Here we will discuss about coil winding machine used for pickup coils

Here we will discuss about coil winding machine used for pickup coils. Most of the pickup coils have high no. of turns wound with fine wire so that it becomes more powerful to induce AC voltage at the output of the coil. Hence for winding pickup coil proper selection of winding machine is more important. The winding machines with specific features mentioned below are more suitable for pickup coil winding.

Manual winding machine or Automatic winding machine: For pickup coils automatic winding machine is recommendedfor two reasons. firstly to wind high no. of turns with fine wire on manual winding machine would not be possible as there are chances of braking wire with uneven tension when wire guided with hand and second is as the turns are more for pickup coils, the speed of the machine should be higher which is not achieved in manual winding machine.

Now as we have concluded that automatic or programmable winding machines are better choice, we will now look for the features required.

Speed Control: The machine should have the complete control of the winding speed including starting and stopping speed. The machine should have soft start or it should start the spindle with slow speed and gradually increase the speed so the wire don’t brake. Similarly the stopping should be gradual as the wire passing through the pulleys are rotating at high speed and when the winding stops, these pulleys should also come to standstill else will pull the wire from the spool and eventually derail from the pulleys. So the best selection of speed control should be individual control of soft start, winding speed and soft stop. The machine should be such that for every winding setup the soft start and stop should be programmable in terms of turn. Acme Mechatronics offers best possible speed control with individual control of acceleration and deceleration in terms of turn while the speed can be set in terms of percentage of maximum speed of the machine.

Tension: As the wire is fine or thin, tension plays important part in winding pickup coil. The tensioner unit should be such that it can be set for very fine tension. There are various tensioners available including servo tensioners. But the servo tensioners are too expensive for such winding application. Graduated tensioner units are best suitable where fine setting is available for winding such coils and is economical choice. Below is the picture of graduated tensioner unit offered by Acme Mechatronics, Inc.

Tailstock:The other accessory is tailstock but it’s not compulsion to use. It only helps in quick loading and unloading without applying additional pressure on the wound coil as there may be chances of damaging the top layer wound while pulling the bobbin from the tool mounted on the spindle of the machine.

Acme Mechatronics, Inc. has the suitable AEX series machine with single spindle or multispindle for winding pickup coils. It has got all the features like soft start, soft stop, programmable speed alongwith optional graduated tensioner unit.

Coil winding equipment is used for winding electrical coils which has wide application.

Coil Winding Equipment

Understanding Coils

Coil is nothing but loops of wire wound on a core and core can be of magnetic material or air. Generally the loops are in specific numbers as per the application and function of the coils. This makes the importance of coil winding equipment to manufacture electrical coils. The coils differ in the length, no. of wound turns and core. Below are the pictures of various coils for various applications.

From the picture of various coils it shows that variety of coils exists. Hence various design, construction and operation of coils are necessary.

Main attributes of coils are as below

Sr. No.	Attributes of coil	Symbol	Unit of measurement
1	Inductance	L	Henry
2	Mutual Inductance	M	Henry
3	Reactance	XL or XC	Ohms
4	Impedence	Z	Ohms
5	Resonacne	Nil	Nil
6	Coil Efficiency	Q	Nil

With so many attributes is becomes important that manufacturing of coils is very important.
Below is the video of winding coil on a programmable coil winding equipment.

Present days winding equipment

Modern technology is advancing fast and so the winding equipment are now even more advance then old mechanically designed coil winding equipment. Now a days machine have programmable features to manufacture wide variety of coils on a same winding machine. Various coil winding equipments are designed depending on its capabilities to manufacture coils. Below are some of the pictures of coil winding equipments.

To make winding equipment having wider winding capabilities more and more programmable features are added. Some of the key controlling parameters are the speed of winding and the programmable traverse unit. Remaining parameters might not be key but would be helpful to achieve one or the other coil winding requirement like programmable direction of winding which helps in winding in phase and out of phase coils. Soft start and soft stop of spindle rotation to have smooth winding for very few turns to tens of thousands of turns alongwith wire thickness. Soft start features are helpful for winding fine wire coils while soft stop feature is helpful is achieving turns accuracy. When wire is very fine of thinner, the ramping in winding speed should be very slow else there are chances of braking off wire and when turns accuracy is required the soft stop is important as the machine will slow down before it reaches its final turns else there will be overshoot in winding turns. Such various parameters of machines help in winding variety of coils. In future we will discuss of various parameters in details.

Acme Mechatronics, Inc. is manufacturing coil winding equipment with wide programmable parameters and also offers more than 30 models of coil winding equipment depending on its winding capabilities.

Pickup coil winding machine by ACME Mechatronics

Pickup coils have an intensive use in electric guitars. Apart from guitar application, such coils are used to convert any form of energy into electrical energy. Basic pickup coil consists of magnets, bobbin and copper wire. Magnets are alloy which are generally in the center of the bobbin and the wire is wrapped about the magnet for which the bobbins are been used. For pickup coils the main design is high numbers of turns of fine wire generally 42 or 43 guage. When fine wire are to be wound some special care is to be taken.

