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

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

During the process of winding the conductor needs to be joined when a conductor from one spool is
exhausted and a new spool is introduced to continue with the winding. Lap joint of two ends of
conductor is done easily and economically by Carbon Brazing machine without damaging the
conductor.VIKRANT’s Trolley mounted 15 KVA Carbon Brazing machine, Model VCB15 is suitable for
Lap joint of twin conductor in parallel with max individual cross section of 15x5mm. The unit is supplied
with a Brazing Tong capable of applying adequate pressing force for a strong joint as good as parent
conductor. Operation of the machine is by means of an electrical Foot switch.

Generally, for removal of heavy coils wound on a Horizontal Winding machine, the coils need to be made vertical so that it can be removed from the winding mandrel with the help of an EOT Crane. This is a highly skilled operation requiring expert handling of the crane. Improper handling may result in damage to the costly Coil and Crane.

The Coil Upender is a very useful Equipment for easy and safe tilting of coil from horizontal to vertical and vice versa. The Equipment is available in both hydraulic and electromechanical versions.

Coil lifting tackle is used for removal of coil in vertical configuration from the winding mandrel as well as for movement of Coil in the shop floor. The Lifting Tackle can be designed to accommodate a wide range of Coil diameters. The operation of the unit can be either manual or motorised as per the customer’s requirement. Min/Max size of coil handled ranges from Diameter 500 – 3000 mm x 3000 mm length. Max weight of individual Coil handledis 15 Tons.

Generally, after winding the axial length of the Coil is found to be more than the desired designed length. To achieve the designed length, the Coil needs to be compressed either with the help of a Standard Hydraulic Press or a by means of a specially designed Hydraulic Coil Pressing fixture.

Hydraulic Press – Preferably a Down stroking Four column or H frame Hydraulic Press with Coil loading Trolley is used for such an application. The Press capacity offered varies from 20 Tons – 160 Tons depending on the size of the Coil. The Coil loading Trolley can either be motorised or moved by means of overhead EOT Crane or motorised Winch.

Hydraulic Coil Pressing Fixture – This is a portable fixture which can be taken to the Coil to be pressed, instead of the Coil being transported to the machine as required in case of the above standard Hydraulic Press. This unit consists of three no robust plates which are adequately stiffened to take the maximum pressing force along with 4 no robust studs. A floor mounted independent Hydraulic Power pack with a set of hydraulic hoses with quick couplings completes the full supply.

The Bottom plate acts as the base frame for the multiple Hydraulic Jacks, the Intermediate plate is the Pressing plate which rests on the Hydraulic Jacks. The Top plate acts as the platen against which the Coil is pressed. The Coil is placed between the Pressing plate and the Top plate. The three plates are held together rigidly by the 4 no studs with double nuts. When the Hydraulic Jacks are actuated the Piston rods of the hydraulic cylinders presses the Intermediate Pressing plate which moves up and compressed the Coil against the Fixed Top plate.

We need the customer to furnish the max dia, min/max axial length of the Coil and the max pressing force desired for us to offer suitable machine/fixture.