Shuhong Machinery releases innovative foil winding machine, defining new standards for transformer manufacturing.

Against the backdrop of increasingly stringent transformer energy efficiency standards and continuously growing market demand for high-quality coils, we are proud to announce the launch of the new generation BRJ-1600-II dual-station foil winding machine. This equipment represents the cutting-edge technology in the field of transformer winding equipment, specifically designed to meet the efficient and high-precision production needs of low-voltage coils for oil-immersed and dry-type transformers. As a leading manufacturer of coil processing equipment, our BRJ-1600-II aims to redefine the productivity and precision standards of coil winding equipment through its innovative dual-station design, intelligent control system, and superior process stability.

I.Innovative Dual-Station Design for a Leap in Production Efficiency

The core breakthrough of the BRJ-1600-II lies in its highly efficient dual-station synchronous production architecture. Compared to traditional single-layer foil winding machines, this double-layer foil winding machine achieves true parallel operation by integrating two independent foil unwinding, feeding, and tension control systems.

Each unwinding machine is equipped with hydraulic automatic unwinding and rewinding functions, using a precision reducer coupled with a servo motor to achieve precise constant tension control within the range of 10-18000N. This design ensures stable tension throughout the entire process from unwinding to winding, effectively preventing defects such as coil loosening and deformation caused by tension fluctuations. Under actual working conditions, this dual-station system can increase production efficiency by at least 40% and reduce foil material waste by more than 15%. For transformer manufacturers facing increasing production capacity pressure, this is not only an improvement in efficiency but also a key enhancement in cost control and market competitiveness. The equipment supports copper or aluminum foil widths of 300-1600mm, with a coil axial length processing range of 320-1650mm and a maximum outer diameter of Φ2100mm. Its wide processing adaptability covers the mainstream production needs from distribution transformers to medium-sized power transformers.

II. Fully Automatic Integrated System, Reshaping the Coil Manufacturing Process

The BRJ-1600-II is not just a winding machine, but a complete coil manufacturing solution. It highly integrates seven major processes: unwinding, alignment, interlayer and end insulation supply, winding, welding, and cutting, completely changing the cumbersome traditional transformer equipment production model of multiple machines working together and frequent loading and unloading.

Its interlayer insulation device is equipped with two independently removable unwinding units, supporting insulation paper rolls with an outer diameter of less than 400mm, and uses electric stepless tension adjustment to ensure that the insulation material is laid flat and wrinkle-free. The end insulation device is particularly cleverly designed, with up to three sets of insulation material reels installed on each side. The support frame can rotate within a range of 0-125 degrees, allowing operators to safely and conveniently change materials from the front, greatly improving the user-friendliness and safety of operation.

The welding system uses TIG AC/DC tungsten inert gas shielded welding, equipped with pneumatic clamping fixtures, and the flatness of the welding surface can reach over 95%. The cutting device uses a video-guided electric rotary cutting method, with a cutting length of 1600mm, a lifespan of over 100,000 times, and a lateral adjustment capability of 0-40mm to meet the precise cutting needs of different coil specifications.

III.Intelligent Control and High-Precision Alignment, Ensuring Ultimate Coil Quality

In transformer coil manufacturing, consistency is the gold standard for quality. The BRJ-1600-II is equipped with an electrical control system based on a Siemens PLC and a 10.4-inch industrial touch screen human-machine interface (HMI). The system can store 100 sets of coil process parameters, supports counting accuracy of 0.01 turns, and has a power-off memory function to ensure the continuity and traceability of production data.

The device's most impressive feature is its high-precision automatic deviation correction system. It uses photoelectric edge detection technology, combined with a servo linear motor to perform deviation correction, achieving a correction accuracy of ±0.5mm. This system responds quickly and can correct foil deviation in real time during high-speed winding, ensuring that the edges of each layer of foil are neat and uniform. This is a fundamental guarantee for manufacturing low-loss, high-mechanical strength transformers. For manufacturers pursuing superior quality, this built-in precision control capability makes producing coils that meet the most stringent international standards (such as IEC and IEEE) a regular occurrence.

IV.Powerful Drive and Rigid Structure to Meet Demanding Industrial Challenges

As the core power source of the transformer winding machine, the BRJ-1600-II's winding device uses a 37kW AC variable frequency servo motor drive. When the equipment is running at the mid-range of the set speed, the winding spindle can output a huge torque exceeding 16,000 N·M, ensuring a tight and uniform winding effect even during the winding of large-scale, high-density coils.

The mechanical structure of the equipment is robust and reliable, with a main shaft diameter of 1700mm and a load capacity of no more than 2 tons. The winding shaft uses one 70x70mm and one 100x100mm winding shaft, and is equipped with a side-opening tailstock for easy mold installation. The length of the V-shaped pressure roller at the machine head can be adjusted between 288-1198mm. It adopts a double-row rubber roller structure and is driven by double cylinders. The pressure can be steplessly adjusted through a pressure regulating valve, perfectly adapting to the winding of coils with various cross-sectional shapes such as circular, rectangular, and elliptical.

V. Positioned for the Future of the Industry, Empowering Green Energy Transformation

Currently, the global energy structure is undergoing a green and efficient transformation. Emerging fields such as wind power, photovoltaic power, energy storage, and electric vehicle charging networks are experiencing explosive growth in demand for high-performance, high-reliability transformers. As manufacturing equipment for the core components of transformers, advanced coil processing equipment is the cornerstone supporting this industrial upgrade. The introduction of the BRJ-1600-II dual-station foil winding machine is precisely aimed at empowering transformer manufacturers to seize this era's opportunities. It not only helps customers reduce costs and enhance market competitiveness by improving efficiency and precision, but its stable and reliable performance also ensures that the transformer coils produced have lower losses, better heat dissipation, and higher short-circuit withstand capability, thereby extending the overall service life of the transformer and contributing to the construction of a more robust and efficient global power grid.

We firmly believe that the BRJ-1600-II is not only another milestone in our company's technological innovation journey but will also become a key partner for our customers in winning in the fierce market competition. We will continue to invest in research and development, committed to promoting the continuous advancement of coil winding equipment technology, and working with industry colleagues to usher in a new era of transformer manufacturing.