Foil Winding Machine BRJ-1000: This foil winding machine has unique appearance, convenient operation, intuitive data display, high degree of automation, and is well received by users. This foil winding machine is widely used in oil-immersed transformer, dry transformer, special transformer and reactor production required.
Foil coils are of different thicknesses copper or aluminum foil as a conductor, with wide ribbon insulation material as the insulation between layers, with narrow ribbon insulation material as the end insulation, completed winding one time, forming a coil. The inner and outer leads of the coil are welded and wrapped up at the same time.
2.1 Standard main parameter table (can be customized)
|1||Coil working range|
|1-2||Axial length (with guide line)||650-1300mm|
|1-3||ID (Excluding row)||Diameter ￠100|
|1-4||OD MAX||Diameter ￠1200|
|1-5||ID MIN||Diameter ￠200|
|1-6||Suitable coil shape||Circle \ rectangle|
|2-1||Material||Copper foil \ Aluminum foil|
|2-3||Thickness||Copper foil: 0.3-2.5mm|
|Aluminum foil: 0.5-3mm|
|3-1||Coil ID||Diameter ￠400\510|
|3-2||Coil OD||Diameter ￠1000|
|3-3||Coil shaft length||1000mm|
|3-4||Core shaft size||Diameter ￠400-520|
|4-2||Wind power||Double layer 15KW|
|4-3||Speed adjustment mode||Frequency stepless governor|
|5-1||Weld way||Argon arc welding TIG|
|6-1||Shearing way||Electric rolling shear|
|7||Insulating layer||Two sets|
|7-1||Air shaf OD and ID||Apply to the coil ID Ф75.5～Ф78|
|8||End insulation device||6 set (can customized)|
|9||Counting precision||0.1 turns|
|10||Deviation correction mode and accuracy||Photoelectric correction ±0.5mm|
2.2 The composition and function of the equipment
(1. Decoiler) (2. Feeding device) (3. Expanding device) (4. Compression device, Dust removal device) (5. Shearing device) (6. End insulation uncoiling device) (7. Winding machine) (8. Welding device) (9. Layer insulation uncoiling device) (10. Deviation rectifying device) (11. Electrical control device).
Two sets, front and back centralized control.
Decoiler is not only support the coil and feeding, but also has automatic deviation adjustment function.The main shaft of the uncoiling machine has a section of square section, and three sets of inclined hair blocks support three arc-shaped expansion blocks, which can tighten the coil material on the material barrel.The main shaft can be actively operated in forward or reverse direction for uncoiling, discharging and receiving, so as to adjust the working condition at any time. In linkage, the main shaft is disengaged from the driving device through the clutch.The main shaft is equipped with two sets of pneumatic controller damping devices, which can be used independently or in parallel, making the adjustment range of expansion force wide.The power of damping device is pneumatic, easy to control, clean and safe.The whole uncoiling mechanism is connected with the main frame by linear guide rail with large specifications, and equipped with servo power system. According to the instructions of the PLC main control system, the uncoiling mechanism will move around the guide rail quickly and accurately, so as to ensure that the foil is always in the accurate position according to the feedback of the deviation detection signal and realize the deviation adjustment function of the foil belt.
2.1.2 Foiling machine
The winding machine is located at the front right of the equipment, and the output torque realizes winding of the coil through the winding shaft. The mechanical strength and output torque of the winding machine are given priority in the design. This design is configured with sufficient margin according to the maximum limit size of the workpiece material and the upper limit of the expansion force required by the process.
The case of the winding machine is composed of thick steel sheet, which is machined after the stress elimination treatment by annealing. The gear of transmission mechanism and reducer are made of large modulus, helical tooth shape and hard tooth surface parameters. It guarantees the mechanical strength of large torque output and the smooth operation of the whole equipment with very low working noise.
Adopt frequency conversion speed regulation mode, provide maximum torque and suitable speed at low speed. High speed provides the right torque, maximum speed. To meet different winding process requirements.When winding the spindle, the slope of acceleration of starting and stopping is set reasonably, and the braking function is configured to improve the operation of the equipment. High power automatic brake motor, abundant reserve power.
2.1.3 Foil belt shearing mechanism
Two sets, High and low configuration, control separately.
