How to Operate a Transformer Winding Machine with PLC Control: A Step-by-Step Guide

How to Operate a Transformer Winding Machine with PLC Control: A Step-by-Step Guide

Transformer winding machines are vital for manufacturing efficient electrical transformers. Modern PLC-controlled machines, like the JC 90Q0 Intelligent Pressure Roller Winding Machine, offer precision and ease of operation. Here’s a step-by-step guide to operating such equipment:

1. Pre-Operation Setup & Safety:

• Power & Environment: Ensure the machine is connected to the correct power supply (AC380V/50Hz for the JC 90Q0). Verify a stable, clean power source and sufficient workspace ventilation.

• Machine Inspection: Visually check for damage, loose components, or debris. Ensure safety guards are in place. Lubricate points as per the manual.

• Material Loading: Mount the enameled wire spool securely onto the uncoiling/rectifying device. Thread the wire correctly through the tensioners, guides, and pressure rollers, ensuring smooth feeding without kinks. Load the core/bobbin onto the winding spindle and secure it firmly.

• Tooling Setup: Install appropriate tooling (mandrels, flanges) based on the desired coil form (Circular, Oblong, Elliptical, Rectangular).

2. PLC Control System Programming:

• Access HMI: Power on the machine and access the Human-Machine Interface (HMI) touchscreen connected to the PLC.

• Input Parameters: Set the critical winding parameters:

  • Wire Feeding Length: Input the exact wire length required (0-9999mm).

  • Winding Speed: Set the rotation speed (0-1000 rpm) appropriate for the wire gauge and precision needed.

  • Wire Tension: Configure the tension (0-2.5 Kg) to ensure consistent layering without stretching or damaging the enamel.

  • Winding Pitch: Define the distance between wire turns for layer consistency.

  • Coil Dimensions: Input target axial height (≤800mm) and outer diameter (≤600mm).

  • Winding Angle: Set the traverse angle (0-360°) if applicable for specific patterns.

• Save Program: Save the parameter set as a specific program for future identical windings.

3. Running the Winding Process:

• Initial Test Run: Perform a short test run without wire or at very low speed to verify spindle rotation, traverse movement, and tensioner operation.

• Start Winding: Initiate the programmed winding cycle via the HMI. The PLC will automatically control:

  • Consistent wire feeding via the rectifying device.

  • Precise spindle rotation speed.

  • Synchronized traverse movement for the selected angle and pitch.

  • Constant wire tension.

• Real-Time Monitoring: Observe the winding process closely on the HMI. Monitor parameters like actual wire length fed, current speed, tension, and layer count.

4. In-Process Quality Control & Adjustment:

• Visual Checks: Regularly inspect the coil for consistent layering, absence of gaps or overlaps, and proper wire alignment. Ensure tension remains stable.

• PLC Intervention: If minor adjustments are needed (e.g., slight tension tweak, speed change), most PLC systems allow parameter modification during operation without stopping (within safe limits). Major changes usually require pausing.

5. Completing the Cycle & Unloading:

• Automatic Stop: The machine will automatically stop when the preset wire length is reached.

• Secure Wire End: Cut the wire and secure the end of the coil to prevent unwinding, often using tape or a designated clamp on the bobbin.

• Unload Coil: Carefully remove the finished coil from the spindle.

• Layer Insulation (If Equipped): If the machine has a TIG Layer Insulation Welding Device or Foil Coiling attachment, follow the specific procedures to apply inter-layer insulation or foil during the winding process as programmed.

6. Post-Operation:

• Clean Machine: Remove any wire scraps, dust, or debris from the machine bed, guides, and rollers.

• Record Data: Log production data (program used, wire length, time, any issues) for traceability and quality control.

• Program Storage: Save or archive successful winding programs on the PLC/HMI for future repeat orders.

Key Advantages of PLC-Controlled Operation (JC 90Q0 Example):

• Precision & Consistency: Eliminates human error, ensuring every coil meets exact specifications.

• Efficiency & Speed: High winding speeds (up to 1000 rpm) and automated processes boost output.

• Flexibility: Easy reprogramming via the PLC HMI allows quick changeovers between different coil types and sizes.

• User-Friendly: Intuitive touchscreen interface simplifies complex parameter setting.

• Repeatability: Saved programs guarantee identical results for mass production.

• Reduced Waste: Precise wire length control minimizes material scrap.

By following these steps and leveraging the advanced PLC control system, operators can efficiently and reliably produce high-quality transformer coils for various applications, maximizing the potential of sophisticated equipment like the JC 90Q0 Transformer Winding Machine. Always refer to the specific manufacturer's manual for detailed safety procedures and operational nuances of your machine.