Fully Automatic Coiling Machine: Features, Applications & Maintenance

1. Introduction to Fully Automatic Coiling Machines

A Fully Automatic Coiling Machine is an advanced industrial equipment designed for precision winding of wires, cables, ropes, or other flexible materials onto spools, reels, or bobbins. These machines eliminate manual intervention through sophisticated PLC (Programmable Logic Controller) systems and servo motor technology, achieving production speeds up to 120 meters per minute with winding tension control accuracy within ±0.5% of the set value. Modern variants incorporate IoT capabilities for remote monitoring, with some models offering ±0.1mm layer alignment precision through laser-guided positioning systems.

2. Key Features with Technical Specifications

2.1 Precision Winding Mechanism

The core winding system utilizes 32-bit ARM processors controlling servo motors with 17-bit absolute encoders, achieving angular positioning accuracy of ±0.01°. The constant tension system maintains forces between 0.1-50N with a response time of 5ms, adjustable through HMI interfaces with 10.1" touchscreen displays offering 100+ programmable winding patterns.

2.2 Automated Material Handling

Integrated robotic arms with 6-axis freedom and ±0.02mm repeatability handle spool changes in under 8 seconds. The automatic wire guide system features 0.005mm/step micro-stepping motors for perfect layering, while vision systems with 5MP CMOS sensors perform 200 inspections/minute for defects.

2.3 Energy Efficiency

Regenerative braking systems recover up to 30% of deceleration energy, coupled with IE4 class high-efficiency motors reducing power consumption by 15-20% compared to conventional models. Some units achieve 0.5kWh/kg specific energy consumption for copper wire winding.

2.4 Safety Systems

Comprehensive protection includes Category 4 PL e safety circuits, 24V DC emergency stops, and light curtains with 14mm resolution. The machines comply with ISO 13849-1 and NFPA 79 standards, featuring 85dB(A) noise emission levels at 1m distance.

3. Industrial Applications

3.1 Electrical Industry

For winding 0.05-10mm diameter copper/aluminum wires onto bobbins for motors, transformers (handling up to 500kg spools), and solenoids. Specialized versions process 800-3000V magnet wires with Class H insulation.

3.2 Cable Manufacturing

Coaxial cables up to 50mm OD with 1000N tension capacity, including fiber optic cables requiring <0.1% elongation during winding. Marine cables with 300m lengths are spooled at 60m/min speeds.

3.3 Automotive Sector

Production of fuel injection coils (0.1mm enameled wire), ABS sensor windings (±5μm positioning), and EV battery busbars requiring 4-layer insulation winding.

3.4 Medical Devices

Precision winding of nitinol shape-memory alloys for stents (0.05-0.5mm wires) and MRI gradient coils with 0.25° pitch accuracy in cleanroom-compatible models.

4. Maintenance Procedures

4.1 Daily Maintenance

• Lubricate linear guides with ISO VG 32 grease every 8 operating hours

• Check pneumatic filters (replace at 0.7bar pressure drop)

• Inspect wire guides for wear (>0.1mm groove depth requires replacement)

• Clean optical sensors with 99% isopropyl alcohol

4.2 Weekly Maintenance

• Torque check all fasteners (8.8 grade bolts at 25Nm)

• Servo motor encoder alignment verification (±1 arc-minute tolerance)

• PLC backup and parameter logging

• Tension sensor calibration (±0.25% FS accuracy)

4.3 Quarterly Maintenance

• Replace harmonic drive grease (SKF LGHP 2)

• Inspect servo motor brushes (replace at <5mm length)

• Cooling fan filter replacement (G4 class filters)

• Full axis alignment using 0.01mm/m precision levels

4.4 Annual Overhaul

• Ball screw backlash measurement (>0.05mm requires replacement)

• Transformer oil analysis (<0.5% water content)

• Safety circuit validation per IEC 62061

• Complete re-calibration of all metrology systems