Coil Winding for Wind Turbines

Description:
With the largest range of coil winding machine sizes available, tailored specifically for generator winding, we can more closely accommodate your winding application.

These models are very heavy duty, solid welded steel construction of the highest quality for many decades of heavy industrial use.

Select From:

Various machine models and sizes
Several speed (rpm) ranges available
Horsepower (hp) and torque (Nm) choices according to application requirement

Wind turbines; locatedin Northern Spain

Above: Example Wind turbines; located in Northern Spain.

Automatic Wire Layering: Programmable wire guide arm and pulleys to assure proper wire placement upon the coil.

Reverse Camber on Wire: We create a wire path through our guide pulleys which reverses the normal camber (bow) in the wire caused by its wrap on the wire supply spool. This causes the wire to form tightly against the pole onto which it is being wound. That has three important effects.

The coil will be more tightly wound.
No additional forming or hammering is required by the winding operator to form the wire to the shape of the pole. This allows the winding machine to keep turning, rather than frequently stopping for the operator to hammer the wire tight. Production and coil quality increases.
Creating a tighter coil will provide a reduction in the amount of copper wire used per coil, a cost savings.

Pole Holding Fixtures: Broomfield offers a range of special holding fixtures to provide for winding onto single, separate rotor poles. These may also utilize special tools to provide spacing between specific coil layers (cooling gaps) on the short sides of the coils, for proper cooling during generator operation. Fast and easy removal of spacer components after winding.

Wire Tensioners: Electro-pneumatic wire dancer/tensioners will keep the winding tension consistent while allowing for the constantly changing linear wire speed which occurs while winding highly rectangular poles.

These systems will enable the following:

Higher winding speeds
Increased production
Reduction of wire stretch, protecting insulation and retaining the highest coil quality
More precise wire positioning on pole
Electric rewind on these dereeler / tensioners is offered if wire back-up onto the supply spool becomes necessary

Stacked Lamination Rotor Holding Fixtures: If your generator design includes multi-pole rotors comprised of punched and stacked laminations, rather than individual poles separately attached to the rotor body, we offer special cantilevered holding fixtures.

Designs to accommodate winding rotors with shaft in or out.
Proper rotor orientation to assure wire parallel to pole. Once the rotor is loaded into the fixture which is mounted onto the output shaft of the winding machine, the rotor orientation is locked for the specific pole being wound. When one pole is finish wound, the rotor is unlocked and easily moved by hand within the fixture to align and lock for the next pole to be wound.
Overhead crane not required to change pole orientation. The crane is only necessary to initially load and then unload a complete wound rotor, not to change from winding one pole to the next. This greatly increases production.
Accompanying wire guide mechanism programmable for straight or skewed stack rotors.

For additional information on coil winding equipment or other Broomfield machines, please contact us directly at 1 (978) 779-6600 or through our online contact form.
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