After winding, cut the foil strip.The cutting mouth must be flat so that can weld well with the lead, especially the butt welding between foil belt. BRJ foil winding machine adopts rolling shear way to cut the foil belt. The upper pressure knife is mounted on a swinging rotary frame with a cylinder on each side of the lower end of the rotary frame to press the upper pressure knife and foil belt on the base. The lower hob is mounted on the sliding frame, and driven by the motor and screw rod to run on the linear guide rail, so that the lower hob rolls along the upper edge of the pressing edge, and the foil belt can be cut.In order to adjust the edge position of the upper press knife, the turning point of the rotary frame can be moved back and forth.In order to make the lower hob and the upper hob close but not bite the knife, the lower hob can move axial, through the spring press up the edge, reduce the difficulty of the assembly between the hob slider and the base, improve the shearing accuracy.
2.1.4 Automatic welding device
In order to meet the needs of lap welding and end welding, the jaws of welding fixture can swing by a certain range. The upper clamp can swing down, and the lower clamp can be replaced as needed. The seat of the automatic welding mechanism is installed on the main axle box of the winding machine, and the welding fixture, welding gun and automatic walking system can all operate on the seat. However, after the completion of the welding process, the welding mechanism will be moved back to the right to free up the winding position for the convenience of winding operation. The welding gun is installed on the walking trolley. The welding gun can be adjusted to various positions to adapt to different welding forms. The trolley is driven by speed regulating motor, speed reducer and lead screw. Can adjust the welding speed easily.
The welding way is argon arc welding (TIG) with AC and DC conversion, no filler.
2.1.5 Layer insulation uncoiling device
The layer insulation uncoiling device is a mechanism that supports the insulating material coil and causes the insulating material to produce expanding force during winding.This series of winding machine has two layers of insulation uncoiling mechanism.Two layers of insulating paper or film can also be provided.The mechanism is composed of four parts: inflatable material barrel, drive system, movable support and damping device.Press the valve at the end of the inflatable material barrel to retract the rubber swelling block of the material barrel, put it into the material barrel directly, use air gun to push out the rubber swelling block through the valve, and fix the insulating coil on the inflatable material barrel.Push the movable bracket into, make the supporting position of the gear bracket at the end of the shaft of the material barrel, and complete the loading of insulation coil.At this time, the drive and damping functions will act on the insulation coil fixed on the support, so that the layer insulation paper will maintain the expansion state specified in the process of winding, and the damping size can be conveniently adjusted randomly.
2.1.6 End insulation uncoiling device
The system consists of a guide rod frame, a feeding frame and a swinging slide frame.The feeding rack can move freely around the guide bar rack, each side feeding rack has feeding tray.The material belt is pulled out of the feeding tray and wound at both ends of the coil through various guide wheels, guide racks and felt pads.The size of material belt expanding force can be realized by adjusting the clamping degree of felt pad by setting screw.
2.1.7 Main frame
The main frame is a frame structure, which is made of thick steel plate and assembled with related components. Two sets of foil guidance system are set at high and low positions respectively, (deburring, dust removal device, pressure roller compression mechanism all can be automatic rectification precision) deviation adjustment detection device, layer insulation cutting device, winding shaft support frame, etc. To meet the double conductive foil guidance and processing. The main frame is designed with high strength to carry various mechanical forces and gravity. The position accuracy of the parallel axis holes on the left and right wallboard is ensured by synchronous machining.
2.1.8 Electric control system
All winding winding, deviation adjustment, number of turns control and various kinds of display, are calculated by PLC control system to give different instructions. Implemented by each system. The operator only needs to input the related working parameters through the large-screen touch-screen man-machine interface, which can easily complete the mass production of the workpiece with the same specification. All devices can also be manually operated by controlling the button, including inching and linkage. A number of emergency buttons are set in the position of the main console and the main device, which can stop in time in case of abnormality to ensure safety. All operations of the system can be carried out by the main console.
2.1.9 Pneumatic system
The system adopts modularized centralized control and a large number of mufflers, making the noise level of the whole machine lower than similar imported equipment.
Each branch pressure, flow independently adjustable.The implementation of each pneumatic action is controlled by PLC implementation program, and the pneumatic pipeline layout is reasonable and reliable.
|3||Correcting deviation system||KPS-C2|
|4||PLC program controller||DELTA|
|5||Electric elements||Schneider/ Omron|
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