Foil Coil Winder

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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.


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 & Processes Applied


  • 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


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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