Integrated Distribution Transformer Foil Winding Machine 

High Voltage/Foil Automatic Winding Machine System 

Model No.: SGW-ZDBXJ-630 

Equipment Positioning 

Developed for small/medium distribution transformer coil manufacturing, this system integrates HV/LV processes for conventional coils, 3D wound core coils, and foil coils, meeting precision requirements for energy-efficient transformer core components. 

Key Advantages 

- Compact Design 

  15%+ coil volume reduction 

  20% material cost savings 

- High Efficiency  

  30% faster winding speed 

  72h continuous operation 

- Precision Control 

  Axial tightness ≤0.12mm 

  Radial density fluctuation <5% 

Foil Winder 

- Integrated Process  

  Combines foil winding, lead welding, surface wrapping (40% faster conversion) 

- Quality Assurance  

  ±0.05mm laser alignment 

  ±1.5N tension control 

- Material Flexibility  

  0.1-3.0mm Cu/Al foils 

  5 insulation standards 

Technical Architecture 

1. Germany KTR real-time tension feedback 

2. Taiwan AIRTAC pneumatic actuators 

3. China Inovance custom servo drives 

4. Proprietary HMI platform 

Smart Features 

- 200+ preset parameters 

- 16-category fault diagnosis 

- Cloud monitoring via 4G 

Technical Specifications 

1. Coil Processing 

- Center Height: 850mm 

- Axial Length: 500mm (3D core) 

- Max Outer Diameter: 1200mm 

- Workpiece Load: 2000kg 

- Coil Type: 3D wound core 

- Material: Wire: Cu/Al; Foil: Cu/Al 

- Wire Specifications 

  Round enameled wire: 0.50-3.50mm 

  Flat enameled wire: 4×12mm 

  Round flattening: <25% 

  Cu foil: 0.3-2.0mm 

  Al foil: 0.5-2.5mm 

2. Winding Machine 

- Torque: Wire: >400N·m; Foil: >3500N·m 

- Power: LV: 11kW (servo); HV: 7.5kW (servo) 

- Speed Control: Servo stepless + pedal auto-speed 

- Winding Speed: Wire: 0-350r/min; Foil: 0-30r/min 

- Winding Mode: Automatic/Semi-auto 

3. Layer Insulation 

- Insulation OD: <400mm 

- Insulation ID: 76mm 

- Torque: Wire: 1-100N·m  Foil: 1-200N·m 

- Working Pressure: 0-0.6MPa (0-10V auto-regulated) 

- Insulation Width: Wire: 12-30mm  Foil: 100-550mm 

4. Wire Alignment 

- Max Counter Setting: 9999.9 turns 

- Min Wire Spacing: 0.01mm 

- Counting Mode: 5-digit display, preset total turns (20 segments), reversible, power-off memory 

- Tension: Wire: Dual-servo 5-220N·m; Foil: Servo 50-2000N·m; Pneumatic 30-1000N·m 

- Working Torque: 0-0.6MPa (0-10V auto-regulated) 

5. Uncoiler 

- Material Core ID: Φ460/500mm 

- Material Core OD: Φ1000mm 

- Drum Effective Length: 500mm 

- Drum Expansion Range: Φ420-520mm 

- Expansion Method: Hydraulic one-touch 

- Drum Load Capacity: 1500kg 

- Tension: 30-2000N 

- Tension Control: 0-0.6MPa (0-10V auto-regulated) 

- Servo Motor: 5.5kW 

- Feature: Forward/reverse constant tension 

6. Control System: PLC automation 

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

8. Appearance: RAL5012 light blue (customizable) 

9. Dimensions: 6200(L) × 8100(W) × 3650(H) mm 

10. Weight: 18,880kg