China Low-Voltage Tension Pay-Off Stand for Transformer Coils - Quality Suppliers & Factory Solutions
Product Specification
| Code | SHZL-4 |
| Max Load Capacity | 200 kg |
| Tray Height | ≤ 400 MM |
| Tray Diameter | ≤ 600 MM |
| Tension Control Range | 5 N – 500 N (adjustable in 1 N increments, for micro-tension needs) |
| Tension Accuracy | ±1% of set value (closed-loop control via tension sensor) |
| Wire Adaptation – Round | Diameter: 0.1 mm – 10 mm (enameled copper/aluminum wire, insulated wire) |
| Wire Adaptation – Flat | Cross-section: 1 mm×3 mm – 5 mm×15 mm (small flat insulated wire) |
| Pay-Off Speed | 0.2 m/min – 5 m/min (stepless speed regulation, synced with winding machines) |
| Speed Stability | ±0.2 m/min |
Advantages
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1Precise Micro-Tension Control for Small-Section Conductors
For fine-gauge conductors commonly used in low-voltage applications (0.1–10 mm diameter enameled and insulated wires), the tension control range is precise, ranging from 5–500 N (adjustable in 1 N increments) with an accuracy of ±1%. This prevents excessive tension from thinning the conductor and damaging the insulation (e.g., paint peeling off the enameled wire), or insufficient tension from causing loose windings and excessive gaps (impacting electrical performance and heat dissipation). This perfectly meets the demand for gentle handling of fine conductors in low-voltage windings.
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2Flexible Adaptability for Multiple Scenarios & Strong Compatibility
Compatible with a variety of conductor types (round enameled wire, flat insulated wire, and thin wire bundles), eliminating the need for frequent replacement of core components; only adjustments to the guide pulley and tension parameters are required. Compatible with diverse products such as low-voltage transformer coils, motor stator/rotor windings, and micro-coils for home appliances (e.g., air conditioners and washing machines). Over 50 pre-set process parameters (e.g., tension and speed for different conductor types) are supported, eliminating the need for repeated adjustments when switching between conductor types, improving multi-batch production efficiency.
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3Good Automation Linkage Reduces Labor Costs
It supports PLC linkage (e.g., RS485 communication) with low-voltage winding machines and wire cutting machines, automatically synchronizing the payout speed (steplessly adjustable from 0.2–5 m/min) with the winding rhythm, eliminating manual adjustments that can cause wire accumulation or wire breakage due to excessively fast payouts. Some models are equipped with a wireless remote control, eliminating the need for workers to operate the machine from close proximity, reducing workshop movement and improving production safety.
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4Comprehensive Safety Measures Reduce Scrap Rates
Built-in abnormal tension alarms (automatic shutdown within ±3% of tolerance), wire break detection, and wire jam protection prevent faults immediately, preventing unqualified windings from entering subsequent processes. (For example, continued winding of damaged wires can cause short circuits in the finished product.) The guide wheels are made of wear-resistant polyurethane, leaving thin wires scratch-free, further reducing the risk of scrap due to equipment wear.
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5Compact and Easy to Deploy, Adapting to Workshop Space
Compared to high-voltage tension pay-off stands, these are more compact (mostly vertical, occupying ≤1.5 m²) and lighter (approximately 300–800 kg). They require no dedicated heavy foundation and can be flexibly deployed anywhere on the low-voltage electrical production line. With an operating noise level of ≤60 dB, they will not interfere with other precision equipment in the workshop, meeting the environmental requirements of precision low-voltage electrical production.
Product Display
Application
For 10kV/0.4kV distribution transformers, it controls 5–300 N tension for 0.5–5 mm wires to keep coils tight (avoids heat loss/looseness). It syncs with layer winding machines to ensure even wire arrangement, preventing turn-to-turn breakdown.
For industrial control transformers (e.g., 220V/36V), it uses 5–50 N low tension to protect thin wires (0.1–1 mm) from breaking or enamel damage. It maintains stable speed to reduce turn count errors (≤±1 turn).
For transformers requiring high insulation (e.g., medical/PV use), its polyurethane guide wheels and ±1% tension accuracy protect thin insulation layers. It balances tension for 2–4 parallel wires to ensure even coil resistance.
For SCB-series dry transformers, it ensures wire spacing error ≤0.1 mm (avoids casting bubbles). It stores process parameters for mass production, guaranteeing coil consistency without repeated debugging.
Frequently Asked Questions
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What types of wire can the SHZL-4 tension pay-off stand handle?
The SHZL-4 is compatible with round enameled copper/aluminum wires (0.1 mm – 10 mm diameter), flat insulated wires (cross-section 1 mm×3 mm to 5 mm×15 mm), and thin wire bundles. This broad compatibility makes it suitable for a wide range of low-voltage winding applications without requiring frequent core component replacements.
Q
How accurate is the tension control, and why does it matter?
The tension control accuracy is ±1% of the set value, achieved through closed-loop control via a tension sensor. This precision is critical because excessive tension can thin fine conductors and damage insulation (e.g., enamel peeling), while insufficient tension causes loose windings and gaps that negatively impact electrical performance and heat dissipation.
Q
Can the SHZL-4 be integrated with existing winding machines and production lines?
Yes. The SHZL-4 supports PLC linkage via RS485 communication, allowing it to automatically synchronize payout speed (0.2–5 m/min, steplessly adjustable) with connected winding machines and wire cutting machines. Some models also include wireless remote control for improved operator safety and workflow efficiency.
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What safety features are built into the SHZL-4?
The unit features built-in abnormal tension alarms with automatic shutdown triggered when tension deviates beyond ±3% of the set tolerance, along with wire break detection and wire jam protection. The guide wheels are manufactured from wear-resistant polyurethane to prevent scratching fine wires, all of which together significantly reduce scrap rates and prevent defective products from entering downstream processes.
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How much floor space does the SHZL-4 require, and is it easy to install?
The SHZL-4 has a compact vertical footprint of ≤1.5 m² and weighs approximately 300–800 kg, requiring no dedicated heavy foundation. It can be flexibly positioned anywhere along a low-voltage electrical production line. Its operating noise level of ≤60 dB ensures it does not interfere with surrounding precision equipment.
Q
How does the SHZL-4 improve efficiency when switching between different wire types or production batches?
The SHZL-4 supports over 50 pre-set process parameter profiles covering different conductor types, tension values, and speed settings. When switching between production batches or wire types, operators simply select the appropriate profile rather than manually recalibrating, which dramatically reduces changeover time and improves overall multi-batch production efficiency.