From Core to Coil: An Analysis of Transformer Equipment Technology Path by Wuxi Shuhong Machinery

How Specialized Equipment for 3D Triangular Winding Cores Reshapes the Precision Boundaries of Power Equipment Manufacturing

 I. The Equipment Logic Behind Transformer Energy Efficiency Upgrades

Wuxi Shuhong Machinery Technology Co., Ltd.'s production base in Hai'an, Nantong, answers the same question daily: how to make the magnetic circuit of the transformer core closer to the ideal state of theoretical design. The answer is written in every piece of equipment leaving the factory—from CNC slitting lines for silicon steel sheets to automatic 3D winding core machines, from foil winding machines to vacuum annealing furnaces, the precision of transformer equipment determines the final performance of the transformer.

For power equipment manufacturers, understanding this logic is crucial. The no-load loss, load loss, noise level, and overload capacity of a transformer—every key indicator—is directly constrained by the process precision of core manufacturing and coil winding. Achieving this process precision relies on the non-destructive processing capability of the core shearing equipment, the millinewton-level tension control of the automatic winding machine, and the thermal repair capability of the vacuum annealing furnace for the magnetic domain structure.

 II. Winding Process: A Leap from Planar to Three-Dimensional

Traditional laminated iron cores have an inherent defect: discontinuous magnetic circuits. Distortion in magnetic flux density at the joints leads to increased no-load current, noise, and losses. The emergence of three-dimensional wound iron cores solves this problem, but it places higher demands on the winding equipment.

Shuhong's SHJR-1200 three-dimensional wound iron core automatic winding machine is specifically designed for closed-type wound iron cores and is also suitable for winding planar single-phase, planar three-phase, and three-dimensional triangular iron cores. Its maximum core outer diameter can reach 300mm, the winding speed is infinitely adjustable from 0-60r/min, and the total installed power is 7.5KW. The equipment adopts servo drive, PLC control, and a touch screen interface, and has automatic reset, automatic stop, processing parameter setting, and real-time display functions.

For three-dimensional triangular wound iron cores, winding accuracy directly determines the symmetry of the magnetic circuit. After combining three identical single-frame iron cores, the three-phase magnetic circuit lengths are completely equal, the magnetic flux distribution is uniform, there are no obvious interlayer zones, and no distortion of magnetic flux density at the joints. This is the technical basis for the 25-35% reduction in no-load loss of the three-dimensional transformer compared to the national standard.

 III. Winding Equipment: Precision Control with Multi-Material Compatibility

After the iron core is completed, the next key process is coil winding. The transformer windings must withstand the thermal stress of long-term operation and the electrodynamic forces during short circuits; the winding quality directly affects the transformer's lifespan.

Shuhong's SHRX-2 three-dimensional iron core winding machine is suitable for transformer capacities ranging from 30-630KVA. It adopts a horizontal winding method, with the drive gear speed infinitely adjustable from 0-300r/min. Its positioning method is internal positioning, which has the advantages of smooth operation, low noise, and high safety and reliability. The equipment uses a PLC control system, a touch screen interface, encoder counting, and has automatic stop and power-off memory functions. The internal top-type iron core clamping device reduces clamping time, is convenient and quick, and improves efficiency.

More complex is the three-dimensional triangular foil winding machine, which needs to simultaneously process four materials: enameled wire, flat wire, paper-insulated wire, and foil strip, and quickly switch between winding and foil winding modes. This equipment supports winding requirements for φ0.3-4mm enameled wire, 4×10mm flat wire/paper-insulated wire, and 100-400mm foil strip, and is specifically designed for round coils.

 IV.Large-scale winding: The load-bearing advantages of vertical structures

 Beyond distribution transformers, there are even larger capacity power transformers. The coils of these devices weigh in tons, placing stringent requirements on the structural strength and stability of the winding equipment.

Shuhong's LRJ series vertical winding machines cover a coil bearing capacity range from 2 tons to 40 tons. Taking the LRJ-20T-3000 as an example, the maximum coil bearing capacity is 20 tons, the maximum rotation diameter is 3000mm, the coil speed is infinitely adjustable, and the maximum torque is 21000N·m. The equipment adopts a telescopic platform with photoelectric protection, anti-reverse design, and pneumatic clamping adapted to multi-conductor systems. The advantages of vertical winding machines lie in their stability under heavy loads. Even with a 20-ton bearing capacity, the machine maintains stepless speed regulation (0-10 rpm) and rapid braking, and features a counting system with power-off memory. The lifting mechanism employs a synchronous design with a lifting height of 3000mm, and an automatic lubrication system with a low-oil alarm to prevent bearing damage due to lubrication interruption.

 V.Foil Winding: Automatic Welding and Tension Control

Foil coils are widely used in distribution transformers and reactors. Unlike round wire winding, foil winding requires simultaneous processing of the foil strip, interlayer insulation, and end insulation, demanding higher levels of equipment integration.

Shuhong's SH series foil winding machines cover foil strip widths from 600mm to 1400mm. Taking the SH-1100 as an example, the coil outer diameter is 200-1000mm, the foil strip width is 200-1100mm, the winding speed is 0-20r/min, and the maximum foil tension is 10000N. The equipment employs an electric motor-driven active tension application technology, maintaining constant tension during winding, stopping, and unwinding to prevent inconsistent coil tightness caused by tension loss during winding.

For transformer manufacturing equipment, the technical challenge of foil winding machines lies in the coordinated control of multiple systems. The timing of each step—unwinding, feeding, alignment, welding, and rewinding—affects the final coil quality. Shuhong's equipment utilizes PLC and touchscreen control, minimizing potential failure points, eliminating frictional noise, ensuring reliable operation, and achieving high production efficiency.

VI.Conclusion: Precision Equals Performance.

From material preparation to winding, from winding to annealing, from the oil tank to assembly, every step in transformer manufacturing accumulates or degrades the final equipment performance. Shuhong Machinery's technological path is clear and consistent: using equipment precision to support transformer energy efficiency.

In the global power equipment market in 2026, the focus of competition has shifted from price to performance. Equipment capable of producing S13 efficiency transformers, handling amorphous alloy materials, and achieving large-scale three-dimensional core manufacturing is becoming the mainstream choice in the market. And all of this begins with the tension stability of every automatic coil winding machine, the sharpness of every pair of scissors, and the temperature uniformity of every annealing furnace.

On the production line of Wuxi Shuhong Machinery Technology Co., Ltd., these details are being repeatedly verified and continuously optimized.