High Precision Transformer Coil Winding Machine Constant Tension Auto Insulation Recipe

The TONGLI DXJ-1600P High Precision Transformer Coil Winding Machine is a premium winding system for manufacturers who demand the most stable electrical characteristics from every coil. It combines closed-loop constant tension, servo precise wire layout control, automated insulation, wide wire compatibility, and smart recipe storage in a single platform, so that identical transformers can be produced batch after batch with almost no operator variation.

Where a general-purpose winder leaves tension, pitch, and insulation quality to the skill of the operator, the DXJ-1600P regulates all three electronically. A load cell feeds tension data back to the PLC hundreds of times per second, a servo traverse carriage places every turn at an exact programmable pitch, and an automated insulation head applies inter-layer tape without stopping the winding cycle. The outcome is tightly packed, dimensionally accurate coils with consistent resistance, low stray loss, and far less rework.

• High Precision Constant Tension: A closed-loop load-cell system holds wire tension steady from the first turn to the last, eliminating loose or over-stretched conductors.
• Precise Wire Layout Control: A servo traverse carriage lays each turn at a programmable pitch for uniform, gap-free, perfectly layered coils.
• Automated Insulation: An integrated insulation head wraps inter-layer and end insulation automatically, shortening cycle time and guaranteeing dielectric integrity.
• Wide Wire Compatibility: Handles round, rectangular, and foil conductors from 0.05 mm to 6.0 mm, covering LV and HV coil production on one machine.
• Smart Recipe Storage: Stores up to 500 winding programs with turns, pitch, tension, and insulation parameters, enabling one-touch changeover between coil types.
• High Torque Servo Drive: Stepless 0-350 rpm with smooth acceleration and stable braking keeps heavy coils under full control.

The DXJ-1600P is used in transformer factories assembling oil-immersed, dry-type, and cast resin transformers up to 3150 kVA, as well as in the production of reactors, chokes, and precision inductors. It is particularly suited to lines that run many product variants, because the smart recipe library and automatic insulation let a single machine handle different wire types and coil geometries with minimal downtime and consistent quality.

Each unit is assembled, load-tested, and sample-wound under full tension before dispatch, then packed in a seaworthy plywood case with a steel-reinforced base and moisture-proof lining for safe ocean transport. TONGLI provides a one-year warranty, free first commissioning and operator training, and lifetime spare parts support, with remote video commissioning or on-site service available worldwide.