In most of the case the turns are in high value around 6000 to 12000 turns and so the speed of winding should be high. The shape of the pickup coil is generally rectangle and when winding is done on the rectangle shape bobbin, the tension becomes uneven within one turns. At two locations the wire is pulled intensively and at two bobbin positions the tension is relieved. For such a winding profile with fine wire wound, the tension becomes important role. So the best choice of winding machine for winding pickup coil is high speed automatic programmable winding machines alongwith graduated tensioner units for fine setting of tension. Using programmable pickup coil winding machine will help in controlling the winding speed alongwith soft start and soft stop. With soft start features available in machine, the braking of wire is avoided or even elongation of the fine wire is avoided. And using fine adjustable tensioner unit the possibility of braking of wire is also avoided alongwith increase in quality winding.

Acme mechatronics, Inc. offers AEX-01 or AEX-02 alongwith graduated tensioner unit to wind guitar pickup coils.

Below picture show the two coils as a time of guitar pickup coil. This machines has the capability to program most of the parameters like wire guage, winding width, starting point of the turns, soft start, soft stop, speed, etc.

Many times when the coil is wound, due to the pressure of wound turns, the bobbin flange expands which affects the functionality of the pickup coil so to avoid the expansion of the bobbin flanges additional accessory is used which will give support from the other side of the bobbin and this accessory is termed as tail stock. Not only this helps to avoid expanding of the bobbin flange but also it helps in quick loading and unloading of the bobbin.

For more information and inquiry please contact us.

Motor Coil Winding Machine : CNC winding machine for motor stator coils

Motors in todays world are key component to provide motion to any device. This makes the reason to design wide variety of motors. Some different types of motor are induction motor, DC motors, servo motors, stepper motors, synchronous motors, torque motors, etc. Again within each category there are various motors depending on its ratings and construction. Out of all the most widely used motors are induction motor. Currently we will discuss about this motors.

Induction motor has two main component viz. core and winding. Core or the body is purely depending on the material selection while winding becomes more dependable on the winding machine.Hence special winding machines are designed with specific features to wind motor coils. When the machine is built to wind motor coils, the machine needs to have special features.

Two basic motor winding machines are available in the market or should be available in the market. One is for production and other is for repair workshop. The main feature to wind motor coils are its capability to have multi section winding possibility. The motor coil consists of successive coils having few turns in each coil. The successive coils can be upto 16 coils with single start and finish terminal. These coils are wound on the Arbours of different shapes and size depending on the motor design and rating. Arbours are key to defining winding capabilities of the machine So the machine should be able to hold such a long arbour. Here we will discuss about motor coil winding machines for production purpose while for motor winding machines for repair workshop would be discussed later.

Main features for motor coil winding machine is to have successive coil winding capability and should be programmable so it can perform wide variety of motor rating.

Advantages of Programmable / CNC winding machine for motor stator coils are

• 0.05 turns accuracy
• 16 coils per winding cycle
• 100% repeatability
• Soft start and soft stop avoids wire breaking
• Minimum setup time with 50 program memory
• Independent of operator’s skill
• Very high production
• Constant tension to avoid elongation of wire
• Equal resistance of every coil
• Ease in insertion of coil in stator due to layer wound coils
• Reduction in joints of coil
• Flexibility to use various formers on single mandrel

Acme Mechatronics, Inc. is offering various models of motor coil winding machine depending on the diagonal length of the motor coil alongwith various options of tensioner units. Also the tooling or the mandrel plays important role in producing motor coils and it should be designed in such a way that minimum time is required to remove the coils after winding as the coils will get tighten on the mandrel once wound making it difficult to remove from the mandrel.

Transformer winding machine

For small VA rating transformer winding machines the video can be watched on below link.

The function of the transformer is to change the output voltage value to its input voltage and doing this the output current will also change with its input current while maintaining the VA nearly same at input and output. The VA becomes the rating of any transformer as it indicates the voltage and current rating. Transformer becomes most common electrical part or component of any electrical or electronics equipment or power system. A small device like mobile charger has a transformer as its vital part and so the huge industry also has the transformer at its power receiving end as a vital part. This means the rating of the transformer varies from few VA to MVA. The important part of transformer is winding of wire and this makes the transformer winding machine a most crucial manufacturing equipment to produce transformer.

Transformer winding machine has to be with different winding capabilitiesand different features as it has to manufacture transformers of few VA to MVA ratingsalongwith very low volume to high volume production. Due to this there is different transformer winding machines available in market. Transformer winding machines available are

• Manual transformer winding machines
• Programmable transformer winding machines
• CNC or Automated transformer winding machines

We have already discussed about manual, programmable and automatic winding machines in past. Manual winding machines are generally considered when the company is just starting to think of manufacturing transformers and needs to build couple of proto type transformers or having limited resources of fund. CNC or automated transformer winding machines are to be considered when you have huge production with very few designs or few variety of transformers to wind. The most recommended winding machines to have in any workshop or shop floor is programmable transformer winding machine due to its features.

Basic requirement the winding machines to have to wind transformer coils are its capability to handle the wire size, bobbin size and speed control. There are no complicated winding patterns required for transformer winding except when we need to wind PT transformers.

