Dual-layer Foil Coiling Machine

Machine uses:

The double-layer foil winding machine is a device capable of winding double-layer foil coils in one operation. It is suitable for winding coils of circular, elliptical, rectangular, and other shapes using copper or aluminum foil strips of varying thicknesses as conductors and wide-band insulating material as interlayer insulation. It is commonly used in the production of electrical equipment such as foil transformers.

Machine composition:

The Synchronous double-layer winding consists of 2 sets of unwinding devices, 2 sets of tensioning devices, 2 sets of expansion devices, 2 sets of creasing devices, 2 sets of decontamination devices, 2 sets of feeding devices, 2 sets of layer insulation devices, 8 sets of end insulation devices (4 sets on each side), 2 sets of foil tape correction devices, 2 sets of photoelectric correction induction devices, 2 sets of shearing devices, 1 set of welding devices, an electrical control system, and a winding main unit.

 Technical parameters :

No.	Items	BRJ-400-2	BRJ-600-2	BRJ-800-2	BRJ-1000-2	BRJ-1200-2	BRJ-1400-2	BRJ-1600-2
1	Coil processing range
1.1	the axial length	150～400	150～600	150～800	150～1000	150～1200	150～1400	150～1600
1.2	the axial length   (including lead)	850 mm	1050mm	1250 mm	1450 mm	1650 mm	1850 mm	2050 mm
1.3	Outer diameter (including row)	φ1000	φ1000	φ1000	φ1000	φ1000	φ1000	φ1000
1.4	Outer diameter	φ800	φ800	φ800	φ800	φ800	φ800	φ800
1.5	The left coil leads length	250 mm	400 mm	400 mm	400 mm	400 mm	400 mm	400 mm
2	Coil material
2.1	thickness(mm)	copper foil：single-layer0.3～2; double-layer 0.5~1.8
		Aluminum foil:  single-layer 0.5～2.2; double-layer 0.5~2.0
2.2	material coil diameter (mm)	φ460／φ520	φ460／φ520	φ460／φ520	φ460／φ520	φ460／φ520	φ460／φ520	φ460／φ520
2.3	Max material coil diameter (mm)	φ900	φ900	φ900	φ900	φ900	φ900	φ900
3	Uncoiler  2 sets
3.1	loading tube length	450	650	850	1050	1250	1450	1650
3.2	bearing cylinder expanding range	φ460／φ520 mm	φ460／φ520 mm	φ460／φ520 mm	φ460／φ520 mm	φ460／φ520 mm	φ460／φ520 mm	φ460／φ520 mm
3.3	bearing cylinder loading (Max)	1500kg	2000kg	2000kg	2500kg	3000kg	3500kg	3500kg
3.4	expansion force	6000N	6000N	8000N	10000N	10000N	12000N	12000N
3.5	Expanding pressure	0～0.6Mpa	0～0.6Mpa	0～0.6Mpa	0～0.6Mpa	0～0.6Mpa	0～0.6Mpa	0～0.6Mpa
4	Winder
4.1	work torque (Max)	8000N	8000N	8000N	8000N	8000N	20000N	22000N
4.2	wind power	11 KW	15 KW	15 KW	22 KW	18.5KW	22 KW	30 KW
4.3	Dimension of winding axis	60×60×770 mm	60×60×970 mm	60×60×1270 mm	70×70×1470 mm	70×70×1670 mm	70×70×1870 mm	70×70×2070 mm

Advantages:

• Doubled Production Efficiency: The CNC double-layer foil winder integrates automatic foil feeding, tension control, deviation correction, shearing, welding, and insulation wrapping functions, reducing manual intervention and facilitating material changes and tension adjustments, further improving overall operational efficiency.
• Optimized Coil Performance: The Automatic double-layer foil winding machine uses a servo motor for constant tension control, ensuring stable foil and layer insulation tension. This results in high axial and radial compactness of the wound coils, good dimensional consistency, effectively reducing coil outer diameter and increasing equipment power density.
• Strong Process Adaptability: The Two-layer Foil Winder supports various winding methods such as overlapping and parallel winding, capable of handling coil designs of different voltage levels and capacities, adapting to complex winding structures, and enhancing product design flexibility.

• High Winding Precision: The double-layer foil winding machine is equipped with a photoelectric hydraulic deviation correction system, achieving a deviation correction accuracy of ±0.05-±0.5mm. It corrects foil misalignment in real time, avoiding interlayer misalignment and insulation damage, ensuring coil insulation performance and operational reliability.The double-layer foil winding machine employs PLC + touchscreen control, combined with precision transmission components such as ball screws and linear guides, to achieve accurate setting and stable execution of winding parameters, ensuring consistency in mass production.
• Easy Operation and Maintenance: The High-precision foil winding machine boasts a high level of automation, a user-friendly interface, and intuitive parameter settings and status monitoring, reducing the intensity of manual operation and the skill threshold.

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