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.

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.

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.