2025-07-17 18:57:26
A Fully Automatic Coiling Machine is an industrial-grade equipment designed to wind materials such as wires, cables, tubes, or strips into precise coils with minimal human intervention. These machines integrate advanced servo motor systems (typically 1-15 kW power rating), PLC-based controls (response time <5ms), and precision tensioners (±0.1% accuracy) to achieve consistent winding patterns. Modern versions feature CNC programming interfaces allowing for coil diameters ranging from 50mm to 2000mm with linear speeds up to 120m/min. The automatic wire guiding systems maintain layer alignment within ±0.5mm tolerance, while integrated sensors monitor parameters like tension (0.1-50N adjustable) and coil count (±0 count error).
Key technological advancements include:
Multi-axis servo control (4-8 axes synchronization) for complex winding patterns
Automatic diameter compensation (real-time adjustment ±0.2mm)
Touchscreen HMIs (10-15" displays) with recipe storage for 100+ configurations
Integrated quality inspection systems (CCD cameras with 5μm resolution)
The versatility of automatic coiling machines makes them indispensable in multiple sectors:
Electrical Manufacturing: For winding 0.05-25mm² copper/aluminum wires in motor stators (up to 5000 turns), transformers (500kg max coil weight), and solenoids. Specialized versions handle HV cables up to 35kV with anti-twist mechanisms.
Automotive Sector: Production of fuel injector coils (0.02mm enameled wire), alternator windings, and sensor components requiring IP54-rated machines for cleanroom compatibility.
Energy Infrastructure: Large-scale coiling of 50-150mm diameter power cables with integrated 3000N tension control for offshore wind farm installations.
Medical Device Production: Micro-coiling of 0.001-0.1mm shape memory alloys for stents and guidewires under Class 7 cleanroom conditions.
Consumer Electronics: Precision winding of FPC cables and 0.3mm pitch flat wires for smartphone components with 0.01mm positioning repeatability.
Proper maintenance ensures >90% uptime and extends machine lifespan beyond 10 years:
Daily Procedures:
Lubricate linear guides with ISO VG 32 grease (apply 2-3g per bearing)
Clean optical sensors with 99.9% isopropyl alcohol
Verify tensioner calibration (±5% deviation limit)
Inspect wire guides for wear (replace at 0.1mm groove depth)
Weekly Checks:
Test emergency stops (response time <50ms)
Measure servo motor temperatures (max 75°C under load)
Backup PLC programs and parameter sets
Inspect pneumatic systems for 0.5-0.7MPa pressure stability
Quarterly Maintenance: Replace timing belts after 2000 operating hours, recalibrate encoders to ±1 pulse/revolution accuracy, and perform vibration analysis on spindles (<2.5mm/s RMS vibration).
Annual Overhaul: Complete bearing replacement (C3 clearance class), servo motor encoder alignment (±15 arc-min tolerance), and control cabinet inspection (tighten terminals to 0.2Nm torque).
Common issues and technical solutions:
Irregular Coil Patterns: Check for backlash >0.05mm in ball screws, verify CNC interpolation accuracy, and recalibrate wire feed servo (0.01mm resolution).
Tension Fluctuations: Inspect dancer arm bearings (replace if friction >0.5N), update PID parameters (Kp 1.5-2.0, Ki 0.05), and check for ±10% voltage stability in control circuits.
Layer Stacking Errors: Adjust wire pitch parameters (typically 1.05-1.15 x wire diameter), clean traverse guide rails, and verify servo following error <±5 pulses="">.
Specialised in automated winding equipment and system development, production, sales and technical services as one of the high-tech enterprises.
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