Automatic 0 to 3150kVA Distribution Transformer Winding Machine using PLC, VFD, HMI.

Abstract

The Automatic 0-3150 kVA Transformer Coil Winding Machine revolutionizes the coil winding process for distribution transformers by integrating advanced automation technologies, including PLC (Programmable Logic Controller), VFD (Variable Frequency Drive), HMI (Human-Machine Interface), encoder, and gear motor. With this system, production is streamlined, accurate and is guaranteed as some of the important functions like counting the layers of coils, controlling tension, and manipulating the speed of the motors become automatic. The PLC is the central controller communicating with the HMI and VFD through Modbus RS232 and RS485 protocols giving operators the facility to program the parameters, such as coil patches, motor speed and tap changer settings with real time monitor performance of the system. This automated solution is far more productive as compared to conventional manual winding method where 3-4 employees require 1-3 coils per day, far less coils are produced compared to the automated one. It also eliminates the human error in patch numbers or winding tension, therefore, producing high quality of the coil and the transformer. This machine will be cost and scale-efficient in terms of companies dealing with current transformer manufacturing as it can reduce labor expenses, limit the time of production, and increase the precision of work due to Industry 4.0 specifications on modern automatized processes and smart computing.