Choosing the right transformer winding equipment is the key to the production of high performance transformers. According to different needs, the transformer winding machine can be divided into the following types:
1.Automatic winding machine
Automatic winding machine is a special equipment for winding high voltage coil of distribution transformer. The coil made by this equipment has compact structure, small volume and high strength. In order to further improve the production efficiency, the main speed of the new winding machine is increased from 300rad/min to 500rad/min. The wiring mechanism is increased from a single head to two or three heads, that is, three coils can be wound at the same time. At the same time, multiple wires (Z more than 4) are used and wound; Adding radial pressing mechanism; The tension of each laying coil is controlled independently, so that the winding wires are arranged neatly, the turns are tight and uniform, and the current density is evenly distributed. At the same time with the end of the insulation unwinding mechanism, wire tensioning mechanism, the computer can be set a variety of parameters, can make the coil winding a complete, greatly improve the degree of automation, reduce the labor intensity of workers.
2.Foil coil winding machine
Foil coil winding machine is the key equipment for winding low-voltage foil coil. Tension control and foil correction are the key techniques of foil coil winding machine. The foil tension of the existing domestic or imported foil coil winding machine is generated by mechanical friction, and its tension is not stable enough, which will lead to the defects such as uneven coil tightness, inconsistent DC resistance between the coils, and abnormal outer diameter of the coils.
Domestic manufacturers have developed a new digital foil winding machine, the machine uses DC motor to produce foil tension, which is characterized by convenient tension adjustment, accurate, good stability, the whole process of winding tension remains unchanged, so as to ensure the winding quality of the coil. Especially its wide tension adjustment range, more suitable for thin foil belt winding, will not cause damage to the end of the foil belt. In addition, the tension motor is in the power generation state when it is in the tension state, and the electricity generated can be fed back to the winding motor or the power grid. The friction energy consumption of friction-free braking tension mode is significant in energy saving. Moreover, the control system will automatically calculate the coil diameter of the uncoiling machine, so as to adjust the output torque of the motor at any time, to ensure the constant tension in the whole winding process, which plays a key role in ensuring the quality of the coil. At the same time, the deviation adjustment system of the equipment adopts photoelectric analog quantity sensor non-contact detection of foil edge, and dynamic deviation correction by servo motor. The system has high precision, fast response, high reliability and high deviation adjustment precision. According to the available data, the equipment technology has been in the world's leading level.
3.Vertical winding machine
The larger the capacity of transformers in use now, the greater the impact on the grid, and the requirements for their safety are increasingly high. The manufacturing quality performance of the transformer requires not only reliable electrical performance, but also more reliable mechanical stability and short-circuit resistance. The stability is mainly reflected in the coil manufacturing process control, that is, high and low voltage coil electromagnetic balance, tight axial turns, uniform distribution. Therefore, the coil winding process is required to press axial, radial to roll tight, vertical winding machine just use the weight of the wire cake, axial natural compression, radial tensioning device to control the tension size. So now the winding of high voltage coil in large transformer is generally used vertical winding machine, even the low voltage spiral coil also uses vertical winding machine production.
The current vertical winding machine has been further developed to large scale. The weight of the original vertical winding airborne is only 20t, now it has been increased to 40t, the diameter of the coil Z is 3500mm, and the maximum height of Z is 4000mm. The use of air bag plate tensioning device, and the digital display of tension, tension control is more accurate, stable and reliable. In order to improve the dimension accuracy of the winding coil and control the radial runout of the vertical winding machine, a fixed device for the shaft head of the winding die is added. In order to control the axial runout, high precision double row roller type large bearings are used. Therefore, through the use of coil winding special equipment, the winding production to a new level. So that the transformer further reduce the loss, reduce the local discharge, reduce weight, reduce the cost of the possibility.
4.Horizontal winding machine
From the point of view of transformer winding structure design, not all the coils can be produced by vertical winding machine. Such as layer structure, multi - helix structure type coil. If this kind of coil using ordinary horizontal winding machine wound, axial without any pressure wound system, line gap is very large, like a compression spring. The diameter of the coil becomes larger after being pressed, and the gap between the coil and the paper tube will be generated, which will cause the axial instability of the coil. In case of axial electric force, the coil may be damaged. Therefore, horizontal winding machine with axial and radial compression has been widely used in the production of large transformer coil. With the transformer performance requirements more and more high, generally small and medium-sized transformer production, also gradually began to use the compression type horizontal winding machine.
In order to control the compression force more accurately, the torque motor or cylinder pressure generated by the compression mechanism has been replaced by a servo motor. In order to control the size tolerance of winding coil, grating ruler is added to measure the size of coil online. The release tension of each wire reel on the multi-axis release vehicle is independently controlled. According to the length of the winding coil, the release vehicle follows up to avoid the distortion and deformation of the wire to produce new stress and reduce the eddy current loss of the winding.
