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Continuously Transposed Conductor Line

The Continuously Transposed Conductor Line is designed for the production of high-performance continuously transposed conductors (CTC) used in transformer windings and advanced electrical applications. By continuously transposing multiple enamel-coated flat copper conductors and integrating optional insulation wrapping, the system produces compact rectangular conductor bundles with excellent electrical performance, dimensional consistency, and winding stability.


With over 16 years of metal forming expertise, GRM provides customized Continuously Transposed Conductor Line solutions for transformer manufacturers, magnet wire producers, and electrical component suppliers worldwide.

Applications

The system is widely used in industries requiring high-efficiency electrical conductors and precision winding solutions.

  • Power and distribution transformer windings
  • EV motor and electrical component manufacturing
  • Household appliance electrical assemblies
  • Medical equipment electrical systems
  • Aerospace electrical components
  • Magnet wire production facilities

How the Continuously Transposed Conductor Line Works

Main Production Process

  • Pay-off
  • Parallel Guiding
  • Precision Transposition
  • Insulation Wrapping (Optional)
  • Take-up Winding

The production line continuously transposes multiple insulated flat copper conductors into a compact rectangular conductor bundle, reducing eddy current losses while improving transformer efficiency and operational reliability.

Technical Specifications

Single Conductor Parameters

Parameter Min Max
Thickness 1.15 mm 3.15 mm
Width 3.0 mm 12.5 mm
Width / Thickness Ratio 3:1 8:1
Enamel Thickness 0.08 mm 0.18 mm

CTC Conductor Parameters

Parameter Min Max
Production Speed 1 m/min 15 m/min
Number of Conductors 5 (odd) 47 (odd)
Height 5.0 mm 80.0 mm
Width 6.0 mm 26.0 mm
Transposition Pitch 20 mm 280 mm
Height / Width Ratio 1:3 8:1
Transposition Push Speed 150 times/min

Key Features

  • Precision transposition mechanism for stable conductor alignment
  • Supports enamel-coated oxygen-free flat copper conductors
  • Optional insulation paper wrapping unit
  • Servo-controlled tension management system
  • Automatic winding and take-up control
  • Suitable for 5 to 47 conductor transposition configurations
  • Designed for continuous production and high operational efficiency

Technical Advantages

Integrated Coating and Inspection Capability

GRM's manufacturing facility incorporates online coating and inspection systems capable of processing specialty magnet wires with multi-layer enamel insulation. Fresh coating treatment within the same production environment helps improve electrical resistance performance and conductor surface quality.

Continuous Quality Monitoring

Real-time monitoring systems ensure conductor dimensional accuracy, insulation consistency, and stable production quality throughout the manufacturing process.

Precision Manufacturing Expertise

Backed by Japanese CNC machining centers, precision laser equipment, and dedicated quality control laboratories, GRM delivers reliable Continuously Transposed Conductor Line solutions for demanding transformer and magnet wire applications.

Why Choose GRM

  • 16+ years of metal forming and rolling mill experience
  • National High-Tech Enterprise certification
  • EU CE certified manufacturing system
  • More than 50 patents and technical innovations
  • Custom engineering based on conductor specifications
  • Global export experience across North America, Europe, and Asia
  • 48-hour after-sales response and lifetime technical support

FAQ

What is a CTC conductor?

A continuously transposed conductor (CTC) is a rectangular conductor bundle formed by continuously transposing multiple insulated flat conductors. It is widely used in transformer windings to reduce eddy current losses and improve electrical efficiency.

What materials can the Continuously Transposed Conductor Line process?

The line is primarily designed for enamel-coated oxygen-free flat copper conductors and other magnet wire materials used in transformer and electrical manufacturing.

Can the equipment be customized?

Yes. GRM provides customized configurations based on conductor dimensions, production speed requirements, insulation structures, and factory layout conditions.

What industries commonly use this equipment?

The Continuously Transposed Conductor Line is commonly used by transformer manufacturers, magnet wire producers, EV component suppliers, aerospace electrical manufacturers, and industrial electrical equipment companies.

Request a Customized Solution

Looking to improve transformer conductor production efficiency and product quality? Contact GRM today for a customized Continuously Transposed Conductor Line solution tailored to your conductor dimensions, insulation requirements, and production capacity goals.

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