Low-Voltage Tension Pay-Off Stand for Transformer Coils - China Suppliers and Factory for Precision Winding Control
Product Specification
| Code | SHZL-4 |
| Max Load Capacity | 200kg |
| Tray Height | ≤400MM |
| Tray Diameter | ≤600MM |
| 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 (0.1–10mm diameter enameled and insulated wires), the tension control range is precise, ranging from 5–500N (adjustable in 1N 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 0.2–5m/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 5–300N tension for 0.5–5mm 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 5–50N low tension to protect thin wires (0.1–1mm) 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 ≤0.1mm (avoids casting bubbles). It stores process parameters for mass production, guaranteeing coil consistency without repeated debugging.
Frequently Asked Questions
Q
What is the tension control range of the SHZL-4 tension pay-off stand, and how accurate is it?
The SHZL-4 offers a tension control range of 5 N to 500 N, adjustable in 1 N increments to meet micro-tension requirements. Tension accuracy is ±1% of the set value, achieved through closed-loop control via a built-in tension sensor, ensuring consistent and precise wire feeding throughout production.
Q
What types of wire can the SHZL-4 handle?
The SHZL-4 is compatible with both round and flat conductors. For round wire, it handles diameters from 0.1 mm to 10 mm, including enameled copper/aluminum wire and insulated wire. For flat wire, it accommodates cross-sections from 1 mm×3 mm up to 5 mm×15 mm (small flat insulated wire), making it highly versatile for various winding applications.
Q
Can the SHZL-4 be integrated with existing winding machines or production lines?
Yes. The SHZL-4 supports PLC linkage via RS485 communication, allowing it to automatically synchronize its payout speed (0.2–5 m/min, steplessly adjustable) with connected winding machines and wire cutting machines. This eliminates manual speed adjustments and prevents issues such as wire accumulation or breakage caused by speed mismatches.
Q
What safety features does the SHZL-4 include to prevent production defects?
The SHZL-4 is equipped with multiple safety mechanisms: an abnormal tension alarm that triggers automatic shutdown if tension deviates by more than ±3% from the set value, wire break detection, and wire jam protection. Additionally, the guide wheels are made from wear-resistant polyurethane to prevent scratching or damaging fine wires, significantly reducing scrap rates and protecting product quality.
Q
How much floor space does the SHZL-4 require, and is it suitable for small workshops?
The SHZL-4 features a compact vertical design occupying no more than 1.5 m² of floor space, with a weight of approximately 300–800 kg. It requires no dedicated heavy foundation, making it easy to position flexibly on any production line. Its operating noise level of ≤60 dB ensures it will not interfere with other precision equipment, making it well-suited for space-limited or noise-sensitive workshop environments.
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Does the SHZL-4 support quick changeover between different wire types or production batches?
Yes. The SHZL-4 supports over 50 pre-set process parameter profiles covering different conductor types, tension levels, and speed settings. When switching between wire types or production batches, operators simply select the relevant preset rather than re-adjusting parameters from scratch. Only minor adjustments to the guide pulley may be needed, greatly improving changeover efficiency and multi-batch production throughput.