High Voltage Coil Winding Machine for Power Transformers 

Model: ZD-GY880 

Core Positioning  

Designed for compact coil production in small/medium distribution transformers and similar applications. Achieves 20-30% volume reduction and 15-25% weight reduction in coils, lowering material costs and operational losses. Optimized insulation layout increases operational speed by 40% and reduces production interruptions by 60%, significantly boosting efficiency. 

Technical Advantages 

1.  Global Technology Integration 

   - German dynamic tension feedback system (±1.5N fluctuation) 

   - Taiwan high-precision pneumatic actuators (0-0.6MPa pressure regulation) 

   - China-made custom servo drives (7.5-11kW power range) 

2. Automated Production 

   - One-touch process switching via proprietary programming platform 

   - Auto layer insulation alignment 

HV Coil Structural Features 

1. Layered Winding Process 

   - Aluminum/copper conductors wound in layers with interlayer insulation paper 

   - Dynamic adjustment of insulation paper tension and thickness 

2. Traditional vs. Upgraded Process 

   - Manual insulation → No tension control 

   - Fixed insulation thickness → No gradient optimization 

   - Single-layer insulation → Limited multi-layer compatibility 

3. Process Value 

   - Voltage gradient-adaptive insulation matching 

   - ~20% insulation paper utilization improvement 

   - ~30% reduction in partial discharge 

Key Components 

1. Main Winding Unit 

- Structure: 

  - Heavy-duty welded steel enclosure (stress-relieved annealing) 

  - High-power servo motor + large-module helical gear reducer (hardened gears) 

- Performance: 

  - Full torque coverage (high torque at low speed/high-speed adaptability) 

  - Optimized acceleration/deceleration slopes with braking 

  - HMI preset parameters for fully automated control 

2. Auto Wire Alignment Unit 

- Material: CNC-machined 6061-T6 aerospace-grade aluminum (anti-deformation) 

- Features: 

  - Tension control/buffer/feedback system 

  - Integrated round/flat wire guidance + round wire flattening 

3. Layer Insulation Unit 

- Material: CNC-machined 6061-T6 aerospace-grade aluminum 

- Functions: 

  - Strip insulation auto-feeding system 

  - Synchronized end insulation filling 

  - Closed-loop tension control (0-10V feedback) 

4. Round Wire Pay-Off 

- Safety: Acrylic protective cover 

- Efficiency: 

  - Dual mobile wire spool carts (fast material changeover) 

  - Guided wire oscillation range 

5. Enameled/Paper-Covered Flat Wire Pay-Off 

- Precision: 

  - Servo constant-tension system 

  - Linear guide synchronization 

6. End Insulation Unit 

- Dual-side design: 2 sets per side 

- Features: 

  - Adjustable tape tension (mechanical screw locking) 

  - End insulation thickness synchronized with coil 

7. Main Frame & Base 

- Robust structure: Reinforced profiles + bolt-fixed anti-shift design 

- Integration: 

  - Dual-level guidance system 

  - Modular pneumatic piping 

8. Safety Door 

- Construction: Aluminum frame + acrylic panels 

- Compliance: CE Machinery Safety Directive compliant 

9. Universal Winding Mold 

- Innovation: 

  - Cost-saving universal design 

  - Quick-change structure 

10. Electrical Control System 

- Smart features: 

  - Proprietary HMI programming platform 

  - Batch parameter presets (cloud data compatible) 

  - Full-range emergency stops 

11. Pneumatic System 

- Low-noise: Modular silencers 

- Flexibility: Independent pressure/flow regulation 

Technical Highlights 

1. Precision Assurance: 

   - Axial winding tolerance: ≤0.3mm 

   - End insulation sync error: <0.5mm 

2. High Productivity: 

   - 60% faster material changeover (mobile spool carts) 

   - 72-hour continuous operation validated 

3. Versatility:  

   - Supports round wire (Φ0.5-3.5mm) / flat wire (4×16mm) 

   - Compatible with Cu/Al conductors 

Coil Processing Range   

1.1 Center Height: 900mm 

1.2 Axial Length: 800mm 

1.3 Max Outer Diameter: Ø800mm 

1.4 Min Inner Diameter: Ø160mm 

1.5 Workpiece Load Capacity: 500Kg 

1.6 Coil Type: Circular/Rectangular/Oval 

1.7 Material: Copper Wire/Aluminum Wire 

1.8 Conductor Specifications  

-  Enameled Round Wire: 0.37-3.5mm 

-  Round Wire Flattening: <20% 

-  Enameled Flat Wire: 4×12mm 

Winding Machine   

2.1 Working Torque: >800N·m 

2.2 Winding Power: 11KW 

2.3 Speed Regulation: Servo Stepless + Auto Speed Control 

2.4 Universal Winding Mold: 80(W)×140(H)×620(L)mm 

2.5 Winding Speed: 0-350r/min 

2.6 Winding Mode: Automatic/Semi-automatic 

Layer Insulation Device (Expansion Type)  

3.1 Insulation Layer Outer Diameter: <450mm 

3.2 Insulation Layer Inner Diameter: Ø76mm 

3.3 Working Torque: 1-100N·m 

3.4 Working Pressure: 0-0.6MPa 0-10V System Feedback Auto-regulation 

3.5 Insulation Layer Width: 12-30mm 

Automatic Alignment Function  

4.1 Max Preset Turns: 9999.9 

4.2 Min Wire Spacing Adjustment: 0.01mm 

4.3 Counting Method  

-  5-digit display 

-  Total turns & 20-segment preset 

-  Reversible counting 

-  Power-off memory 

4.4 Alignment Range: 0-800mm 

4.5 Constant Tension Servo: 2×3KW 

4.6 Tension Feedback System  

-  0-0.6MPa 0-10V 20-220N (Imported from Germany) 

-  0-0.6MPa 0-10V 5-30N (Imported from Germany) 

4.7 Auto Alignment Tracking System: 0.75KW Servo Motor 

Flat Wire Uncoiler (Synchronized with Alignment)  

5.1 Inner Diameter: Ø36mm 

5.2 Outer Diameter: Ø700mm 

5.3 Servo Motor Power: 5.5KW 

5.4 Effective Length: 800mm 

5.5 Load Capacity: 500Kg 

5.6 Tension Feedback System: 0-0.6MPa 0-10V 500N (Imported from Germany) 

6 Control System: HMI Automatic Control 

7 Power Supply: 380V/50Hz 3-phase 5-wire 

8 Appearance: RAL5012 Light Blue (Customizable) 

9 Dimensions: 6000(L)×2500(W)×2300(H)mm 

10 Weight: Approx. 3000Kg