Transformer Coil Winding Machine Servo PLC 2000mm Axis 2000kg Load 0.02mm Precision

The TONGLI DXJ-2000 Transformer Coil Winding Machine is a heavy-duty, servo-driven winding system engineered for manufacturers who wind the low-voltage and high-voltage coils of oil-immersed, dry-type, and distribution transformers. Built on a rigid cast-iron bed with a hardened 2000 mm winding axis, the machine supports coil weights up to 2000 kg and transformer capacities up to 2500 kVA, making it equally suited to single prototype coils and continuous production lines.

At the heart of the machine is a fully digital control architecture that combines a programmable logic controller (PLC) with a high-torque AC servo drive and a 10-inch colour touchscreen HMI. Operators can store and recall winding recipes, monitor live tension, and switch between manual and automatic modes without re-tooling. Automatic servo tension control holds the wire at a constant, programmable force throughout every layer, eliminating the loose or over-tight turns that cause insulation damage, buzzing windings, and premature transformer failure.

• Servo PLC Control: Closed-loop AC servo drive with PLC logic and a 10-inch touchscreen for recipe storage, live monitoring, and one-touch changeover.
• 0.02 mm Winding Precision: Digital turn counting with 0.1-turn accuracy and 0.02 mm wire placement tolerance deliver evenly layered, tightly packed coils.
• 2000 kg Heavy Duty Load: A hardened 2000 mm axis, 1250 mm centre height, and reinforced tailstock track support the largest distribution and power transformer coils.
• Automatic Servo Tension Control: Constant programmable tension across the full traverse prevents insulation damage and inconsistent coil resistance.
• Variable Speed Gearbox: Stepless 0-320 rpm with forward and reverse jog gives a smooth start, stable braking, and low-noise operation.
• Wide Wire Compatibility: Handles round copper and aluminium wire from 0.1 mm to 5.0 mm as well as flat and foil conductors.

The DXJ-2000 is deployed across transformer manufacturing plants, coil winding workshops, and electrical equipment repair shops. It winds the primary and secondary coils of oil-immersed distribution transformers, dry-type cast resin transformers, rectifier and furnace transformers, and instrument current and potential transformers. The machine is also used for inductors, reactors, and chokes that demand tight layer winding and repeatable electrical characteristics.

Every unit is assembled, loaded to rated capacity, and test-wound before shipment, then packed in a seaworthy plywood case with a steel-reinforced base and moisture barrier to withstand ocean freight. TONGLI provides a one-year warranty, free first commissioning and operator training, and lifetime spare parts support. Our engineers deliver remote video commissioning or on-site service within five working days of equipment arrival.