Heavy Duty Transformer Coil Winding Machine Constant Tension 3500mm Axis 8000kVA

The TONGLI DXJ-3000B Heavy Duty Transformer Coil Winding Machine is our largest standard platform, engineered for power transformer works that wind very heavy coils of very large cross-section. It integrates the five core strengths our customers rely on, namely high precision constant tension, precise wire layout control, automated insulation, wide wire compatibility, and smart recipe storage, into a rigid 3500 mm machine capable of handling coils up to 6000 kg.

The machine targets the upper end of distribution and small power transformer production. A heavy cast bed and a reinforced tailstock rail absorb the torque of large foil and strip conductors, while dual PLC controllers synchronise the main spindle and the servo traverse carriage. The closed-loop tension system continuously corrects wire force so that even very large conductors are wound without slack or over-stretch, and the automatic insulation head applies inter-layer tape in step with the winding cycle for reliable dielectric performance.

• High Precision Constant Tension: Heavy-duty load-cell feedback holds constant tension on large conductors, protecting insulation and stabilising coil resistance.
• Precise Wire Layout Control: A servo traverse carriage lays every turn at an exact programmable pitch, producing dense, uniform layers on large coils.
• Automated Insulation: An integrated insulation head applies inter-layer and end insulation automatically, raising dielectric strength and shortening cycle time.
• Wide Wire Compatibility: Winds round, rectangular, strip, and foil conductors from 0.05 mm to 10.0 mm, covering LV and HV power coils.
• Smart Recipe Storage: Stores up to 1000 winding programs with turns, pitch, tension, and insulation data, recalling complete settings in seconds.
• Dual Servo Drive: Stepless 0-250 rpm with smooth acceleration and powerful, stable braking keeps very heavy coils fully under control.

The DXJ-3000B is built for power transformer plants and large distribution factories producing oil-immersed, dry-type, and cast resin transformers up to 8000 kVA, as well as heavy reactors and power inductors. It is the natural choice where very large coils with heavy strip or foil conductors must be wound with the same repeatability and insulation quality as smaller units, all under the control of a single operator.

Each machine is assembled, load-tested, and sample-wound at full tension before dispatch, then packed in a seaworthy plywood case with a steel-reinforced base and moisture-proof lining for safe sea 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.