Hedrich Winding Systems is going to deliver to Siemens Sabugo, Portugal a foil winding machine for low-voltage coils of distribution transformers. The equipment comprises a new foil guiding design allowing winding coils in a considerably more compact way and process the employed copper foil with almost no waste.

Hedrich Winding Systems is going to deliver to Siemens Sabugo, Portugal a foil winding machine for distribution transformers. This machine is meant to increase for Siemens the production output for distribution and power transformers in Portugal, Spain and selected markets in the world. The new HWS system HFW 1200-2 is scheduled to be launched out for production in the third quarter of 2010. In the course of the project handling, Hedrich will also be responsible for the supervision of erection, installation and commissioning of the system as well as operator training and will render project planning services.

With the HFW 1200-2, low-voltage coils of distribution transformers are manufactured which are made of copper conductor foil. HFW stands for Hedrich Foil Winding, 1200 marks the foil width of 1200mm. The 2 indicates that the system is also capable of processing two conductor foils at the same time.

The HFW 1200-2 is a highly automated winding machine supplied by Hedrich with a specific winding program for each coil design. All process parameters are continuously monitored by the control, resulting in high process reliability that ensures a high and reproducible quality for each individual coil.

The most essential innovation implemented in the HFW 1200-2 is a combined brake system, consisting of a conductor foil unwinder with motor brake and a pneumatically activated brake station adjacent to the winder. This brake system allows a considerably higher foil tension even with full storage coil diameter and a significantly better exploitation of the storage coil involving less waste than with other foil winding machines available on the market.

Considerably higher foil tension even with full storage coil diameter

The conventional solution to only brake the storage coil is of disadvantage especially with coil diameters of more than 800mm. Due to the fact that the torque can no longer be transmitted, the coil slides off. With the additional brake station of the HFW 1200-2, only part of the foil tension must be generated at the unwinder whereas the larger part of the tension is created by especially coated brake rolls at the brake station. The result is a uniformly high foil tension even with full storage coil diameter, and the coil to be wound becomes more compact.

Significantly better exploitation of the storage coil, less waste

Another disadvantage of the commonly available brake system is the insufficient exploitation of the storage coil. The last windings of the conductor coil slide off on the cardboard cover and thus no tension can be generated any more. However, the Hedrich system is capable of providing much better exploitation of the storage coil because most of the foil tension is generated at the brake station which is located at a distance of approx. two meters from the winder.

Hedrich winding systems offers semi-automatic stand-alone machines as well as fully automatic production systems for manufacturing coils for transmission and distribution transformers as well as instrument transformers in the high- and medium-voltage range. The machines process most different wire and insulation materials and are used for cast-resin, oil or SF6-insulated high- and medium-voltage applications. The Hedrich systems in operation worldwide are characterized by high productivity and user friendliness. New control software developed by Hedrich with graphical user surface monitors and controls both the process parameters and the material storage and manufacturing progress. The cost savings resulting from this along with the increase of efficiency mean sustainable advantage to the user compared to competition.

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