American Type Single Phase Winding Machine

American Type Single Phase Winding Machine, 1.Width of the decoiler:350mm, 2.Revolving speed:0~200rpm - details see: https://www.machineto.com/american-type-single-phase-winding-machine-10325411

Place of Origin:Zhejiang China (Mainland)	Brand Name:SENERCE	Model Number:ZBRJ-I/300	After-sales Service Provided:Engineers available to service machinery overseas
Axial length:Max:300 mm	External diameter(mm)(not include wire):350mm	Coil type:Round, ellipse, rectangle	Width of the decoiler:350mm
Load the decoiler(max):300 KG	Pull force:Max:1000N.M(Stepless adjustable)	Speed regulation:Frequency stepless speed regulation	Revolving speed:0~200rpm
Electrical system:PLC auto control	Total power:8KW

1Summary

ZBRJ-I/300 Combined foil & wire winding machine is designed to wind coils of reactor, transformer and other electrical equipments. HV lead coil is wire structure, whereas LV coil is foil structure. It can simultaneously complete LV foil winding and HV foil winding .This equipment is used in electrical industry of the similar coil.

LV Foil coil is the completed thing on the combined winding machine with the copper or aluminum foil strips of the various different thickness as the conductor,and the strips insulation material as layer insulation.

HV coil use round wire or rectangle wire as conductor to be winded.The coil can be round, ellipse and rectangle.

PLC control which is highly automatic, various different configurations, ensure the axial compactness and radial firmness. Various configurations provide the support for producing qualified electrical coils. It is essential machine to manufacture the electrical products.

2Key Specification

Below is the specification of combined foil & wire winding machine; the machine can fully be customized to meet the customer requirements.

S.N	ITEM	SPECIFICATION	REMARK
1	Coil range
1.1	Axial length	Max:300 mm
1.2	External diameter(mm) (not include wires)	Φ350
1.3	Inner diameter(min)	No limited
1.4	Coil type	Round, ellipse, rectangle	Coil weight≤200kg
2	Coil material
2.1	aluminum foil	width≤600mm thickness : aluminum foil(0.3-1.2mm)x2layer Coil inside diameter:Φ300, Coil outside diameter≤Φ800
3	Conduct foil decoiling device
3.1	Width of the decoiler	350
3.2	Diameter range of the decoiler	Φ290--φ310
3.3	Load the decoiler(max)	300 KG
3.4	pull force	Max:1000N.M	Stepless adjustable
3.5	Tension working expressure	0~0.6 Mpa
3.6	Centering way(deviation Recertify)	Electric control, inching
3.7	Decoil press force	Pneumatic press unit
4	Winding device
4.1	Revolving speed	0~200rpm
4.2	Working torque(max)	≥ 1000 N.M	10kg Mechanical damping tension≤10kg
4.3	Power Main Moter	5.5 KW
4.4	Speed regulation	Frequency stepless speed regulation
5	Layer insulation decoiler device		Main expanding fore when back up
5.1	Installation axle of Layer insulation
5.2	outer diameter of insulation Layer coil	≤φ400 mm
5.3	Inner diameter of insulation Layer coil	Φ76 mm
5.4	Width of Layer insulation coil	Max:300mm
5.5	Decoiling way	Mechanic clamping
5.6	Damping force	≤50 N.M
6	deviatin Rectifying device
6.1	Counterdeviating method	Adjusted by hand
6.2	Counterdeviating precision	As operator
7	HV auto alignment device	Adopting ac servo motor system
7.1	Alignment method	Automatic alignment, limit Winding pitch 0.01mm
7.2	Suitable wire	Round wire:Φ0.3mm-Φ3.3mm, Rectangle wire: Max 3×7mm
8	Electrical system	PLC auto control
8.1	Count digits	5 digits(0.0-9999.9)	Count precision:0.1 turn
8.2	Basic function	Step input, revisable, power off memory
8.3	Work interface	Color touch panel	Chinese and English
8.4	Total power	8kW

3 FoilComposition and function

BRJ-I/300 Combined foil & wire winding machines consists of: 1) foil decoiler , 2)conducting device, 3)expanding device, 4)press device, 5)insulation decoil device, 6)winding device, 7)layer insulation decoiler, 8) rectify device; 9) electrical control device ;10) welding device.

3.1 The function of the various device

3.1.1 Foil decoiler

Foil belt decoiler is used not only for supporting and dispelling coil except for automatic rectify function.

