Transformers are devices that help conduct the transfer of electrical energy between multiple circuits through induction. Thousands of power transformers for residential, industrial, and commercial applications are manufactured in the US every year. The manufacturing of transformers is a lengthy process, and it involves many steps. Production of coils or windings is an important step in the transformer manufacturing. The coils feature several turns of copper wires, which are alternated between layers of insulation. Generally, these coils are wound on the winding machine at high speeds. You may ask how tension contributes to this process. Read on to know more.


Understanding the Importance of Tension in Coil Winding Machine


Consistent tension needs to be applied to the wire during the coil winding process. The coil is usually rectangular, or round shaped. The consistency and quality of the tension applied depends on the shape of the wire. In a round coil, the tension remains consistent during one revolution. However, in the rectangular coils, the wire tension is not consistent and experiences fluctuations. These fluctuations are due to rapidly changing wire path length.


The varying tension may affect the operation of shaft, and produce excessive forces, which may cause machine vibrations and non-uniform coil winding. When this happens, the rectification process is extremely time consuming, and it also may affect the productivity.


Today, various types of tension control machines are available in the market, which helps maintain constant wire tension during high-speed coil winding processes.


Benefits of Wire Tension Control Devices


Tension control devices are classified into three main categories – electronic, mechanical, and computerized control. The computerized control devices provide the best response time. Although the features of these devices may vary across brands, there are certain benefits that they offer. Some of the benefits are summarized below:


  • Helps Achieve Quality Standards: The rising demand for tight tolerance is driving the manufacturing industry to adopt stricter coil winding tension control measures. They are depending on automated tension control devices to meet the rising quality expectations. Many of the advanced tension control devices help them achieve high coil winding quality as well as repeatability.
  • Versatility: Many computerized control devices are designed to allow parameter changes to suit the diameter range. The wire tension control can be set as per the requirement.
  • Helps Maintain Process Efficiency: Most of the wire tension control devices are designed to match the maximum machine speed of the winding machine, which helps minimize wire breakages.


If you have any interest in automatic coil winding machine or other related devices, please do not miss DETZO Co., Ltd. – the company specializes in kinds of high quality automated production lines. Now, contact with Detzo for more details!


Article Source: