Motorized Tension Foil Winding Machine 

Model: BRJ-1600-Ⅱ (Latest Version) 

Core Positioning 

Upgraded with EU/US design concepts, this essential equipment is engineered for precision foil coil production in transformers and electrical industries. Supports single/double-layer winding and parallel winding processes, compatible with full specifications of 0.1-3.0mm Cu/Al foils for integrated HV/LV production. 

Core Advantages 

1. Smart Tension Control 

   - Servo tension system ensures balanced tension for large/small rolls 

   - Non-contact photoelectric alignment (±0.3mm accuracy) 

   - Hydraulic adaptive uncoiling with one-touch expansion 

2. Full-Process Integration 

   - Single-machine operation: foil winding, lead welding, surface wrapping 

   - Dual-station hydraulic uncoiler for composite winding 

   - Seamless material path improves threading efficiency 

3. Optimized HMI 

   - Touchscreen displays real-time parameters & fault history 

   - 100+ process parameter storage/retrieval 

   - Integrated solenoid valve control 

Key Features 

- Precision Winding: Triple-axis control for axial/radial tightness 

- Smart Welding: Auto-positioning for left/right winding copper busbars 

- Convenience: Electric unloading cart, waste paper recycling, one-touch layer insulation 

- Safety: Emergency stop + overload warning 

Process Assurance 

- Coil DC resistance consistency meets design standards 

- Compatible with 0.1-3.0mm Cu/Al foils 

Technical Specifications 

Coil Processing Range 

- Axial Length: 1600mm 

- Axial Length (with leads): 2100mm 

- Outer Diameter (with leads): Φ1500mm 

- Outer Diameter (bare): Φ900mm 

- Min Inner Diameter: Φ100mm 

- Lead Extension Length: 400mm (left/right) 

- Coil Shapes: Round/Rectangular/Oval 

Coil Materials 

- Material: Cu/Al foil 

- Width: 400-1600mm 

- Thickness: Cu: 0.3-2.0mm (max 1.8+1.8mm layered); Al: 0.5-2.5mm (max 2.5+2.5mm layered) 

Two Uncoilers 

- Material Core ID: Φ480/500mm 

- Material Core OD: Φ1000mm 

- Drum Effective Length: 1600mm 

- Drum Expansion Range: Φ460-520mm 

- Load Capacity: 5000kg 

- Max Tension: 12,000N 

- Tension Control: Electric adjustable 

- Motor Power: 11kW (asynchronous servo) 

- Features: Forward/reverse tension retention 

- Drum Expansion: Hydraulic one-touch 

- Additional Features: Magnetic powder tension waste paper recovery; Rubber roller manual feeding 

Winding Machine 

-Working Torque: >16,000N·m 

- Power: 30kW (asynchronous servo) 

- Speed Control: Variable-frequency stepless 

- Winding Shaft: 60×60×2100mm (customizable) 

- Winding Speed: 0-20r/min 

Automatic Welding 

- Method: TIG 

- Speed: 0-1m/min (variable frequency) 

- Lead Direction: Left/right 

- Welding Clamp: 320mm×5=1600mm modular (replaceable) 

- Clamp Fixing: Pneumatic 

- Motor Power: 0.37kW 

Two Automatic Cutters 

- Mechanism: Lead screw disc cutter 

- Speed: 1.5m/min 

- Cutting Length: 1600mm 

- Lateral Movement: 0-40mm 

- Blade Life: 100,000 cycles 

- Motor Power: 0.75kW 

Two Pneumatic Layer Insulation Devices 

- Insulation OD: <400mm 

- Insulation ID: 76mm 

- Working Torque: 400N 

- Operation: Electric tension stepless adjustment 

- Motor Power: 1.5kW 

- Shaft Length: 1700mm 

- Alignment: Electric/manual 

- Alignment Motor Power: 0.37kW 

- Design: Frame structure with single movement; (One-touch electric forward/retract, no external rails) 

- Feature: Forward/reverse tension retention 

End Insulation Devices 

- Quantity: 12 sets (6 left/6 right, customizable) 

- Insulation OD: <300mm 

- Insulation ID: 56mm 

- Width: 5-60mm (supports multiple end rings) 

- Guide Frames: 2 sets (left/right) 

- Movement: Linear rail tracking 

- Range: 300-1600mm 

- Feature: Integrated loading ladder (space-saving) 

Two Front Foil Tension Devices 

- Max Tension: 1500N 

- Operation: Electric tension stepless adjustment 

- Motor Power: 1.5kW 

Control System 

- Display: 10.1" HMI (touchscreen) 

- Control: PLC automation + button operation 

- Counting Accuracy: 0.1 turn (0-999.9) 

- Storage: 100 preset profiles + power-off memory 

Auto Alignment 

- Method: Photoelectric edge detection 

- Accuracy: ±0.3mm 

- Range: 200mm center ±100mm 

- Motor: Servo linear motor, 0.75kW 

- Appearance: RAL5012 Light Blue (customizable) 

- Dimensions: 6850×5990×3000mm 

- Power Supply: 65kW (380V 50Hz 3-phase 5-wire) 

- Air Consumption: 0.2m³/min @0.6MPa