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.

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.

Types of Coil Winding Machine:

Coil Winding Machine Manufacturer

Today’s world is growing fast and so the requirement of the automated products. When any product is automated, there will the some sort of power used which might be either electrical mechanical or both. Almost all the products operated by electrical power will have coils to transform the power in one or the other way. This makes the requirement of the coil winding machines in the manufacturing of product involving of using electrical power. Due to this the coil winding machine requirement is intensive in today’s Industries.

The function of the coils in the product is either to convert the level of the power in form of current or voltage or frequency. Depending on this the coils are designed and as per the coils the winding machines are required. The coils might have few turns to thousands of turns in single coil. This makes the requirement of the coil winding machine which can be hand operated, semi-automatic coil winding machines or complete automatic coil winding system.

 Hand operated winding machines are simple and can also be build in-house or at college with very little knowledge of mechanical rotating components. This hand operated machines can be used to wind the coils where the coils have few turns to hundreds of turn in the coil. Basic hand operated coil winding machine consist of the handle mounted on the gear and with multi gears the shaft is mounted on the final output gear on which the coils are rotated. When the multi gears are involved the labour of the operator to rotate the coil is drastically reduced as for single manually rotation of the handle, multi turns are been wound on the coil.

Semiautomatic coil winding machines are the one where basis winding operation is done by the machine which can be achieved either by mechanical or electronics control. While other operation like loading or unloading of the coils is done by the operator including wire termination. Basic requirement of the coiling parameters like no. of turns to be wound, width of the coil within which the wire is to be wound are controlled by the machine. Acme Mechatronics, Inc. is involved in manufacturing semi automatic coil winding machines in wide range to fulfil the coiling requirement for wide applications.

Automatic coil winding machines are the one where all the coiling operation is been done by the machine. The turns in the coils may be in thousands. This automatic coil winding machines will perform the loading of coils, winding and unloading of coils including wire termination.

Every type of coil winding machines has its own pros and cons. We will discuss each and every type of machines in depth in future.

Acme Mechatronics, Inc. is expert in the field of the coil winding machines and can be visited at acmemechatronics.com for any of your queries about coils or coil winding machines.