10-Ton Hydraulic Coil Upender for Transformer Winding Assembly

A major power transformer manufacturer in Dresden, Germany, required a reliable, damage-free method to upright heavy copper winding coils from a horizontal assembly position to a vertical installation orientation [FZ6]. Weighing up to 8 metric tons (17,637 lbs), these copper-and-wood components are highly sensitive to surface friction and localized compressive forces. Relying on traditional overhead crane slings to tilt the coils risked tearing critical insulation paper, potentially causing catastrophic electrical shorts. To resolve this, the client integrated our FZPT-10 10-ton hydraulic upender, custom-engineered with adjustable sliding support cradles [FZ6, FZ7].

Client Profile: High-Voltage Electrical Grid Infrastructure Supplier
Project Location: Dresden, Germany
Core Equipment: FZPT-10 Custom Hydraulic Coil Upender (10,000 kg Capacity)
Project Objective: To safely tilt 8-ton copper transformer coils 90 degrees within 60 seconds while preventing deformation of the windings or damage to the delicate insulation

Challenge & Solution

Challenge

Handling highly valuable and structurally sensitive electrical windings presented severe engineering and safety challenges for the client’s assembly line:

High Risk of Insulation Crushing: Winding coils are wrapped in layers of pressurized insulating paper. Tilting them via standard crane slings creates concentrated crushing points, which can tear the insulation and destroy multi-million-dollar components.
Incompatibility with Variable Diameters: Winding diameters fluctuate significantly based on transformer capacity. A static upender platform cannot securely cradle varying cylindrical shapes, presenting lateral rolling and sliding hazards.
Strict Control and Fall-Prevention Requirements: Due to the severe safety hazards of handling heavy suspended loads, the system demanded seamless, vibration-free movement with reliable physical locking mechanisms in case of hydraulic pressure loss

Solution

To meet the high-standard safety and operational requirements of the European energy sector, our team delivered a customized FZPT-10 hydraulic upender with integrated micro-adjustable tooling

Lead-Screw Driven Sliding V-Cradles: Engineered dual blue sliding cradles on linear rails, micro-adjustable via reverse lead screws and handwheels to conform perfectly to different cylindrical diameters, distributing the 8-ton weight evenly
Smooth Quad-Cylinder Hydraulic Actuation: Implemented a robust 11kW motor and four heavy-duty $Φ160$

cylinders fitted with Japanese NOK seals, executing a controlled, jerk-free 90-degree rotation in exactly 60 seconds [
Fail-Safe Valves & Flush Floor Pit Design: Equipped the hydraulic unit with pipeline explosion-proof safety valves that immediately lock fluid in place if power or hose integrity is compromised, mounted inside a pre-buried floor pit for space-saving operation

Technical Specifications

Parameter	Delivered Specification / Value
Model Designation	FZPT-10 Custom Hydraulic Coil Upender
Rated Load Capacity	10,000 kg (22,046 lbs)
Designed Application Load	8,000 kg (17,637 lbs)
Platform Dimensions	$3, 000 mm \times 3, 000 mm$ ( $9.8 ft \times 9.8 ft$ )
Required Installation Space	$6, 500 mm \times 3, 100 mm$ ( $21.3 ft \times 10.2 ft$ )
Tilting Angle	90°
Tilting Speed	60 seconds / cycle (Controlled, uniform speed)
Platform Height (Self-Height)	$800 mm$ ( $31.5 in$ )
Platform Structure Frame	$200 \times 100 \times 8 mm$ Rectangular Tube (Q235B Steel)
Platform Plate Material	$8 mm$ Checkered Plate (Q235B Steel)
Tilting Shaft Diameter	$Φ80 mm$ Solid Steel Shaft (45# Steel)
Hydraulic Pump Station Power	$11 kW$ AC380V, 50Hz, 3P
Hydraulic Cylinders	4 Units, Bore diameter: $Φ160 mm$
Main Cylinder Seals	NOK brand (Imported from Japan)
Core Safety Features	Hose-rupture safety locking, Overload relief valve, Emergency stop
Installation Configuration	Pre-buried pit installation (Platform flush with floor)

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10-Ton Custom Hydraulic Coil Upender for Power Transformer Plant in Dresden, Germany: Protecting Fragile Copper Windings During 90° Tilting

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Challenge & Solution

Challenge

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Technical Specifications

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