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Dual-Station High-Efficiency Foil Winding Technology Revolutionizes Transformer Coil Production
2026-01-26
Introduction: A Key Technological Breakthrough in Transformer Manufacturing
In modern power transformer manufacturing, foil winding technology has become the preferred choice for low-voltage coil production due to its excellent electrical performance and compact structure. With the upgrading of global energy infrastructure and the construction of green power grids, the demand for high-performance, high-efficiency transformer equipment continues to grow. As a core equipment in transformer coil production, the technical level of the foil winding machine directly affects the quality, efficiency, and reliability of transformers. Recently, the introduction of the BRJ-1600-II dual-station foil winding machine marks a significant breakthrough in foil winding technology in the field of multi-layer, large-size coil processing, providing transformer manufacturers with a more efficient and precise solution.
Dual-Station Foil Winding Machine Technology Analysis: High-Efficiency Integrated Production of Multi-Layer Coils
The BRJ-1600-II dual-station foil winding machine represents the cutting edge of current coil processing equipment. This equipment is specifically designed for low-voltage coils of oil-immersed and dry-type transformers, with a coil height processing range of 200-1600 mm, meeting the production needs of most standard and customized transformers. Compared with traditional single-station foil winding machines, the dual-station design allows for simultaneous unwinding, feeding, and winding of two sets of foil materials, increasing production efficiency by more than 40%.
The dual-station structure of this equipment is not simply parallel processing, but rather achieves precise synchronization through an integrated control system. Both foil unwinding machines are equipped with hydraulic automatic unwinding and rewinding functions, using precision reducers and servo motors to achieve constant tension control. During the winding process, regardless of whether the equipment is accelerating, at a constant speed, or decelerating, the foil tension remains constant, ensuring the tightness and electrical consistency of the coil. In addition, the equipment is equipped with a double-layer insulation paper automatic feeding system and end insulation device, which can simultaneously complete the laying of inter-layer insulation and end insulation during the winding process, reducing subsequent processes and improving overall product quality.
Core Technological Innovation: Intelligent Control System and High-Precision Processing Capabilities
The advanced nature of modern coil winding equipment is reflected not only in its mechanical structure but also in the integration of intelligent control systems. The BRJ-1600-II foil winding machine is equipped with a control system based on a Siemens PLC and a 10.4-inch touchscreen, allowing for the storage and recall of 100 sets of process parameters. It features power-off memory, ensuring convenient operation and high repeatability. The winding count accuracy reaches 0.01 turns (0-9999.9 range), guaranteeing the repeatable production of high-precision coils.
In terms of tension control, the equipment utilizes an intelligent control system combining feedforward and feedback. Through a servo tension device and a photoelectric edge detection automatic correction system, real-time correction is achieved during the foil strip feeding process, with a correction accuracy of ±0.5 mm, effectively avoiding the common "flaring" and uneven edge phenomena found in traditional foil winding machines. This precise control capability is crucial for ensuring the electrical performance of the coil, especially for the uniform distribution of the electric field in high-voltage applications.
The winding device is driven by a 37 kW AC variable frequency motor, and the maximum torque of the winding shaft can reach over 20000 N·M when operating at the mid-range of the set speed. The equipment supports various coil cross-sectional shapes, including circular, rectangular, and elliptical, and adapts to the winding needs of different coil specifications through an adjustable V-shaped pressure roller device (length adjustment range 288-1198 mm). In addition, the equipment also includes a vertically adjustable pressure roller, specifically designed to apply pressure to the copper foil and maintain constant tension during the winding of elliptical or rectangular coils.
Welding and Cutting System: Integrated Innovation of the Complete Processing Flow
Unlike traditional transformer equipment where winding, welding, and cutting processes are performed separately, the BRJ-1600-II foil winding machine integrates these key processes. The equipment is equipped with an automatic welding system using TIG AC/DC tungsten inert gas shielded welding (630A Aotai welding machine), with an adjustable welding speed of 0-1 meter/minute. The welding fixture has a width of 320 × 5 = 1600 mm, supporting free splicing. Pneumatic clamping ensures a flat and even welding surface, with a surface smoothness exceeding 95%.
The shearing device uses a screw-driven disc shear (two sets), with a maximum shearing length of 1600 mm and a service life of over 100,000 cycles. The innovation lies in the use of a video-guided electric rotary shearing method, allowing operators to perform shearing operations intuitively and accurately through a visual display system. The shearing device can be manually adjusted forward and backward, with a lateral movement range of 0-40 mm, adapting to the processing needs of different coil specifications.
