Project Overview

A leading transformer manufacturer in Jinan required a reliable and safe solution for turning heavy transformer coils during the production process. Due to the large size, high weight, and precision requirements of transformer coils, traditional manual handling methods presented challenges in terms of operational safety, efficiency, and product protection.

To address these requirements, GRADIN provided a customized 5-ton mechanical coil upender designed specifically for transformer coil handling applications.

The solution enables smooth 90-degree rotation of transformer coils, improving production efficiency while ensuring stable and damage-free handling.

Customer Industry: Transformer Manufacturing
Application: Transformer Coil Turning & Positioning
Equipment: 5-Ton Mechanical Upender
Quantity: 2 Units

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Project Challenges

Transformer coils require careful handling throughout the manufacturing process. The customer faced several key challenges:

• Heavy-load turning requirements: The equipment needed to safely handle transformer coils with a maximum load of 5,000 kg.
• Different coil sizes: The solution needed to accommodate coils with different diameters and support stable positioning during rotation.
• Surface protection: The coil surface required protection against scratches and deformation during the turning process.
• High safety standards: The equipment needed reliable locking, emergency protection, and operator safety functions.

According to the project requirements, the equipment was designed for transformer coils with a maximum diameter of 1400 mm, a coil body height of 1560 mm, and a maximum height of 2500 mm including leads.

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Customized Solution

Based on the customer’s production requirements, GRADIN developed a customized FZPT-5000 mechanical coil turning platform.

1. Stable 90-Degree Mechanical Turning

The upender adopts a mechanical turning structure with a rated load capacity of 5,000 kg and supports 90-degree rotation with stop-at-any-angle positioning, allowing operators to accurately control the coil position during the process.

Key parameters:

• Loading Capacity: 5,000 kg
• Tilting Angle: 90°
• Tilting Method: Mechanical
• Platform Size: 1650 × 1400 mm + 1400 × 1650 mm

2. Adjustable V-Block Support Design

To accommodate different transformer coil diameters, GRADIN designed a customized V-block supporting system.

The V-frame consists of two layers:

• Lower V-block angle: 155°
• Upper V-block angle: 95°
• Six adjustable V-block supports in total
• T-slot fixing structure for flexible adjustment

A 15 mm thick phenolic board layer is installed on the V-block surface to prevent damage to the coil during lifting and rotation.

3. Safety Protection System

The equipment integrates multiple safety protection features to ensure reliable operation:

• Mitsubishi variable frequency drive for smooth acceleration and deceleration
• SEW motor with braking and self-locking function
• Schneider electrical components
• Overload, short-circuit, and leakage protection
• Sound and light alarm system for fault warning

The system supports both manual inching mode and automatic operation mode, allowing precise positioning and improving operator convenience.

4. Floor-Level Installation for Easy Integration

To maximize workshop space utilization, the upender adopts a pit-mounted installation design.

The equipment height is controlled within 850 mm, allowing the two platforms to remain level with the workshop floor, ensuring smooth loading and unloading operations..

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Project Results

After implementation, the customized mechanical coil upender provided significant improvements:

✅ Safer transformer coil turning operations

✅ Reduced manual handling risks for heavy components

✅ Improved production efficiency and workflow continuity

✅ Flexible handling of different coil dimensions

✅ Better protection of precision transformer components

The solution successfully met the customer’s requirements for heavy-duty transformer manufacturing and provided a reliable handling system for future production expansion.

GRADIN provides customized industrial handling solutions for transformer manufacturing, heavy equipment production, and special material handling applications. From design optimization to manufacturing and integration, we help customers achieve safer, smarter, and more efficient production operations.

For more information or to request a tailored system for your project, please contact us.