Vikrant machines cover a wide range of winding machines suitable for winding of Transformers from 25KVA
Distribution Transformers to 1200 MVA Large Power Transformers in 11 KV – 765KV class. Vikrant’s winding
machines can be broadly classified into following categories;

Wire Winding Machine – CWR Series

This machine is widely used for winding of HV coils of Distribution Transformers from 25KVA – 1000
KVA with enamel or paper covered round Aluminium or Copper wire. This is a very popular and
economical choice for high speed winding of Cross over coils with wire feeding arrangement from the
operator side and manual guiding of wire by hand. No Tailstock and pitch winding arrangement is
required for such coils. An Electromagnetic brake is provided on the winding spindle.

The same machine can be used for single longer coils when equipped with Tailstock support and pitch
winding arrangement. In such cases the wire is fed from the front side of the operator.

The machine is supplied with one no wire bobbin stand with dancing wire pulley arrangement for wire
tension. All machines are fitted with AC VVF drive for infinite speed control and has provision for
bidirectional rotation. Standard machine is fitted with a Digital programmable revolution counter and
Rotary incremental Encoder. The Machine is operated by an electrical foot switch.

Programable Winding Machine – HLV Series

This is an high speed programmable HV & LV Coil winding machine for automatic winding of HV & LV
coils of Distribution Transformers from 200 KVA – 3000 KVA with single or two no enamel or paper
covered wire or strip conductors. Considerable reduction of winding time is achieved by using this
machine. The machine allows continuous winding with provision for automatic/manual feeding of full
width interlayer paper insulation. The Machine has recipe management which is useful for repetitive
winding of coils.

The major units of the machine are:

• Decoiler for Wire/Conductor with braking arrangement
• Servo motor driven Wire carriage unit with wire guide pulleys
• Decoiler for full width interlayer Paper insulation and paper cutting unit
• VVF controlled AC motor driven Basic Winder unit with brake on spindle
• Swing away type Tailstock unit for easy removal of coils
• PLC & HMI based centralised electrical control panel with AC motor & Servo motor drives

Optional Accessories:

• Edge Insulation Decoiler
• Expandable Winding mandrel

HV & LV Coil Strip Winding Machine upto 5 MVA Coil – CWMNG Series

This series of machines is the most popular for winding of HV &LV coils of Distribution
Transformers from the smallest size to 5 MVA with multiple paper insulated strip
conductors. Two speeds ranges are available on the machines which makes it convenient to wind
at high speed with relatively low toque requirement for lesser no of conductors and low speed
with high torque for winding of larger cross section of conductors. All models of this machine are
provided with AC VVF drive giving the flexibility of stepless speed control for operator’s
convenience. The machines are equipped with a sliding type Tailstock on bed to accommodate
different lengths of winding mandrels. Optionally swing away type Tailstock can be offered for
easy removal of coils. The operation of the machine is by means of twin electrical footswitches
which provides the option of bidirectional rotation. The standard Machine is fitted with a Digital
programmable revolution counter with Rotary incremental Encoder for displaying the no of Turns.

Accessories offered with the machines are

• Auto Rolling conductor guiding cum tensioning device
• Bobbin stand on wheels to accommodate max no of conductor Bobbins
• Collapsible Winding mandrel

High Torque HV & LV Horizontal Strip Winding Machine – CW & CWNG Series

This is the most popular and versatile model of Horizontal Coil winding machine for winding of
both HV & LV coils of large Power Transformer coils with multiple and heavy cross section/pre
transposed strip conductors. These machines are widely used by all major Transformer
manufacturers in the country for winding of 66 – 800 KV class &upto 500 MVA rating Transformers
The range of machine starts with capacity from 3.5 Ton – 25 Tons weight (Coil + Winding
mandrel). The machine can handle a max coil dia of 3000 mm and length of 3500 mm with max
Torque rating of 4000 Kgm. The machines are fitted with large diameter faceplate and heavy duty
Tailstock with Revolving centre and Roller support. Other arrangements of Mandrel
mounting/fixing as per customer requirement is also available. All machines are provided with AC
VVF drive for stepless control of winding speed and jerk free start/stop. The operation of the
machine is controlled by twin electrical foot switch with option for bidirectional rotation. The
machines are fitted with Digital revolution counter and Rotary Incremental Encoder, capable of
displaying 1/36th of a turn.

