WD-3500 CNC Vertical Generator Rotor Winding Machine

The WD-3500 CNC Vertical Winding Machine is an advanced assembly system primarily engineered for the precise winding and forming process of generator rotor coils. Utilizing a vertical disc winding mechanism, the equipment is capable of bending and winding both copper flat wire and round wire. The system is driven by high-performance Mitsubishi servo motors and features an intelligent automated continuous workflow. A standout feature is its real-time constant tension control—monitored via detection devices and adjusted via a magnetic powder damper—which ensures optimal wire tightness as the winding diameter changes. From hoisting and pre-winding to synchronized coil advancing, the entire operation is completed automatically with exceptional precision.

Application Scenarios:

• Large-scale high-voltage motor manufacturing

• Heavy-duty generator rotor component production

• Industrial alternator and turbine coil winding

• Large electrical machinery repair and assembly plants

FAQ:

• Q: What is the maximum load capacity for the rotor?
  A: The machine is built for heavy-duty applications and can support a maximum overall rotor weight of up to 5500 KG.

• Q: Can this machine handle both flat and round wires?
  A: Yes, it is designed to wind both flat copper wire (5-7 mm) and round copper wire (3-7 mm) using the wide edges of the material.

• Q: How does the machine maintain wire tension during winding?
  A: It utilizes a highly precise PLC control system combined with a magnetic powder damper. A detection device monitors the winding diameter in real-time and automatically provides stepless adjustments to maintain constant output tension.

• Q: Is the machine difficult to program for different rotors?
  A: No, it is highly user-friendly. The HMI touch screen allows operators to easily input parameters. Furthermore, it has a memory storage function that saves settings for common rotor specifications, allowing you to retrieve them with a single click without manual re-entry.

• Q: What happens if there is a mechanical or electrical fault?
  A: The CNC system includes built-in self-diagnostic functions that monitor the motor, sensors, and controllers in real-time. If an anomaly occurs, it triggers a warning, attempts automatic repair, and precisely locates the fault point for easy maintenance.

• Exceptional Accuracy: Employs advanced CNC technology to control wire positioning at the millimeter level. This ensures neat, symmetrical winding and prevents cargo loosening or surface defects caused by wire misalignment.

• High-Efficiency Production: Delivers operating speeds several times faster than traditional manual or semi-automated equipment. Combined with intelligent sensing devices, it minimizes intermediate manual steps, significantly shortening the production cycle.

• Stable & Reliable Operation: Core transmission gears are forged from high-strength alloy steel with carburizing and quenching treatments for superior wear resistance. Additionally, the CNC system features a built-in self-diagnostic and error-correction function to monitor components and facilitate rapid troubleshooting.

• Intelligent & Easy to Operate: Features a clean, intuitive HMI large touch screen displaying parameters in text and graphics. It includes memory storage functionality to save and retrieve parameter settings for common specifications with a single click, drastically reducing training time for new operators.