GZR-800 High-Voltage Winding Machine: Driving the automation upgrade of transformer manufacturing.

In today's rapidly developing power and electrical equipment manufacturing industry, the production precision and efficiency of core components such as transformers, current transformers, and reactors directly affect the performance and reliability of the final products. Coils, as the heart of these devices, are particularly critical in their winding process. Traditional manual or semi-automatic winding methods can no longer meet the market's demand for high consistency, high complexity, and large-scale production. Against this backdrop, high-voltage coil automatic winding machines have emerged as core equipment for industry transformation and upgrading. This article will delve into the technical characteristics and application advantages of the GZR-800 (2+1) high-voltage coil automatic winding machine and how it provides a revolutionary solution for manufacturing precision components such as "wound cores."

High-Voltage Coil Automatic Winding Machine: The Core Driver of Precision Manufacturing

An advanced high-voltage coil automatic winding machine, such as the GZR-800 (2+1) model, is far more than just a simple winding device. It is a complex system integrating precision mechanics, servo control, intelligent sensing, and flexible design. The core mission of such equipment is to achieve full automation and high-precision control of the coil winding process, ensuring that every coil produced has excellent electrical performance and mechanical stability. For the production of "wound core" transformers, the axial tightness of the coil, the uniformity between layers, and the perfect fit to rectangular and other irregularly shaped frames are key indicators of the equipment's capabilities. An excellent automatic winding machine lays the foundation for the manufacture of high-quality transformers by addressing these pain points.

In-Depth Technical Analysis of the GZR-800 (2+1) Automatic Winding Machine

The GZR-800 (2+1) model represents the technological forefront in this field. The "(2+1)" in its name reveals one of its outstanding capabilities: supporting parallel winding of two round wires while also being compatible with single round or single flat wire winding. This flexibility allows manufacturers to meet diverse product specifications and production needs without changing equipment.

The technical advantages of this equipment are reflected in several aspects:

1. Power and Rigid Structure: The maximum working torque of up to 200 N/M and the machine body weighing approximately 1600 kg ensure stable and reliable operation when winding large workpieces weighing up to 500 kg and with an outer diameter of 600 mm. The 840 mm center height design optimizes ergonomics for the operator.

2. Intelligent Wire Laying System: The core of the equipment is its servo motor-driven automatic wire laying device, which, combined with ball screws and linear guides (TBI brand), achieves a minimum wire spacing adjustment accuracy of up to 0.01 mm. The synchronous movement of the wire laying mechanism and the wire feeding frame effectively eliminates tension fluctuations caused by asynchronous movement, which is crucial for maintaining the flatness of flat wires or parallel round wires.

3. Advanced Control System: The control center, built with Inovance PLC, servo system, and touch screen, allows the operator to perform stepless variable frequency speed control (0-220 r/min) and preset start and stop slopes to achieve optimal winding conditions. Five-digit reversible counting, power-off retention, and up to 20-segment winding functions meet the programming needs of complex coil processes.

4. Tension and Compatibility: The adjustable tension wire feeding frame and pneumatic clamping device can accommodate a wide range of wire gauges, from Φ3mm enameled wire to 3×12mm flat wire, ensuring constant tension and tight coils during the winding process.

Why Automatic Winding Machines are Key to Producing "Wound Core" Transformers

"Wound core" transformers, as a high-performance transformer core structure, place extremely high demands on the coils wound on them. The coils need to be wound uniformly and tightly on the core column; any uneven winding or looseness can cause inter-turn short circuits, local overheating, or increased electromagnetic noise. The GZR-800 automatic winding machine ensures the quality of "wound core" transformer coils through the following methods:

• Absolute Consistency: PLC program control of the winding pitch and number of turns completely eliminates human error, ensuring that the geometric parameters of each coil are exactly the same in mass production.
• Exceptional Tightness: Constant tension control and precise wire placement ensure that each turn of wire is tightly wound against the previous turn, reducing inter-layer gaps and thus improving space utilization and coil mechanical strength.

• Handling Complex Processes: For high-voltage coils requiring inter-layer insulation insertion, segmented winding, or special transposition, the equipment's programmability allows these complex processes to be executed accurately and flawlessly.

Beyond Winding: The Overall Benefits of Automation

Investing in a high-end automatic coil winding machine like the GZR-800 brings multi-dimensional benefits:

• Doubled Production Efficiency: Compared to manual winding, automation significantly increases speed and allows for 24-hour continuous operation, significantly shortening delivery cycles.

• Significantly Reduced Losses: Precise control reduces scrap rates caused by wire breakage and winding errors, while optimized tension settings reduce damage to the wire insulation layer.

• Optimized Labor Costs:Reduces reliance on highly skilled operators; ordinary employees can manage multiple machines after training, freeing up manpower from repetitive tasks to focus on quality control and process optimization.

• Enhanced Product Competitiveness: The consistency and high reliability of the produced coils directly improve the performance level and market competitiveness of the final transformer products.

Industry Outlook and Conclusion

As global demands for power quality, energy efficiency, and renewable energy integration continue to rise, the demand for high-performance transformers and their core coils will continue to grow. High-voltage coil automatic winding machines, especially equipment like the GZR-800 (2+1) model with high flexibility, high precision, and intelligent control functions, are becoming a necessity rather than an option. It is not only a tool for achieving production automation but also a core component for enterprises to move towards Industry 4.0 and build smart factories. By digitizing process knowledge and embedding it into the equipment, manufacturers can ensure that their core intellectual property is accurately and efficiently replicated and passed on.

In short, automatic coil winding machines have become a strategic piece of equipment in modern electrical manufacturing. The GZR-800 (2+1) model, with its powerful technical specifications and future-oriented design, provides transformer manufacturers with a reliable solution to meet market challenges and improve the quality of high-end products such as "wound cores." Choosing a suitable automatic winding machine is undoubtedly a crucial step for companies to build a long-term technological competitive advantage in the fierce market competition.