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.