Programmable winding machine has the facility to store no. of programs and this makes easy to hold the design of various transformers into the memory of machine which can any time recalled and start winding. The variable speed makes easy in winding as the wide variety of wires(thin and thick) are required as per design of transformer. The thin wire winding requires high speed while thick wire required low speed. Acme Mechatronics, Inc. has variety of transformer winding machines with programmable features depending on its winding capabilities. Three most suitable models are AEH-01, AEW-5501,1200RPM and AEH-11. More details and features can be found on our acme mechatronics website www.acmemechatronics.com

Manual winding machines are the cheapest and most easiest machine to wind coil

Manual Coil Winding Machine

The coils are of infinite design and applications and so the winding machine has to be there to make such coils. Manual winding machines are the cheapest and most easiest machine to wind coil. To build the coil the most important part is the rotation of the coil on which the wire is been wound. Hence the spindle becomes important part of the manual winding machine. A simple counter is coupled to the spindle rotation to display the turns wound on the coil. The counter is having reset options when a new coil is wound.

In manual winding machine the spindle can be rotated with two options. One is with hand and other with the motor coupled on the spindle. Manual winding machines came with the solution to wind coils. The machine is simple that it can be built at any workshop. When the coils are to be wound in few numbers or when the coils are been under development, manual winding machines are the best option as the cost of the machine justifies the requirement. Manual winding machine also sometimes come with traverse mechanism which is manually handled. With the help of this traverse the spreading of the turns wound is better and it would not be dependable on the operator.

The switching of the direction of layer is done manually by the operator by just shifting the lever form left to right or from right to left. This traverse is coupled with the spindle rotation through the rubber roller and gears. In other words the manual winding machine with only spindle has been incorporated with the traverse unit to minimise the operator’s skills requirement. The picture is of manual winding machine with spindle and counter alongwith handle to rotate the spindle manually.

With manual winding machine there are some limitations as mentioned below:

1. Basic coil can be wound with poor quality.
2. The turns cannot be accurate as well the tension of the wire will not be equal.
3. The time taken to wind the coils is more.
4. The repeatability of the coil is not possible and there will be difference in every coil.
5. Somewhat skilled operator is required to perform the winding as both the hands are used to wind the coil and it is not easy for unexperienced operator to rotate the spindle and guide the wire at a time with two hands.
6. Chances of getting hurt as the fine wire sometimes cuts the figure.

Due to many disadvantages, Acme Mechatronics, Inc. have developed coil winding machine with programmable functions so the best quality of coils can be wound with high production and high repeatability. Acme Mechatronics offers wide variety of machines to wind simple to complex coils with automated functions.

WHAT IS COIL WINDING MACHINE:

In today’s world the technology plays major role in once life. And so as the technology is driven by one or the other form of the power, electrical power is also a major form of energy. In electrical power some of the components are used as a default and one of the component is coil. Mostly coil is used to generate magnetic field which is later used for various ways like stepping up the voltage, stepping down the voltage or only as a purely magnetic field. The coils will vary in size and quantity. So to produce the coils, machine is used which is termed as a coil winding machine. Basic function of this machine is to rotate the wire on any form of the core or bobbin or air.

Coil winding machine is having two major functional parts.

First is the rotating spindle and the second is the wire layering traverse. In short Spindle assembly and traverse mechanism are two major parts of winding machine while other parts may be part of the machine but its optional.

Spindle assembly can be rotated by various forces like hand or by motor. When the spindle is rotated by hand, it is generally called as hand winding machine or manual winding machine and when the motor is used to rotate the spindle, it is termed as motorized coil winding machine. The main function of the spindle is to rotate the bobbin or core on which wire is been wound which is called coiling of the wire. Now depending on the wire size and final coil weight alongwith the production required, either it can be hand rotated or with motor. Various HP motors are selected depending on the weight of the coil after winding. When the production required is too low then manually rotated spindle is generally preferred.

While when the coils are with high no. of turns or needs high production, motorized spindle is required. The spindle is coupled with the counter which displays no. of turns wound as the coil function on no. of turns. In the coils, there is requirement to include more turns in limited space of the bobbin and this need arise the requirement of the system which can spread the turns wound evenly or proper wound layer. The traverse mechanism performs this function of proper spreading of the turns. This traverse is either mechanically coupled with the rotation of the spindle motor or separate motor is used to move the traverse mechanism. When the spindle is rotating, the traverse unit is also moving synchronously as per the wire diameter so that the turns are been spread adjacent to each other. When one layer is completed the traverse unit will change its direction of moving so the second layer is been wound over the previous layer. The changing direction of the traverse unit can be either manually or automatic. The most important factor of the machine is the synchronization of the spindle with the traverse with respect to the wire diameter.

Acme Mechatronics, Inc. has expertise is designing various coil winding machines with highest degree of accuracy w.r.t. the synchronization between spindle and the traverse as this is been controlled by electronics circuit and not any mechanical part. The traverse unit reduces the speed or increases its speed w.r.t. the rotating speed of the spindle.