Decoil device’s principal axel with a rectangle section tightens the coil through 4 tension block supported with 4 sets of connecting rod. It is easy to adjust the working process through the principal axis moving forward or backward to decoil and coil. During the Linkage stage, It withdraw the clutch spindle and driving device. The expanding force ranges much wide as brake damping device on principal axis. Damping devices us pneumatic method, with easy control, safe and clean.

The decoiler use large linear guide to connect with the main frame, it is deployed with the counter-deviation system and the mechanical speed regulation system. The decoiling mechanism can sway along the guide rail quickly and precisely on PLC control command, ensuring foil always at the precise position and fulfilling the counter-deviation function. Meanwhile, it has one extra wires decoil device.

3.1.2 Winding device

Winding device seated at the front left side, complete the wire winding process through winding roller. The mechanical strength and output torque is the primary consideration in design, the maximum size of coil and technical requirements of maximum tension force must also considered , then the design is completed through multiplying safe coefficient of the different varieties of quantity.

The frame of Winding device is made of tailed-welded thick steel plate annealing and machining. Transmission mechanism and reduction device’s gear all adopt large mold, helical form and hard-toothed surface gear, the terminal tooth profile is formed after grinding. Therefore it ensures mechanical strength at the large output torque, stable working and low working noise.

Frequency changer for speed adjustment is combined with speed change box. maximum output torque and desirable rotate speed is gotten at low speed, whereas at high speed the desirable output torque and the maximum rotate speed , thus the winding device meets various technical requirements of HV and LV coil. When the main roller winding, start, stop and accelerating gradient are reasonable. The brake system improve the operational performance. Motor capacity is sufficient.

3.1.3 Layer insulation decoiler

Layer insulation decoiler supports insulation material coil and provides tension at the winding stage. This serious of winding machine have two sets of layer insulation decoiler, and supply two insulating layer or thin film.

This device is composed of the support roller, the damping device. The insulation material is directly put to the supporting roller, and then the position block is fastened to fix the insulation material on the support roller. It can adjust the working pressure of the damping device, thus the damping status is kept on the technical requirement of winding.

3.1.4 Main frame

Main frame is a kind of single wall structure characterized with open feature; it is welded with thick steel plate after finish machining. Except for some main devices, the most of assistance devices are installed on it. foil guiding system, deburring device, cleaning roller and the lattice component of winding coil roller are respectively installed at suitable position to meet the conduction and procession of double layer foil.

Main supporting structure features the highly rigidity, which it supports the various mechanical forces and the gravity. The precision of the axle hole on the single wall can be ensured by highly finish machining.

3.1.5 Welding device

It is used for welding foil and lead .The jaw of the welding jig can be adjusted. The upper jaw can be pressed downward, and the lower jaw can be changed if necessary.

The welder base is fixed on the spindle box of winder. The welding jig, welding torch can move left and right, upward and downward on the welder base. After finishing welding, the welder move above to make space for winding process.

The welding torch is fixed on the moving dolly and can be accommodated to different welding requirements. The moving dolly is driven by motor, gear box and ball screw to change welding speed conveniently.

3.1.6 Auto alignment device

The set of equipment has automatic alignment function. Servo motor and PLC control systems are adopted in Auto alignment device, high-definition Touch screen implements the parameter display and the man-machine interface, the fine ball screw drive and straight movement mechanism satisfy the precise of the aligning line. The special lines implement the synchronization between automatic alignment and winding. The Alignment device has tightening function, and the expanding force can be adjusted to meet the requirements of different wire. It also has pneumatic device to adapt to the working need.

Auto alignment pitch is set according various wire configurations. During the winding, it can do manually fine adjustment to ensure coil tension at some possible error.

3.1 Electrical control system

The equipment have owned source program and operation process, all configuration of winding, turns control and segment control are controlled by PLC and indicated on the touch panel. Operator only set the working parameters through the touch panel to complete the volume production of the same product. The equipment can also manually be operated through the control button to realize inching and linkage work.

Emergency stop buttons are set on the main console and main devices in case of abnormal situation to ensure safety. All operation can implement on the main control console.

3.2 Pneumatic system

This system adopts the modular centralize control using the large quantities of the silencer, which ensures lower noisy compared with similar equipment. Each shunt pressure, flow is independent and adjustable. All pneumatic movement is controlled by PLC. Pneumatic tube arrangement is rational and stable.

4Main parts Suppliers

No	Item	Supplier
1	Touch screen	Mitsubishi
2	HP frequency converter	Mitsubishi
3	PLC	Mitsubishi
4	Low voltage Electric part	Schneider
5	Main motor for winding	ABB
6	Pneumatic part	E.MC
7	Linear guide rail	TBI
7	Ball screw	TBI