Transformer Core Winding Machine

The iron core of a transformer is the "heart" of the transformer, and its structural accuracy directly determines the energy efficiency, noise, and service life of the transformer. The transformer core Winding Machine, as a core automation equipment specifically used for processing transformer cores, rolls silicon steel sheets (core material) into specific shaped core components through precise winding technology. It is a key production equipment in the field of power equipment manufacturing.

Core functionality

The traditional processing of transformer iron cores relies heavily on manual cutting and stacking, which results in low efficiency, poor accuracy, and high loss of silicon steel sheets. The core value of the winding machine lies in achieving "high-precision, low loss, and large-scale" production through automated winding, with specific functions including:

Precision winding of silicon steel sheets

According to the design parameters of the iron core, the rolled silicon steel sheets can be automatically wound evenly on the mold with the set tension, ensuring that each layer of silicon steel sheets is tightly adhered and offset free, avoiding gap errors caused by manual stacking.

Intelligent control of tension and speed

Equipped with a tension control system to adjust the winding tension of silicon steel sheets in real time, preventing deformation of silicon steel sheets due to excessive tension or interlayer looseness caused by insufficient tension; At the same time, the winding speed can be adaptively adjusted according to the thickness of the silicon steel sheet and the specifications of the iron core, balancing production efficiency and forming quality.

Automatic cutting and shaping assistance

When the winding reaches the preset number of layers or size, the equipment can automatically cut off the silicon steel sheet and cooperate with the clamping mechanism to preliminarily shape the wound iron core, ensuring the stability of the iron core shape and facilitating subsequent welding, annealing and other processes.

Multi specification compatible production

By replacing molds and adjusting parameters, it is possible to adapt to the production of iron cores for transformers of different capacities, meeting the processing needs of iron cores for transformers ranging from tens of kVA to tens of thousands of kVA.

Working principle

The workflow of the transformer core winding machine is based on the closed-loop logic of "mold positioning silicon steel sheet conveying tension control winding forming", and the core principle can be decomposed into the following four steps:

Mold installation and parameter setting

Fix the customized iron core mold on the spindle of the equipment, and input core parameters such as winding layers, number of turns per layer, winding speed, tension value, cutting position, etc. through the human-computer interaction interface.

Silicon steel sheet conveying and tension adjustment

The rolled silicon steel sheets are released by the unwinding mechanism and transported to the winding spindle through the guide roller; During the process, the tension sensor detects the tension changes of the silicon steel sheet in real time and feeds them back to the control system. By adjusting the braking force of the unwinding mechanism or the speed of the traction motor, the tension is ensured to be stable within the set range.

Spindle drive and winding forming

The servo motor drives the winding spindle to rotate at high speed, while the mold rotates synchronously with the spindle. The silicon steel sheet is tightly wound on the surface of the mold under tension; Some high-end equipment is equipped with a "dual spindle" design, which can achieve synchronous winding unloading and improve production efficiency.

Automatic cutting and iron core removal

When the number of winding layers reaches the set value, the spindle stops rotating and the cutting mechanism accurately cuts the silicon steel sheet; Subsequently, the mold is released, and the formed iron core is taken out through the unloading mechanism and enters the subsequent annealing and welding processes.

Shanghai Baoduan Machinery Manufacturing Co., Ltd. is located in Baoshan District, Shanghai, an international metropolis. It is a professional mechanical production enterprise engaged in equipment manufacturing and equipment R&D.

The company focuses on production equipment for metallurgical processing, as well as winding and packaging machine equipment for metal strips, pipes, profiles, tires, etc. Meanwhile, to solve problems such as product packaging and transfer in the actual production of metal strip processing enterprises, our company has also developed winding and packaging equipment for materials like metal strips, metal plates, pipes, and wires—including steel strip winding machines, copper coil winding and packaging machines, steel wire winding machines, steel pipe winding machines, horizontal winding machines, etc.—as well as industrial turning equipment such as 90-degree Steel Coil tilters, aluminum Coil tilters, Mold tilters, and 180-degree tilters.