China High & Low Voltage Horizontal Winding Machine for Transformers - Reliable Suppliers & Factory Solutions

Adopting an integrated rigid base design for the headstock and tailstock, it has a load capacity of 1,000 kg to over 25 tons, enabling stable support for large-diameter (≤3,500 mm) and heavy high-voltage pancake coils or large low-voltage layer coils. Compared with vertical winding machines, the horizontal layout distributes the coil's gravity, avoiding radial runout (runout ≤0.1 mm) caused by center-of-gravity deviation during winding—ideal for precision winding of heavy workpieces like transformer high-voltage coils. It is also equipped with an electromagnetic brake device to quickly lock the spindle during shutdown and prevent coil loosening due to reverse rotation.

It covers the winding needs of low-voltage coils (≤10 kV) and high-voltage coils (110 kV–500 kV), and is compatible with various wire types such as round wires (0.3 mm–3 mm diameter), flat wires (≤3×12 mm cross-section), and transposed conductors. Through a modular tension adjustment system (adjustable 5–5,000 N), it applies micro-tension control to thin low-voltage wires (e.g., 0.3 mm enameled wires) to avoid breakage, and increases tension for thick high-voltage wires (e.g., 12 mm paper-insulated flat wires) to ensure tightness. No equipment replacement is required to meet the production needs of multiple transformer types (distribution, power, dry-type transformers).

Equipped with a wire arrangement mechanism driven by a servo motor, ball screw, and linear guide, the wire arrangement precision reaches 0.01 mm level, enabling tight and uniform turn-to-turn wire arrangement (gap ≤0.1 mm) and effectively reducing coil eddy current loss. Combined with a PLC-controlled turn counter (maximum setting 99,999.9 turns, error ≤±1 turn), it accurately controls the number of coil turns and avoids transformer voltage ratio deviation caused by winding errors. Some models are also equipped with a radial pneumatic pressing device to further improve the radial tightness of the coil and reduce the risk of partial discharge during operation.

Adopting a "touchscreen HMI + PLC control system," it supports preset storage of over 30 sets of process parameters (e.g., wire arrangement pitch, winding speed), eliminating the need for repeated debugging when switching coil specifications. It can link with high-low voltage tension pay-off stands, insulating paper winding machines, and other equipment via RS485 interface to realize integrated production of "pay-off – winding – insulation wrapping," with production efficiency increased by more than 5 times compared to manual winding. The variable frequency speed regulation system (0–60 r/min stepless adjustment) automatically matches the winding speed according to wire specifications, and the start/stop slope can be preset to avoid wire damage caused by impact.

It is perfectly adapted to core transformer coil processes: during layer winding, the wire arrangement mechanism operates synchronously with the spindle to ensure parallel wire arrangement between layers; during pancake winding, it can cooperate with a spacer adding mechanism to achieve spiral forming, solving the problem of easy spacer slipping in vertical winding machines. It supports 2–4 wire parallel winding processes, and ensures balanced force on multiple wires through independent tension control, meeting the low-loss winding needs of low-voltage coils for large transformers.

Adopting a hard-tooth surface gear transmission system, it operates with noise ≤70 dB and transmission efficiency over 95%. Built-in functions such as tension deviation alarm (automatic shutdown when deviation >±3%), wire breakage detection, and overload protection can block faults in real time to prevent unqualified coils from entering subsequent processes, reducing the rejection rate to below 0.5%. Equipment parameters can be synchronized and stored via the network, enabling unified management of production data for multiple devices and ensuring performance consistency of mass-produced transformer coils.