Synthesis Hosur, Bangalore, Karnataka

We offer Automatic Multi-channel Online Wire Twisters which convert single strand winding wire to multi strand twisted wire for giving mechanical strength (to the wire) at the termination points of the coil. The twister incorporates a programmable microprocessor based control unit. The number of strands, twist turns, length of twist etc., are adjustable to achieve optimum results for any application.  

In-depth knowledge and understanding of the winding process requirements has led to development of wide range of Wire Tensioning Devices that efficiently combine mechanical and electronic technologies for superior Tension control. Our wire tensioner series consists of mechanical, magnetic and electronic tensioning devices which delivers accurate and consistent wire tension, and therefore ensures better coil formation and improved productivity. GRADUATED TENSIONER Precision wire tensioners, with graduated scale give high performance coupled with ease of use. With two separate settings for basic tension & back tension, the response of the tensioners can be fine-tuned. A high precision feed-back mechanism and low inertia moving parts ensure consistency in tensioning. Diamond lapped ceramic wire guides have a very long life and minimizes any possibility of damage to the enamel.

Wire / Strip de-reelers ensure smooth dispensing of wire, provides constant feed and minimal free-length variation during winding operations. We offer application specific de-reelers and straightening units for both round and rectangular conductors  

We offer Wire De-reeler / Wire Unwinder. Wire Strip de-reelers ensure smooth dispensing of wire, provides constant feed and minimal free-length variation during winding operations. We offer application specific de-reelers and straightening units for both round and rectangular conductors

Toolings/ Winding Jigs is one of the key performance optimizer for the winding machines. We design and manufacture toolings/ winding jigs, for diverse winding applications, in accordance with the optimal winding. The toolings are methodically designed, to deliver superior winding quality with exceptional ease, even at higher winding speeds.  

These tensioners are specifically designed for Thick wires. Compact dimensions & integrated wire guide makes this tensioner suitable for mounting directly on the machine traverse. A tension release mechanism and absence of back tension makes it easy to handle the wire during termination.    

Synthesis Tape Winding Machines comprises of narrow and Wide Band Tape Winding Machines to wind condenser bushing and CT limb. These machines are designed to wind condenser bushings and CT limbs from plain craft AWW paper (Narrow band and Wide band) and foil, by rotating winding head around a conductor  

  Stator winding machines are automatic winding machines designed to wind multi-pole stator coil / magneto coils used in automobile sector. These machines facilitates automatic Core indexing, tap pulling and cutting and contribute to better productivity.

We are offering semi automatic winding machine. The smart winder range of versatile & user friendly semi-automatic winding machines are available in several configurations, offering optimum and comprehensive winding solutions based on coil complexity, size and productivity; leading to minimum stat up time and cost-effective solutions.

Semi automatic H.V. Coil Winding Machine (Smart Winder HV 400 S ) designed for winding Distribution Transformers Main features of the base machine 1 Closed loop servo tension control with dancer feedback mechanism for conductor. 2 Air shaft mounted inter layer paper insulation feeders with constant tension control & tailstock support 3 Edge cutting arrangement for the full width insulation paper and edge fill paper feeder. 4 Pneumatically operated tension control for the end fill tape.. 5 Adjustable Wire guide unit close to winding

Self-compensating wire tensioners are suitable for thick wires. Robust construction with twin brake shoes, low inertia moving parts and a feedback mechanism ensure high level of consistency and long operational life.    

We are offering self compensating tensioner. Self compensating wire tensioners are suitable for thick wires. Robust construction with twin brake shoes, low inertia moving parts and a feed back mechanism ensure high level of consistency and long operational life.

Magnetic tensioners can produce long term and stable tension. Non contact mechanism design provides stable, consistent and precision tension to the wire. These kind of tensioners are suitable for both high and normal speed windings.    

We offer automatic multi-channel online wire twisters which convert single strand winding wire to multi strand twisted wire for giving mechanical strength (to the wire) at the termination points of the coil. The twister incorporates a programmable microprocessor based control unit. The number of strands, twist turns, length of twist etc., are adjustable to achieve optimum results for any application.

