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.

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