding process. The amorphous core is very sensitive to external stress based on the material characteristics, and the vibration during the winding process will have a great impact on the performance of the core, which will lead to a doubling of the loss and a rising risk of short circuit. This all-in machine of our company creatively uses the mechanism of the gear die suspended in the core. Although the coil surrounds the core during the winding process, it does not touch the core, so it will not have any impact on the performance of the core, so the coil production has zero impact on the performance of the core.

High and low pressure dual-use integration technology
Conventional coil production method requires two equipment with different functions, first install the core clamp to the foil winding machine, after winding the low-voltage foil coil, then move the semi-finished product to the high-voltage winding machine to re-clamp the installation and winding of the high-voltage coil, and use one manual, five times back and forth to wind a coil, the whole process is not only time-consuming and laborious. It also affects the performance of the core. The high and low voltage dual-use integrated equipment developed by our company has a high degree of integration, winding the low voltage foil coil followed by the high voltage coil until the three high and low voltage coils of a transformer are all wound. The two core processes of low-voltage foil winding and high-voltage wire winding can be completed in the same equipment by only one clamping.
Automatic winding technology (including round wire flattening)

Because the triangular three-dimensional coil core is closed, the coil needs to be wound with an iron core, so the degree of automation is required as high as possible, and only in this way can the production efficiency be improved. The equipment developed by our company uses more than 20 sets of full-digital high-performance servo systems and a large number of intelligent sensors to achieve core motion control, foil/cable motion control, monitoring and remote digital operation and maintenance functions. Among them, core motion control mainly includes core 120° automatic transposition, core horizontal/vertical position following and other core function algorithms; The foil/cable motion control mainly includes automatic wiring function, round wire flattening function, high pressure flat wire servo constant torque rising force holding function, foil frame hydraulic self-locking function and other tension control functions. Monitoring and remote digital operation and maintenance functions mainly include four-station video monitoring system, remote communication and remote control functions, MES digital interface, etc. The automatic high and low voltage winding machine effectively improves the consistency and production efficiency of the product, and also provides a rich HMI and data interface, which provides convenience for the subsequent equipment remote operation and maintenance and digital factory, and is the best choice for non-crystal three-dimensional coiling transformer winding equipment.

Monitoring and remote digital operation and maintenance technology
The equipment has monitoring and remote digital operation and maintenance functions, including four-station video monitoring system, remote communication and remote control functions, MES digital interface and other functions. The collected data can immediately obtain the factory production monitoring and equipment abnormal alarm information, including real-time view of the running status of the production line and output information, to achieve real-time monitoring of the production status of the equipment. In addition, the factory manager can remotely view the production status through the computer, ensuring that the real-time operation of the equipment is monitored and managed.
In addition to obtaining production information, device anomaly monitoring can also be implemented through device networking. After networking, through the Internet of Things technology means, the standard parameter data of the equipment can be monitored, abnormal data exceeding the standard range will be warned, and the manager will obtain abnormal early warning notification through the computer side, so as to avoid production losses caused by unexpected failures.