2025-07-17 18:55:35
The Dual Spindle Automatic Winding Machine is a high-precision industrial device designed for efficient coil winding in various manufacturing processes. This advanced machine features two independent spindles that operate simultaneously, significantly improving production efficiency while maintaining consistent quality. With applications ranging from electrical components to automotive parts, this machine has become indispensable in modern manufacturing.
1. Dual Spindle Operation: The machine features two independent spindles (typically rated at 3000-5000 RPM each) that can operate simultaneously or independently, increasing production capacity by 80-100% compared to single spindle machines.
2. Precision Winding: Equipped with servo motors (resolution of 0.01mm) and high-accuracy encoders (±0.05% precision), the machine ensures consistent winding tension (adjustable from 0.1-10N) and layer alignment.
3. Programmable Control: Features a PLC-based control system with touchscreen interface (typically 10-15" color display) that stores up to 500 winding programs with parameters including turns count (1-999,999), wire diameter (0.02-3.0mm), and layering patterns.
4. Automatic Wire Handling: Includes automatic wire threading, cutting (with precision of ±0.5mm), and tension control systems (with feedback mechanism maintaining ±2% tension variation).
5. Multi-material Compatibility: Can handle various wire types including copper (0.02-3.0mm diameter), aluminum, and enameled wires with temperature resistance up to 200°C.
6. Safety Features: Integrated with emergency stop (response time <50ms), overload protection (current monitoring ±1% accuracy), and enclosure guards meeting IP54 standards.
The Dual Spindle Automatic Winding Machine finds applications in numerous industries:
Electronics Manufacturing: For producing transformers (including SMPS transformers with 0.1mm precision), inductors (with Q factors up to 200), and solenoids (up to 10,000 turns).
Automotive Industry: Manufacturing ignition coils (handling up to 50kV insulation), alternator windings, and EV motor components (with slot fill factors up to 85%).
Energy Sector: Production of generator windings (for machines up to 5MW), current transformers (0.2 class accuracy), and power inductors (handling up to 100A currents).
Medical Equipment: Precision winding of miniature coils for MRI systems (with positional accuracy of ±5μm) and defibrillator components.
Aerospace: Manufacturing of high-reliability coils for avionics (meeting MIL-STD-810 standards) and satellite components.
Proper maintenance ensures optimal performance and longevity of the Dual Spindle Automatic Winding Machine:
Daily Maintenance:
Clean machine surfaces and components using compressed air (at 2-3 bar pressure) and lint-free cloths
Check wire tension system calibration (maintain within ±5% of set value)
Inspect guide rollers and pulleys for wear (replace if groove depth exceeds 0.2mm)
Verify spindle runout (should be <0.01mm TIR)
Weekly Maintenance:
Lubricate spindle bearings with high-speed grease (NLGI grade 2, quantity 1-2g per bearing)
Check servo motor encoder alignment (adjust if error exceeds ±0.1°)
Inspect electrical connections (torque to 0.5-0.8Nm for terminal blocks)
Test emergency stop functionality (response time verification)
Monthly Maintenance:
Perform spindle dynamic balancing (vibration should be <0.5mm/s RMS)
Calibrate tension control system using reference weights (accuracy verification to ±0.5%)
Check linear guide ways (re-lubricate with ISO VG 32 oil if necessary)
Verify PLC program backups and update if necessary
Quarterly Maintenance:
Replace air filters (for machines with pneumatic components)
Check insulation resistance of electrical components (>10MΩ at 500VDC)
Inspect and replace worn belts (if elongation exceeds 3% of original length)
Perform full machine calibration including turn counting accuracy verification
Irregular Winding Patterns: Check for worn guide rollers, verify tension system calibration, and inspect wire feed mechanism alignment
Spindle Vibration: Verify dynamic balance, check bearing condition (replace if noise exceeds 65dB), and ensure proper mounting torque (typically 25-30Nm for spindle nuts)
Wire Breakage: Adjust tension settings, inspect wire path for sharp edges, and verify wire quality (elongation should be >15% for copper)
Programming Errors: Check for software updates, verify parameter limits, and ensure proper grounding of control system (resistance <1Ω)
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