COIl manufacturing

Ridgway Machines manufactures a full range of Coil Manufacturing Equipment, including Rotor Winders, Loop Winders and ancillary equipment such as Capstan Tension Units, Winding Beams and Drum Stands.

Manufactured to high specifications and incorporate the latest safety features and fully programmable operator control.

Ridgway Machines also manufactures a range of Coil Pull-Out Machines.

Ridgway W-LAP Loop Winding Machine

with automatic pin positioning and active drum tensioning

Designed for the precision winding of looped coil

Technical Specification

Loop Winder

Maximum torque

Up to 8500 Nm

Speed range

0 to 25 rpm

Fully programmable operator HMI

Winding Beam

Maximum loop length

Up to 4.5 metres

Servo controlled winding pin positioning

Quick Release Tooling

‘D’ Tooling for Trapezoidal shaped coils

Pay Off Drum Stand

Drum shaft diameter

Ø 32mm

Maximum number of drums

Up to 26

Maximum drum diameter

Ø 800mm

Maximum drum width

300mm

Maximum drum weight

150kg

 Improved Quality

Fast, accurate and consistent winding of looped coils

Programmable winding pin positioning

Automatic winding pin positioning and end of cycle release

 Servo motor drives

The W-LAP incorporates the latest servo drive technology

 Anti runback

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

 Quick release tooling

Operator friendly solutions for both the conductor clamping and winding pin assemblies

 Conductor active tensioning

Compared to the alternative of friction braking, the W-LAP offers a wear free solution with accurately controllable individual constant drum tensioning

 Operator HMI Control

Easy to operate control panel for the adjustment of loop length, winding speed and individual conductor tensions.

Other functions include the ability to set and count the number of turns per coil and the quantity of coils per set.

Coil winding details can also be stored within the control system for future use.

 Cost effective solution

The ability to regenerate electrical energy and reduce the overall machine running cost by up to 33%

Technical Specification

Heavy Duty Loop Winder

Maximum torque

Up to 8500 Nm

Speed range

0 to 20 rpm

Fully Programmable and full auto control or manual mode available

Heavy Duty Winding Beam

Maximum & Minimum loop length

500 – 4,500mm

Servo controlled pin positioning

Auto Quick Release at end of winding

‘Squirrel’ Tape Turner & Support Gantry

STT Rotation Taping Speed

up to 200rpm

STT Linear Speed

6m per minute maximum

Number of Tape Pads

1 to 3

Maximum Tape Pad Diameter

180mm

Maximum Conductor Stack

30 x 30 mm

Ridgway W-LAP Heavy Duty – Loop Line

with in-line tape turner

Designed for the precision winding of large looped coils

This automated winding line produces large conventional coil loops. Capable of accepting multiple conductors which are passed through gathering boxes and conductor guidance systems, the correctly orientated and bunched conductors are either taped by the ‘Squirrel’ Tape Turner or guided directly into the loop winding beam. The loop winder has servo driven, adjustable pins which are automatically set to pre-programmed positions to produce a range of variable loop lengths.

Programmable Operator Interface and Control System for:

 Loop Recipe and Selection

  • Required number of turns
  • Winder maximum rotational speed
  • Conductor clamping
  • Pin position setting
  • Mode: Manual Loop, Auto Loop, Auto with Tape

 Taping Parameters Recipe

  • Auto calculation & display of amount of tape required per coil loop
  • Scaling of Turn Taper linear and rotation maximum speeds
  • Amount of conductor used per coil loop
  • Tape break detection
  • Tape remaining calculation
  • Calculation of pitch setting and tape pad angles
  • Auto lead tape length at end of process

Servo drive and position control of Turn Taper Gantry

Auto positioning of ‘Squirrel’ Turn Taper (STT) in relation to beam position and synchronised with wind beam rotational speed

More machines in our coil manufacturing and winding  range

Ridgway W-LMP Loop Winding Machine

Designed to offer a comprehensive range of modern, easy to use, accurate loop winding machines

Loop Winding Machine

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.

The loop winding machine offers quick and accurate set up, vector motor drive, anti runback and easy to operate control panel.

 

Technical Specification

Maximum torque

Up to 8500 Nm

Speed range

0 to 25 rpm

Bi-directional

Maximum loop length

Up to 4.5 metres

Pin diameter

Min. Ø 15mm – Max. Ø 80mm

Quick Release Tooling

‘D’ Tooling for Trapezoidal shaped coils

Quick release winding pins

Drum shaft diameter

Ø 32mm

Maximum number of drums

Up to 26

Maximum drum diameter

Ø 800mm

Maximum drum width

300mm

Maximum drum weight

150kg

Ridgway W-MAW Loop Winding Machine

Designed for the automated production of complex coils, from on edge field coils to wind turbine stator coils.

