Coil Manufacturing

The LWDS Loop Winder Drum Stand range is designed to compliment Ridgway’s range of loop winders during the loop winding process. A fabricated steel frame with cantilever drum shafts support the conductor drums. The number of drum positions can be configured to suit individual customer requirements.

The drum shafts carry individual back tension brakes, comprising of a brake drum onto which a brake shoe operates.

Each drum shaft has individual tension adjustment. The tension adjustment is provided via a pneumatic cylinder connected to an individual lever valve with a pressure regulator and visual pressure gauge.

Active drum tension control

Compared to the alternative of the LWDS friction braking, active tensioning offers a wear free solution with accurately controllable individual constant drum tensions.

Tension adjustment for each drum is provided via a HMI on the winder control panel. Tension range is 0 – 35kg per drum and is constant throughout the life of the drum.

For a versatile and cost effective solution to suit your loop winding requirements.                 

Sturdy construction, free standing control panel and digital turns counter are key features of our loop winding solutions.

Vector motor drive

The W-LMP incorporates the latest vector drive technology. A variable speed geared motor directly drives the main spindle, providing a high torque capability with soft start.

Quick release tooling

Operator friendly solutions for both the
conductor clamping and winding pin assemblies. Optional “D” loop tooling also available.

Operator controls

Easy to operate control panel for the adjustment of winding speed and direction of rotation. Large digital turns counter with reset capability.

Guides

Free standing, adjustable conductor guides are incorporated into the winding line as standard.

Quick, accurate set up

All winding beams incorporate a pair of fully adjustable winding pins and a conductor
clamping arrangement. For reference, scales are fitted to the winding beam, ensuring fast and accurate set-ups can be achieved.

Anti-run back

The winder incorporates an electrically released brake, preventing run back and
eliminating tension loss during stopping and starting.

Operator platforms

Optional work platforms are available, designed to ensure a safe working environment for your operators.

Designed for organisations that need complex 3D-shaped coils for various applications.
The Ridgway Multi-Axis Coil Winding Machine meets these needs by winding coils in
multiple planes.

The operator control unit features a wireless controller linked to the machinery control system, allowing the operator to safely approach the coil winding area.

Improve production effectiveness by utilizing the Ridgway W-MAW. Incorporating a programmable multi-axis winding machine with active drum tensioning and conductor guidance systems, the equipment ensures fast, consistent and high quality production of complex shaped stator coils.

Main spindle drive

The W-MAW incorporates the latest servo drive technology. A variable speed geared motor directly drives the main spindle, providing a high torque capability throughout the speed range.

Multi-axis winding beam

Encoder feedback ensures accurate positional control of the winding beam. An additional servo driven gearbox, mounted directly to the winding beam also provides rotational movement of the coil tooling.

Conductor guidance

The W-MAW incorporates the latest servo drive technology. A variable speed geared motor directly drives the main spindle, providing a high torque capability throughout the speed range.

Operator control

Conductor guidance is provided via a free standing guide post to ensure vertical, horizontal and angular positioning is maintained. Additional servo controlled conductor guidance can also be fitted to the coil tooling if required.

The HCP Hot Coil Compaction Press is designed to heat and consolidate stator coils & bars. Standard models are available however, each machine can be tailored to the customer’s specific requirements.

The HCP incorporates a set of hydraulic rams built into hinged arm assemblies across the top length and rear face of the working envelope, with independent hydraulic circuits. Each ram can deliver 10 tonnes of force and the number of rams can be selected to suit specific coil lengths.

Coil heating is achieved using a set of electrically heated platens (heater bars) at the front and rear sides of the machine. Each platen is independently operated/controlled from a
free standing HMI cabinet.

After pressure is applied, the platen temperature is raised to a set point and held for a period of time (soak time). The platens are then cooled with an air blast followed by recyclable cooling water prior to hydraulic ram release and unloading of the coils.

Full HMI Process Control

Full HMI operator control is provided from a free standing cabinet. This covers the entire compaction process from hydraulic, air and temperature control to cooling and power consumption for each of the control zones within the machine, including fault diagnosis.