This integrated design significantly reduces the transfer and repositioning of coils between different equipment, not only improving production efficiency but, more importantly, reducing human error and improving product consistency and quality stability. For transformer manufacturers requiring high-precision, high-volume production, this integrated solution offers a significant competitive advantage.
Material Handling System: Innovative Design of Multi-layer and End Insulation
In transformer winding machines, insulation processing is a critical step in ensuring the electrical safety and reliability of the product. The BRJ-1600-II foil winding machine incorporates several innovative designs in this area. The inter-layer insulation device uses two independent movable structures, with an insulation paper roll outer diameter of less than 400 mm, an inner diameter of 76 mm, and a shaft length of 1500 mm. This device uses electric tension stepless adjustment to ensure constant tension of the insulation paper during winding, preventing wrinkling or excessive stretching.
Particularly noteworthy is that the two insulation unwinding devices can be pulled out of the machine frame separately, facilitating the replacement of insulation layers. It is also equipped with a shrinking and tensioning device for the insulation material paper tube, ensuring smooth transport of insulation materials of different widths. The insulation material cutting function supports adjustable offset cutting, adapting to production processes with different insulation requirements.
The end insulation device also reflects thoughtful design. The equipment can install three sets of end insulation materials on each side, totaling six sets (outer diameter Φ350 mm, inner diameter Φ56 mm), with an insulation tape width adjustment range of 5-40 mm. The end insulation support frame can rotate from 0 to 125 degrees, allowing operators to stand in front of the winding shaft to replace the end insulation discs, greatly improving operational convenience and safety. The equipped insulation tape guiding system and tensioning device allow the insulation tape spacing to be adjusted according to the coil width, meeting diverse production needs.
Industry Impact and Application Prospects: Driving the Upgrade of Transformer Manufacturing Technology
The launch of the BRJ-1600-II dual-station foil winding machine comes at a critical time for global energy transition and power grid modernization. With the large-scale integration of renewable energy and the development of DC transmission technology, the demand for high-performance transformers is increasing. This advanced foil winding equipment provides transformer manufacturers with a powerful tool to meet market challenges.
For transformer manufacturers, the benefits of adopting dual-station foil winding technology are multifaceted. The significant increase in production efficiency means that more orders can be completed in the same amount of time, the equipment footprint is reduced by approximately 30% compared to traditional multi-unit single-station equipment, and energy consumption is reduced by approximately 25%. More importantly, the high precision and consistency of the equipment reduce material waste and rework rates, significantly lowering production costs in the long run.
In terms of application areas, this equipment is not only suitable for traditional power transformer production but can also be widely used in the manufacturing of special transformers, such as electric furnace transformers, rectifier transformers, and traction transformers. With the development of the new energy sector, especially the rapid growth of wind and solar power generation, the demand for supporting transformers is constantly increasing, and foil winding technology has broad application prospects in these fields.
Conclusion: The Future Development Direction of Foil Winding Technology
Foil winding machines, as an important branch of wire winding equipment, have always had their technological advancements closely linked to the development of the transformer industry. The introduction of the BRJ-1600-II dual-station foil winding machine demonstrates the trend of foil winding technology towards higher efficiency, higher precision, and more intelligent integration. In the future, with the in-depth advancement of Industry 4.0 and intelligent manufacturing, foil winding equipment will further integrate with the Internet of Things, big data, and artificial intelligence technologies to achieve advanced functions such as predictive maintenance, adaptive process adjustment, and remote expert support.
At the same time, with the application of new materials such as high-temperature superconducting materials and new insulating materials, foil winding technology also needs to constantly innovate to adapt to the processing characteristics of these new materials. Environmental protection and sustainable development requirements will also drive foil winding equipment towards more energy-efficient and less waste-generating directions. Overall, the progress of foil winding technology will continue to provide strong support for the transformer industry, contributing to the modernization and upgrading of global energy infrastructure.
In the field of transformer equipment manufacturing, innovation is endless. The successful development and application of the BRJ-1600-II foil winding machine not only provides transformer manufacturers with advanced production tools but also sets a new benchmark for technological progress in the entire industry. With the continuous promotion and improvement of this technology, it will undoubtedly drive the transformer manufacturing industry towards a more efficient, reliable, and intelligent future.