Discount Industrial High & Low Voltage Foil Winding Equipment for Transformers Manufacturers, Products

The foil winding machine is suitable for winding foil coils of transformers and electrical appliances. Developed by referencing US similar equipment technology and integrating the company’s transformer equipment design-manufacture experience, it uses varying-thickness copper/aluminum foil as conductor. With wide insulating strips for interlayer insulation and narrow ones for end insulation, it winds coils in one pass, while welding inner/outer leads and wrapping the outer surface, supporting qualified coil production and being essential for transformer components.

Product Description

Product Drawing

Product Drawing

Product Specification

Code SH-600 SH-800 SH-1100 SH-1400
Coil outer diameter 150-750mm 150-850mm 200-1000mm 200-1000mm
Foil width 100-600mm 150-800mm 200-1100mm 300-1400mm
Foil layers Single or double
Foil thickness Copper Cu:0.3-2.5mm   Aluminium Al: 0.5-3.0mm
Winding speed 0-30r/min 0-30r/min 0-20r/min 0-20r/min
Max tension of foil 6000N 8000N 10000N 14000N
Welding speed 0-0.5 m/min
Correction precision ±0.5mm
Welding method TIG or cold pressure welding

Detail Display

1,Picture of layer insulation device
1. Layer insulation device
2,Picture of end insulation device
2. End insulation device
3-1,Picture of decoiler with off-set regulation system
3-1. Decoiler with off-set regulation system
3-2,Picture of decoiler with off-set regulation system
3-2. Decoiler with off-set regulation system
4-1,Picture of welding device
4-1. Welding device
4-2,Picture of welding device
4-2. Welding device
5,Picture of winding device
5. Winding device
6,Picture of scissors device
6. Scissors device
7,Picture of touch screen
7. Touch screen
8,Picture of distribution cabinet
8. Distribution cabinet

Structure

Structure

Advantages

  • 1. Motor Initiative Supplying Tension Method

    Adopting motor initiative supplying tension advanced method, stable tension, there is stable tension in foil winding, stopping and foil returning. It can avoid loosen situation when the tension lost in winding.

  • 2. Turbine Shaft Reducer

    Winding speed reducer is turbine shaft reducer, it can keep main shaft auto-locked whenever power on or power off status.

  • 3. Photoelectric Analog Sensors

    Correction system using photoelectric analog sensors, it is not meeting with foil edge, both thick and thin foil are accepted.

  • 4. Parameter Management & Display Screen

    Foil tension, layer insulation tension, coil parameters, winding status and other data, all of them can be set and showed on screen, easy for operating, accurately and intuitively.

  • 5. PLC & Touch Screen Control

    Equipment is controlled by PLC and touch screen, less fault of whole machine, no friction noisy, stable working, high working efficiency.

Application of Foil Winding Machine

Applied in the field of power transformer manufacturing
  • High-voltage power transformers:

    Used in 110kV and above power transmission and transformation systems (such as substations and inter-regional power grids), these transformers produce high-voltage windings with copper/aluminum foil conductors to meet high-voltage, low-loss power transmission requirements.

  • Medium- and low-voltage distribution transformers:

    Suitable for 10kV and below distribution networks (such as urban power grids and industrial park distribution), these transformers produce low-loss, high-efficiency foil coils to ensure stable power supply to end users.

  • Specialty power transformers:

    These include dry-type power transformers (used in fire-resistant environments such as high-rise buildings and subways) and oil-immersed power transformers (used in large outdoor substations). Their foil windings must be wound using this equipment.

Applied in the field of industrial special reactors/transformers
  • Filter reactors:

    Used in high-power industrial applications such as steel and chemical industries, they filter grid harmonics and protect precision equipment. Their foil windings require high insulation strength and overload resistance.

  • Rectifier transformers:

    Suitable for industrial production lines requiring DC power, such as electrolytic aluminum and electroplating. High-current-resistant foil coils are wound to ensure stable operation of the rectifier system.

  • Electric furnace transformers:

    Used in industrial furnaces (such as arc furnaces and induction furnaces), they produce foil windings capable of withstanding short-term high loads to meet the power needs of high-temperature smelting.

Applied in the fields of new energy and energy storage equipment
  • New energy transformers:

    These include wind turbine box transformers (connecting wind turbines to the grid) and photovoltaic inverter transformers. Their foil coils must withstand harsh outdoor environments (low temperatures, wind and sand) and exhibit low losses.

  • Energy Storage Converter (PCS) Inductors:

    These are used in energy storage power plants to wind foil windings for filter and boost inductors in energy storage systems, ensuring efficient conversion between energy storage and release.

  • Charging Pile Transformers:

    These are designed for fast-charging charging piles and feature compact, high-power-density foil coils to meet the power needs of electric vehicles for rapid charging.

Frequently Asked Questions

What is the winding speed and foil width capability of this machine?

Depending on the specific model, the winding speed ranges from 0-30 r/min (for SH-600/800) to 0-20 r/min (for SH-1100/1400). The machine supports foil widths from 100mm up to 1400mm, ensuring adaptability to various industrial specifications.

What materials and thicknesses are supported by the foil winding machine?

It processes both copper (Cu) and aluminum (Al) foils. Specifically, it supports copper foil thicknesses of 0.3-2.5mm and aluminum foil thicknesses of 0.5-3.0mm, configured for single or double layers.

How does the machine maintain stable tension during operation?

The equipment uses an advanced motor-driven active tensioning method. This ensures stable tension is maintained during winding, stopping, and foil returning, effectively preventing looseness caused by sudden tension drops.

What kind of correction system and welding methods are used?

The correction system operates via photoelectric analog sensors with a correction precision of ±0.5mm, without physically touching the foil edge. Welding options include TIG (Tungsten Inert Gas) welding or cold pressure welding, operating at speeds of 0-0.5 m/min.

What control system is implemented in this machinery?

The machinery is managed through a central PLC and a touch screen control system. Key parameters like winding status, foil tension, and insulation settings are adjusted directly on-screen, minimizing manual errors and noise output.

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