Heater Platens

Available in a range of sizes

Press space availability

Can be configured to suit exact requirements

Water chiller/ Recirculating Unit

Interfaced with the HCP through a water manifold arrangement and controlled via the PLC.

POM-STD – Coil Pull-Out Machine

The POM-STD range of coil forming machines are used to spread coils quickly, accurately and efficiently into their final shape according to the coil design.

Capabilities

Pneumatically powered, the POM-STD range has the capability to form stator coils having a maximum loop length of 2500mm with a maximum coil stack size of 60mm x 30mm

Adjustable tooling

Fall away pin type knuckle holders guarantee firm clamping action and quick release. Both the length and the thickness of the coil knuckle holders are adjustable.

Easy to operate

The coil forming process is driven by using air pressure. Little manual effort is required of the operator. After the loop has been loaded, actuation of a foot pedal closes all four slot clamps simultaneously. The exclusive ballast tank minimizes air supply fluctuations, producing coils smoothly and quickly.

Easy to set

For reference, linear scales are fitted to ensure repeat accurate set ups are quickly and easily achieved.

POM-WPB – Wind & Pull-Out Beam

For a versatile and cost effective solution the POM-WPB wind and pull-out beam offers a simple production solution to dramatically reduce the overall coil manufacturing time. The POM-WPB enables phase groups of single and multi-turn coils to be loop wound and pulled-out in one operation.

 Quick, accurate set up

The POM-WPB is fully adjustable. For reference, linear scales are fitted to the beam, ensuring fast and accurate setups can be achieved.

Tooling and fixtures

Exclusive bespoke tooling design is incorporated, offering a complete manufacturing solution. Variable length
slot section and interchangeable loop bend radius tooling are available.

Turn-key solution

The wind and pull-out beam is a standalone fixture designed to fit to an existing winding machine faceplate.
Offering a turn-key solution, to complement the POM-WPB, a complete range of winding machines and drum
stands is also available.

Operator platforms

Optional work platforms are available, designed to ensure a safe working environment for your operators.

The Ridgway NCT Narrow Coil Taping machine offers an advanced and cost effective automated solution for taping narrow profile wind turbine generator stator coils.

The NCT features a unique multi-axis motion control system with a free standing programmable HMI, making it a truly versatile machine that simplifies the precision taping of all narrow coil configurations, straight or diamond shaped.

The innovative design solves a common problem where traditional taping machines have limited access to both sides of the coil. The coil support system features automatic coil turn-over and height adjustment. This simplifies set-up and eliminates the need to remove or reposition a coil to tape both sides.

Unique Taping Motion

The NCT uses a unique multi-axis head motion. Lateral movement of the NCT taping head is controlled via a servo motor driven ball screw. This in turn is synchronised with the servo motors that drive the rotational aspects of the taping head. The action of this complex head motion results in a precise process that consistently provides high
quality taped coils.

Constant Tension Control

The Ridgway NCT features constant tension control between 20N and 50N.

Fully Programmable

The machine is fully programmable, for example, to set the number of layers required for each coil side, tape pitch and linear speed, the angle of diamond coil legs. Auto reverse at the end of each pass allows for uninterrupted, multiple tape layers without downtime.

Taping Head

The taping head rotates around the coil applying a pair of tapes simultaneously with the tensions between 0.5kg and 7.0kg. Tape reel carriers automatically follow the natural angle of the tape being applied to the coil in relation to the coil axis. The MTM head can apply tapes at a rotational speed of up to 250 rpm.

Drive System

The MTM uses twin variable speed motors to provide and synchronise the taping head drive and carriage traverse functions. These are controlled by a foot pedal mounted on the taping head carriage, with reversing selection by joystick control.

Coil Support

Pneumatically assisted coil support and clamping system with 3 retractable arms, fully adjustable rear clamp stands and coil eye clamps/supports.

Safe Guarding

The MTM is equipped with fixed mesh screen fencing on 3 sides for operator safety. On the open side of the machine enclosure an electronic light sensor guard automatically detects any intrusion and activates the safety circuit, cutting power to stop the machine.

BTU 100 – Band Tension Unit

Designed to apply preset tension to tapes and wires when banding armatures.