Mechanical Coil Upender: 5-Ton 90-Degree Flipper for Transformers

Country / Destination: Gothenburg, Sweden
End-User Facility: High-Voltage Electrical Power Transformer Manufacturing Plant
Equipment Model: BXZ5.0-5.0 Customized Heavy-Duty Mechanical Coil Upender
Rated Load Capacity: 5,000 kg (11,023 lbs) continuous operating payload
Cradle Platform Geometry: Dual-surface L-shaped platform ( $1, 650 mm \times 1, 400 mm$ flat plate + $1, 400 mm \times 1, 650 mm$ V-block plate)
Flipping Angle: 90° (Single-direction mechanical rollover via chain drive)
Compatible Coil Dimensions: Maximum winding diameter $Φ1, 400 mm$ ( $Φ4.59 ft$ ), body height up to $1, 560 mm$ , total height including terminal leads up to $2, 500 mm$
System Aesthetics: RAL1023 Traffic Yellow finish with high-visibility “Max. 5000kg” load stencil

This custom-engineered Mechanical Coil Upender (Model BXZ5.0-5.0) has been deployed by our team to automate the vertical handling of heavy electrical windings. Our client, a leading power grid supplier in Gothenburg, Sweden, required a highly secure and non-contaminating method to rotate massive transformer coils 90 degrees during assembly.

These 5-ton coils are tightly wound with copper wire and delicate insulating paper. Relying on hydraulic cylinders was strictly prohibited by the plant’s cleanroom guidelines, as any hydraulic oil leak could contaminate the copper windings, violating strict IEC 60076 power transformer standards.

To overcome this, we designed a fully mechanical, chain-driven upender that installs in a shallow pit to sit flush with the laboratory floor, eliminating hydraulics completely. This custom design integrates seamlessly into the client’s high-precision workstation, providing a safe, repeatable, and clean tilting process that can be explored in our main catalog of upenders and tilters

Challenge & Solution

Challenge

To handle highly sensitive transformer coils without causing deformation or surface scratches, our engineering team developed a specialized, adjustable V-block tooling system mounted directly onto one face of the L-cradle.

Dual-Row Adjustable V-Supports with T-Slots: We mounted two parallel rows of heavy-duty steel V-blocks (3 blocks per row, total 6 blocks) onto the platform surface. These blocks are secured via integrated sliding T-slots, allowing operators to easily adjust their spacing to fit different winding diameters.
Split Multi-Angle Contact Geometry: To support various coil profiles, we designed each V-block with a split upper and lower structure. The lower section features a wide 155-degree angle to cradle larger-diameter coils, while the upper bolt-on section features a 95-degree angle to securely capture smaller, compact coils.
Insulation Damage Prevention with Phenolic Lining: To prevent metal-on-metal friction and avoid scratching the fragile wire insulation, we lined the entire contact surface of all six V-blocks with a 15mm thick phenolic fabric board. This non-metallic lining distributes dynamic pressure evenly during the 90-degree roll-over.
Height-Adjustable Foldable Support Claws: To prevent wood and steel transportation pallets (ranging in size from $1, 200 \times 1, 200 mm$ down to $800 \times 800 mm$ ) from tipping forward when tilted 90 degrees, we welded adjustable, foldable support claws to the edges of the platform. These claws can be mechanically adjusted to match the pallet thickness or detached completely when handling oversized coils.

Solution

Mechanical power is generated by a high-torque 5.5 kW SEW-Eurodrive motor paired with a heavy-duty 16A-2 double-strand roller chain drive. To control this high-torque kinematic rotation smoothly, we programmed a Mitsubishi variable frequency drive (VFD) to execute controlled, low-speed acceleration and deceleration ramps (running at 2 to 4 meters per minute), completely eliminating mechanical vibration and ensuring zero platform drift.

The master control cabinet is a pedestal-mounted unit fixed directly outside the safety area, constructed using premium Schneider electrical components with integrated thermal overload, short-circuit, and leakage protection. We designed the control logic to offer two distinct operating modes:

Precision Jog Mode: The operator presses and holds the push-button; the platform rotates smoothly and stops instantly at any angle when the button is released.
Fully Automatic Single-Touch Mode: The operator presses the start button once, and the platform automatically completes the full 90-degree rotation. For safety, pressing the button again at any point during this cycle will instantly lock the platform in its current position.

To meet strict European factory safety regulations, we installed a comprehensive 1,200mm high grid-style safety fence measuring $4, 000 mm \times 1, 700 mm$

around the entire pit boundary. We integrated an electro-mechanical interlock microswitch on the gate; if the gate is opened during operation, the power is immediately cut to the motor, instantly locking the platform.

Furthermore, we integrated a three-color operational beacon light and an acoustic buzzer to provide continuous visual and audible warnings during movement. If you need a specialized mechanical upender with active safety enclosures tailored to your facility, please contact our engineering team for a factory-direct technical layout and consultation.

Technical Specifications

Parameter	Delivered Specification / Value (SJG5-90)
Model Designation	SJG5-90 Customized Mechanical Coil Upender
Rated Load Capacity	5,000 kg (11,023 lbs) continuous operating payload
Mechanical Tilting Drive	SEW Motor + 16A-2 Double-Strand Roller Chain (No Hydraulics)
Platform Table Dimensions (L-Shape)	$1, 650 mm \times 1, 400 mm$ (flat deck) + $1, 400 mm \times 1, 650 mm$ (V-support deck)
Platform Deck Plate Thickness	$\geq 6 mm$ ( $0.24 in$ ) Solid Steel with reinforced sub-frame J160805 mm
Adjustable V-Support Cradles	2 Rows of heavy steel V-blocks (3 per row, total 6 blocks) via sliding T-slots
Cradle Angle Configurations	Lower V-angle: 155° (for large coils), Upper V-angle: 95° (for small coils)
Contact Surface Protection	15 mm (0.59 in) thick non-metallic phenolic fabric lining on all 6 V-blocks
Pallet Support Claws	Foldable, detachable, and height-adjustable steel support claws
Master Drive Motor Power	5.5 kW SEW-Eurodrive Gearmotor with electromagnetic self-locking
Tilting Adjustment Speed	2 to 4 meters per minute (Variable VFD adjustable)
Electrical Controls Brand	Schneider electrical components + Mitsubishi variable frequency drive (VFD)
Operation HMI Console	Pedestal-mounted panel with Jog/Auto selector & emergency stop
Pit-Mounted Self-Height	$\leq 850 mm$ ( $33.5 in$ ) flush with laboratory floor (Variance $< 3 mm$ )
Safety Fence Enclosure	1,200 mm high safety grid fence with microswitch door-open power cut
Power Grid Voltage Supply	3-Phase, 380V AC, 50Hz (Standard industrial grid voltage)

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Mechanical Coil Upender: 5-Ton 90-Degree Flipper for Transformers

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