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Amorphous Triangular Three-Dimensional High And Low Voltage Automatic Machine
Our innovative amorphous high and low voltage integrated fully automatic winding machine is designed to revolutionize the production of amorphous three-dimensional transformer cores. This cutting-edge equipment is designed for efficient and precise winding of low voltage foil windings and high voltage windings.
With its novel design, compact structure, high integration and dual functions, it significantly reduces winding time while providing convenience to operators and minimizing their workload. The resulting high and low voltage windings exhibit excellent performance consistency.
Application scope
Our company's amorphous high and low voltage integrated fully automatic winding machine is a multi-functional automatic winding equipment specially used to wind the core windings of amorphous three-dimensional transformer cores.
Suitable for producing low-voltage foil windings and high-voltage windings of 50KVA-630KVA amorphous (silicon steel) three-dimensional transformer cores.
It is easy to assemble and can also produce flat high and low voltage windings. It achieves the perfect balance of versatility and efficiency, making it an all-in-one solution.
Innovative technical features of amorphous magnetic cores
Utilizing amorphous alloys, known for their excellent magnetic properties, as core materials for transformer manufacturing, extremely low loss values can be achieved. However, amorphous alloys have unique properties that must be carefully considered during design and production, focusing on their sensitivity to mechanical stress. Compared with traditional silicon steel core winding, this requires new breakthroughs in key equipment.
Non-contact core winding technology
Structural design must avoid conventional design solutions that use the iron core as the main load-bearing component. In traditional low-voltage foil winding, the slide rail of the winding gear mold is fixed on the iron core through bolts, exerting the entire mechanical stress of the winding process on the iron core. Due to their material properties, amorphous cores are highly sensitive to external stresses and can be significantly affected by vibrations during the winding process.
This can lead to increased losses and even an increased risk of short circuits.
Our innovative machine introduces a mechanism that suspends the gear mold on the iron core, allowing the winding coil to surround the iron core without any contact. This ensures that the winding process has zero impact on core performance. ii) Integrated high and low voltage
Dual-function Technology
The traditional winding process requires two separate machines with different functions. The iron core must be clamped and installed on the foil winding machine, and then the semi-finished product is transferred to the high-voltage winding machine for secondary clamping and winding of the high-voltage winding.
This process requires multiple manual interventions and repeated back and forth movements, making the operation time-consuming and labor-intensive. In addition, it affects the performance of the core.
Our company's research and development results are highly integrated high and low voltage dual-function equipment. Using this machine, the low voltage foil winding follows the high voltage winding, completing all three high and low voltage windings of a single transformer. With just one clamping, the machine can handle both low-voltage foil winding and high-voltage winding processes, eliminating unnecessary steps and increasing overall efficiency. iii)
Fully automatic winding technology (including round wire flattening)
Since the three-dimensional coil form of the triangular core needs to be wound with the core, a high degree of automation is crucial to ensure increased production efficiency.
Our equipment Integrates more than 20 sets of fully digital high-performance servo systems and numerous intelligent sensors to achieve precise control of core movement, foil/line movement, monitoring, and remote digital operation and maintenance functions.
Key features include automatic 120° core repositioning, core lateral/longitudinal position tracking algorithm, automatic wire arrangement, round wire flattening function, high-pressure flat wire servo constant torque tension control, and foil frame hydraulic self-locking for tension control.
The fully automatic high and low voltage winding machine improves product consistency and production efficiency, and provides rich HMI (human machine interface) and data interface capabilities to easily realize remote operation and maintenance of equipment, which is conducive to the transition to digital factory operations.
It is the first choice for amorphous three-dimensional transformer winding devices. iv)
Monitoring and remote digital operation and maintenance technology
Our equipment is equipped with monitoring and remote digital operation and maintenance capabilities, including four-station video surveillance systems, remote communication and control functions, and MES (Manufacturing Execution System) digital interfaces.
The collected data can be obtained instantly to monitor production status and equipment alarm information, such as viewing production line operation status and yield information in real time to ensure real-time monitoring of equipment production status.
In addition, factory managers can remotely access production information through computer terminals to ensure effective monitoring and management of real-time performance of equipment. In addition to capturing production information, equipment abnormalities can also be monitored through equipment networking.
After being connected to the Internet, the standard parameter data of the device can be monitored using IoT (Internet of Things) technology. Abnormal data that exceeds the standard range triggers early warning, and managers receive alerts on computer terminals, thereby avoiding production losses caused by unexpected failures.