Optionally the machine can be equipped with a PLC/HMI and VIKRANT BAYWATCH Software for
programmable winding. The programme will accurately stop the machine at pre designated
position for transposition thereby eliminating the operator errors. The programme also has a
limited recipe management which is useful for repetitive winding of coils.

The Major Accessories for these machines are as follows:

• Auto rolling Conductor guiding cum Tension device with pneumatic/manual operation. Height adjustment feature is optional so is Loadcell for display of tension
• Conductor Bobbin stand for multiple Bobbins. Motorised traverse of Bobbin stand on Rails is optional, so is individual pneumatic braking arrangement for Bobbins.
• Motorised scissor type height adjustable Operator working platform
• Hydraulic Transposition/S Bend Tool & 900 Lead Bender
• Axial and radial coil pressing attachment

Vertical Coil Winding Machine – CWV Series

Vertical Coil Winding machines have a number of advantages over the conventional Horizontal Winding
machines in case of winding of large power Transformer Coils as well as some special design coils like
Loco coils were the radial winding depth is normally higher.

VIKRANT manufactures two versions of Vertical Coil Winding machines as follows:

1. Pit type Winding machine, series CWV/P – The Turntable is installed inside
a pit in the floor. The Turntable along with the coil moves up/down as the winding progresses with the
winder and conductor bobbins and Tensioning arrangement all at floor level. An Iris type platform is
provided at the floor level to accommodate various diameter of coils. The major advantage of this version
of winding machine over the Floor type Vertical winding machine is that it allows removal of coil from the
winding mandrel with low level of overhead crane hook height.

2. Floor type Winding machine, series CWV/E – The Turntable is at the floor level with the winder
along with the Bobbins and Tension arrangement moving up/down on a mechanical /Hydraulic elevating
platform as the winding progresses. The platform goes all around the coil and has an Iris type mechanism
to adjust to different coil diameters. This type of winding machine is preferred where ever higher crane
hook height is available and construction of a pit in the floor is not possible.

For winding with strip conductors transposition of conductors is an essential operation. Manual bending of
heavy cross section conductors is a difficult operation for the winders resulting in damage to conductor
insulation, non-uniform bending and loss of time. VIKRANT manufactures Spring Balancer suspended hand
held Hydraulic Transposition Tool which makes the operation very simple and gives uniform quality of Bend.
The Bend Tool is powered either by an Hydraulic Power pack or by means of an Hydro-Pneumatic Booster.

VIKRANT offers two models of Transposition tool suitable for both PICC and CTC conductors
Model SB 40 and SB 70

Washer Cutting Machine is used to producewashers by cutting the OD & ID from Pressboard sheets of 2 – 6
mm thickness. The circular cutting is achieved by rotating the pressboard with the twin circular cutters
providing a scissor action to cut the press board in a circular configuration. VIKRANT manufactures
Washer cutting Machine which can cut Washers having min/max diameter from 250 – 2500 mm from max
Press board sheet size 2.6 x 2.6 mtr.

VIKRANT manufactures a wide range of Collapsible/Expandable Winding Mandrel/ Former from min diameter
180 mm – 2800 mm with length as per customer’s requirement. The diameter setting is done on the winding
machine itself with a suitable Ratchet handle supplied by us, reducing the set-up time drastically.

These Mandrels work on Link/Taper wedge type Umbrella principle with central leadscrew and provision of
locking the set diameter. The Top surface of the mandrel can either be polished Densified Laminated wood Or
Cast Nylon as per customer’s requirement with straight OR zig-zag type configuration.

