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Design and Manufacturing of a Foil
Coil Winder for the Electrical
Distribution Transformer Industry

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Foil Coil Winder

This foil coil winder was designed and manufactured for use in coil winding applications in the electrical distribution transformer industry. It was built with CNC machining, laser cutting, and MIG welding by certified welders. It features two foil dereelers and three paper pneumatic dereelers, with hydraulic operated side-to-side shift on both types of dereelers, and a manually operated foil steering feature. This machine is set up to wind four magnet wire conductors in parallel and features touch screen MMI control and teach functions for program set up (including prep for Cold Weld positioning). Accessories include a winding mandrel, Cold Weld tooling, a spindle magnet wire dereeler, and a wire flattener. We shipped it within 90 working days to Spruce Grove, Alberta (Canada). We will manufacture according to third party electrical system approval certification to meet your local legislation and regulatory needs, and we offer on-site commissioning and training.

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Project Highlights for Design and Manufacturing of a Foil Coil Winder

Product Description ETSM Designed and manufactured this HV/LV Foil Coil Winder for use within a coil winding application
Capabilities Applied/Processes
  • Create Concepts
  • Create 3D CAD Models and CAD Detail Drawings
  • Electrical System Approval Certification by 3rd Party to meet Local Legislation
  • Operation/Installation Manual
  • Maintenance Manual
  • Electrical Schematics
  • Hydraulic Schematics
  • CAD Detail Drawings
  • Flame Cutting
  • CNC Machining
  • Laser Cutting
  • MIG Welding
  • Painting
  • 1 Year
On-Site Commissioning & Training
System Specifications
Machine: Right Hand Orientation
7.5 HP Variable Frequency Motor & Drive
4 Speed Transmission
2 Foil Dereelers
  • 12" Diameter
  • 18" Face
3 Paper Pnuematic Dereelers
  • 12" Diameter
  • 30" Face
Hydraulic Operated Side to Side Shift on Foil and Paper Dereelers
  • 2" Stroke
Manual Operated Foil Steering Feature
Pneumatic Coil Pressing Roll
Programmable Traverse for HV Conductors
  • 30" Travel
Set Up to Wind 4 Magnet Wire Conductors in Parallel
Tailstock Support for Winding Mandrel
Touch Screen MM1
Teach Functions for Program Set Up
  • Includes Prep for Cold Weld Positioning
Foot Pedal for Spindle Control
  • w/ Reversing Switch
1 Winding Mandrel
  • 30" Saddle Length
  • 3" Minimum Width
  • 5" Minimum Height
Cold Weld Tooling
Spindle Magnet Wire Dereeler
Wire Flattener
System Size CNC Lathe, CNC vertical machining centre, CNC horizontal boring mill
Foil Dimensions Max. Width: 15"
Manufacturing Tightest Tolerances Typical Machine Tolerance ±.001"
Materials Used Steel
Material Finish Powder Coated
In process testing/inspection performed Operational Test and Certification
Mechanical Destructive Weld Test
Industry for Use Electrical Distribution Transformer
Delivery Time 90 Working Days
Delivery Location Spruce Grove, Alberta
Standards Met Customer supplied specification
Product Name HV/LV Foil Coil Winder

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