WD-3500 CNC Vertical Winding Machine for Generator Rotor Coil Winding 27KW Servo Motor PLC Constant Tension

Product Overview

The WD-3500 is a CNC-controlled vertical winding assembly system engineered for the winding and forming process of generator rotor coils. The rotor is hoisted to the designated position, clamped on the mechanical chucks of the two end supports, and secured with locking bolts. After the operator sets the number of turns, the pre-winding cycle begins automatically. Once pre-winding is complete, the wire is guided into the slot and the left-right movement mechanism runs in synchronization with the rotating main shaft to keep the coil advancing at the preset stacking ratio.

The system is built for large generator rotors up to 3100mm in length, 1000mm in diameter and 5500kg in weight, with a 27KW aggregate servo drive and a 15KW main spindle. Constant tension control is delivered through a magnetic powder damper monitored by PLC, so output tension stays within range as the winding diameter changes. The unit occupies 9500x5250x3500mm and weighs approximately 17000kg, ready for high-volume rotor winding in modern generator manufacturing.

Key Features

• Millimeter-level winding accuracy — advanced CNC positioning keeps the wire neatly and symmetrically placed, eliminating loose windings and surface defects caused by misalignment.
• PLC constant tension control — magnetic powder damper adjusts output torque in real time so every layer maintains the same tightness, replacing manual guesswork.
• High-efficiency production — servo-driven main spindle and traversing mechanism shorten cycle times versus manual or semi-automatic winding, suiting large-scale generator production.
• Stable and reliable — high-strength alloy steel gears with carburizing and quenching treatment, plus multi-layer self-diagnostics for motor, sensor and controller.
• Easy to operate — 10-inch HMI touch screen with parameter memory; presets for common rotor specs can be recalled with one click.
• Five integrated subsystems — unwinding, wire guiding, winding, fixture and electrical control, supplied as a complete turnkey package.

Industries Covered

• Generator manufacturing (hydro, thermal, wind, diesel generator rotors)
• High-voltage electric motor production
• Large motor and traction motor assembly lines
• Ship propulsion generator and marine motor workshops
• Wind turbine generator manufacturing and service
• Hydro power generator production
• Heavy industry coil forming and rewinding
• Industrial motor repair and rebuild workshops

Heavy-Duty Machinery and Equipment Types Supported

• Hydro generator rotor winding stations
• Thermal power generator rotor winding lines
• Wind turbine generator rotor production
• Ship main propulsion generator rotor assembly
• Locomotive traction motor rotor winding
• Large mining motor rotor winding
• Industrial compressor motor rotor assembly
• Heavy-duty elevator traction motor rotor production

Compatible Rotor Specifications

• Rotor length range: 1100 to 3100mm
• Shaft diameter range: 70 to 180mm
• Rotor winding length: 300 to 1000mm
• Rotor diameter: 400 to 1000mm
• Rectangular coil dimensions: 150x200mm and 250x300mm
• Round copper wire: 3 to 7mm
• Flat copper wire: 5 to 7mm
• Maximum rotor weight: 5500kg

Core Components and Brands

• Mitsubishi servo motors (15KW, 5.5KW, 2KW, 1KW combination)
• Mitsubishi FX80 PLC with 10-inch Weilun touch screen
• Shangyin (Hiwin) ball screws 4010 and linear guide rails 65 series
• SKF bearings throughout the drive train
• Schneider Electric low-voltage components
• Hailing magnetic powder damper for tension control
• Beijing Yacont control software

Why Choose WD-3500

The WD-3500 is designed as a direct alternative to OEM-equivalent rotor winding equipment for generator manufacturers who need large-format, PLC-controlled vertical winding with stable tension and proven servo performance. Reach out to our team to discuss the configuration that fits your workshop, the rotor size range you need to handle, and the delivery package for your region.

Service and Support

• Complete installation manual and electrical schematics supplied with each machine.
• Remote commissioning support and on-site engineer dispatch available on request.
• Spare parts package and wear-item list included for the first year of operation.
• Multi-language operator training (English / Spanish / Russian) for the HMI and PLC.
• 12-month warranty on core components from the date of acceptance.