The mandrels have been designed/engineered suitably to take the heavy winding torque and the conductor
tension without any distortion or shrinkage in the set diameter.

OPTION FOR MOTORISED OPERATION OF MANDREL IS ALSO AVAILABLE ON REQUEST

Features:

• Easy to operate
• Rugged design, roundness and taper within +/-1.5 mm
• High performance

VIKRANT offers a versatile multi head milling machine which is capable of following multiple operations on Press board strips (Runners/Blocks) widely used in the Transformer industries.

1. Edge rounding operation
2. Edge beveling operation
3. ‘T’ cutting operation
4. Thickness machining

The machine consists of a fabricated Table on which the multiple Vertical and Horizontal Milling heads are mounted. The machine has a provision for automatic strip feeding and suitable strip guiding arrangement, which is to be set manually according to the strip width. All the cutter motors and the strip feeding motor are controlled with AC VFD drive giving a wide range of cutting speed and feed rate making the machine very flexible for machining of different sizes of press board strips.

The customer can opt for the full machine capable of all the above operations or can request for any specific operation as required by them according to which the machine will be configured by VIKRANT

The machine is suitable for milling inner and outer diameter on laminated wood of various thicknesses ranging from 10 – 60 mm. The machine consists of a vertical turntable on wheels with a large diameter faceplate with multiple ‘T’ slots for clamping of the laminated board. Additional roller supports are provided if required for support of the overhang portion of extra-large diameter boards.

A traveling type milling head with provision for vertical adjustment is mounted on horizontal tubular rails. The milling head is positioned on the rails with secure clamping according to the diameter to be machined. The travel of the milling head on the rails is motorized for easy positioning. Machine is equipped with an independent dust collector.

End supports for large Power Transformer coils are made by joining individual strips of max 4metre length x 600 mm wide by applying glue under pressure and heat and then wound to the required length on a motorized Coiler/Decoiler. Thereafter the continuous strips are rewound on a winding machine according to the required diameter on adjustable diameter wooden formers under tension while passing through a gluing station.

The machine basically comprises of the following major units:

1. Motorized Coiler/Decoiler with tensioning arrangement
2. Fabricated Table with clamping pressure pad and heating pad
3. Coiling machine with adjustable diameter winding former
4. Gluing station
5. Pneumatic radial Coil pressing device is Optional.

The machine is used for cutting the Press Board cylinder to the final desired length as required for the winding of the Coil. The Equipment basically consists of two large ‘V’ shaped plates with slots at regular intervals resting on a fabricated base frame. Two shafts with four nylon wheels of adequate dia are placed in the slots of the ‘V’ plate according to the diameter of the cylinder.

The cylinder to be cut is placed on the shaft so it rests on the four nylon wheels. The two rear nylon wheels are adjustable and mounted on the shafts according to the length of the cylinder. One of the front wheels, which is keyed to the shaft is driven by a geared motor. An adjustable type end support is provided at the other end of the cylinder. The slitting saw machine Bosch/equivalent make is mounted on a ‘L’ type stand. The cutting unit is manipulated through a pneumatic cylinder for engaging and withdrawing during cutting operation. A swing away type end gauge is provided at the front side for aligning the cutting edge. An arrangement for taking up the cut piece ring is provided. Machine is equipped with Vacuum dust collector arrangement.

Prior to putting the Pressboard cylinder in the oven for removal of moisture, it is required to be impregnated in a bath of transformer oil. The rolled cylinder is dipped in a bath of transformer oil and rotated at a very low rpm. Provision for motorized cylinder upending arrangement is in built in the machine.

Adjustable support arms with rollers are provided as support for different diameter of cylinders. Separate dripping area is available on two sides of the machine. Provision for manual oil filling & draining arrangement is made in the machine. Acrylic cover is provided to prevent contamination of oil when not in use.