Advanced Loop Winding Machine

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.

Automatic winding without the need for operator intervention.

Technical Specification

Loop Winder

Maximum torque

Up to 9000 Nm

Speed range

0 to 10 rpm

Fully programmable

Winding Beam

Maximum length

Up to 2.5 metres

Servo controlled beam positioning

Servo controlled tool rotation

Ridgway W-RHD Rotor Winding Machine

Designed for bi-directional, indexed winding of rotor pole coils

Technical Specification

Maximum torque

Up to 10000 Nm

Speed range

0 to 10 rpm

Maximum rotor weight

W-RHD5000 – up to 5000kg

W-RHD10000 – up to 10000kg

Faceplate centre height

1300mm (other heights available)

Ridgway Capstan Tension Unit

Variable tension control

Adjustable guide rollers

Pneumatic brake override

For a complete solution to enable the fast and effective winding of rotor pole coils.

Geared servo drive system

The W-RHD 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.

 Pneumatic holding brake

The spindle is fitted with a pneumatic holding brake to ensure a positive stop.

Operator controls

The main control panel used to vary speed and direction of rotation is mounted on a free standing pedestal giving greater operator flexibility. The operator has full control of both the acceleration and deceleration through the entire speed range simply by using the remote foot pedal.

 Drum stands

A range of single and double friction braked or wear free active tensioned drum stands is available.

 Capstan tension unit

For optimum conductor control a range of pneumatically actuated single or double capstan tension units is available.

 Indexing

Rotor support tooling available, featuring indexing clamps, enabling easy repositioning of the rotor between winding cycles.

 Tooling and fixtures

Providing you with greater flexibility, a large faceplate is fitted as standard to enable easy direct fitting of existing tooling. Exclusive tooling/fixture design can also be incorporated offering you a complete solution.

Coil Pull-Out Machines

Ridgway Machines manufactures a range of Coil Pull-Out and Coil Forming Machines.

Manufactured to high specifications and incorporate the latest safety features and fully programmable operator control.

POM-STD Coil Pull-Out Machine 

POM5000 Coil Pull-Out Machine

POM-WPB Wind & Pull-Out Beam

POM-CC Continuous Coil Forming Machine

Technical Specification

Coil stack height

Dependent on tooling

Coil stack width

Dependent on tooling

Slot length

Max: 4064mm

Min: 115mm

Overall loop length (eye to eye)

Max: 5300mm

Min: 875mm

Angle between coil sides

Max: 120° (included)

Min: 0°

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

Offering a cost effective and versatile solution, the machines are fully adjustable and simple to operate.

Technical Specification

Coil stack height

Max: 85mm

Min: 12mm

Coil stack width

Max: 40mm

Min: 6mm

Length of cell (coil straight)

Max: 4128mm

Min: 440mm

Overall loop length (eye to eye)

Max: 5000mm

Min: 950mm – using extensions

Nose bend radii

25mm, 35mm, 50mm, 75mm

Core bend radii

25mm, 35mm, 50mm, 75mm

Coil nose pin diameter

Max: 63mm

Min: 20mm

Angle between coil sides

Max: 130°

Min: 20°

Coil spread

Max: 1200mm

Min: 400mm

Nose twist angle

Max: ± 30°

Min: 0°

The POM5000 large hydraulic coil forming machine is used to pull-out stator coils into their final shape according to the individual coil design requirements.

The machine has the power to shape coils of the largest cross section and the flexibility to be adapted for different bend radius at the nose and in the core bend region.

Technical Specification

Coil stack height

Max: 50mm

Min: 10mm

Coil stack width

Max: 17mm

Min: 5mm

Length of cell (coil straight)

Max: 1520mm

Min: 440mm

Overall loop length (eye to eye)

Max: 2300mm

Min: 756mm

Winder

Maximum torque

Up to 5000 Nm

Speed range

0 to 20 rpm

Bi-directional

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.

Technical Specification

Coil stack height

Dependent on tooling

Coil stack width

Dependent on tooling

Length of cell (coil straight)

Max: 1000mm

Min: 380mm

Overall loop length (eye to eye)

Max: 2000mm

Min: 875mm

Angle between coil sides

Max: 120° (included)

Min: 0°

Coil spread

Max: 900mm

Min: 150mm

The POM-CC servo driven coil forming machine is used to simultaneously form single and multi-turn coils in phase groups of up to eight coils.

Enabling the fast and effective winding of stators, this turn-key production solution dramatically reduces the number of winding connections required. Simple to operate, production efficiencies of 50% can easily be achieved.

Our experienced team are here to support you

Get in touch