These are low cost wire tensioners designed for basic winding applications. The tension is adjusted by varying the spring pressure acting on a rotating friction pad mounted on the tension wheel. The tension wheel is made of high performance polymers for low inertia, corrosion resistance and long life.    

Semi Automatic foil Winding Machine-Model:Is designed to wind a wide variety of LV Coils for Transformers using copper or aluminium foils. This machine is capable of winding large foil cross sections with high winding tensions and is designed to wind round & oval shaped coils. The machine has an advanced, high efficiency, TIG welding unit which welds the bus bar / lead -out to the foil. The machine frame is robustly built steel structure, capable of supporting the other functional units & providing a strong frame to withstand the large forces generated during the winding of the coils The winding core / mandrel is suitably supported by a telescopic tailstock with a live centre, mounted onto a swing-out frame to facilitate easy loading and unloading

We are offering hv coil winding machines.

We are offering h t capacitor winding machines are designed to wind the elements of h t capacitors (foil and film type). The automatic machine has diverse features such as : superior closed loop tensioning mechanism, automatic foil cut and fold unit, online dry element testing and sorting unit, element conveyer unit and many more.

The machine is designed and equipped for insulation kit preparation for power transformers. The machine is built for precise indexing of heavy power transformer core held horizontally between faceplate (1800 mm dia) & tailstock (which can move axially on the base plate)   Features: 1. Offset helical reduction gear motors with built in resolver delivers precise revolutions of the core. The revolution speed is programmable in steps of 1 degree or through continuous operation by means of foot pedal. 2. The machine can address jobs up to 2500mm winding diameter and with a maximum weight of 5000 kgs (inclusive of expanding mandrel) 3. High performance PLC based controller with colour touch screen user interface governs the motion of spindle accurately. 4. Laser beam from overhead self levelling laser system provides reference line on the width of the core, along which the press board strips are pasted.

We are offering general purpose transformer winding machine.

  Flyer type Winding machines are automatic multi - spindle coil winding machines with flyer-type winding head facilitating high speed winding on fixed & asymmetric formers.

Electronic wire tensioners with electromagnetic brakes delivers high performance coupled with ease of use. An integral amplifier controls the braking torque in proportion to the command voltage. The tension value can be remotely set and varied either by the winding machine PLC or through a potentiometer even during winding cycle.    

Automatic CVT Winding Machine for winding elements with tabs (axial configuration) for Capacitor Voltage Transformers (CVT). The machine also facilitates automatic online testing and sorting of wound elements. The optimum combination of mechanical, pneumatic and electronic systems incorporated in the machine provides high performance coupled with reliable operation and simplicity in maintenance. By utilizing the latest technology, materials and manufacturing techniques, the machine offers several features such as high productivity, repeat accuracy, reliability etc. Wound capacitor elements are sealed with adhesive tape, automatically extracted, flattened and transferred to a high voltage tester for dry stage testing and sorting. Integrated Dry-element tester with automatic transfer and sorting of wound elements eliminates manual handling of delicate elements ensuring better quality. Closed-loop tension control with AC servo motors for each unwinding spool to maintain consistent tension throughout the winding cycle while facilitating very high acceleration rates and line speed. Automatic edge alignment system for each material feeder ensures high quality element produced through automatic alignment of film and foil edges during winding.

The Core Taping machine is designed for wrapping Resin-glass tapes on core limbs of power transformers with high degree of precision. The limbs of the pre-assembled, laminated core packs need to be bound tightly by wrapping a high strength tape before assembly of the coils. The core taping machine consists of a rotating ring that carries 2 rolls of resin-glass tapes and wraps them tightly over the core limb. The ring is in-turn mounted on a vertical carriage that is also motor driven and travels the entire height of the limb. The taping ring and vertical carriage motors are driven through variable speed drives and controlled by a PLC system to achieve precise control over the tape pitch and wrapping length.   FEATURES: - PLC based control of winding parameters to achieve good consistency. - Robust hydraulic braking system for conveniently achieving very high tape tension values. - Operator platform travelling with taping head for easy access to taping area. - Dual control consoles on main panel and a hand held pendant for easy access.