Key Structure And Working Principle Of Inductor Coil Winding Machine

The structural design of the inductor coil Winding Machine is centered on the core requirements of "stability, precision, and Automation". Its working principle realizes the fully controllable whole process from raw material transportation to finished product output through the collaboration of multiple systems, which is an indispensable core equipment in the electronic component manufacturing industry.

Detailed Analysis of Core Structural Components

1. Frame and Base

The frame and base are mostly made of high-strength cast iron or steel plate welding, and undergo aging treatment to eliminate internal stress, avoiding the impact of vibration on winding precision during operation. The bottom is equipped with leveling feet or shock absorption pads, which can adjust the levelness of the equipment and isolate external vibrations from interfering with the winding head and positioning system. The frame is reserved with modular installation interfaces, facilitating subsequent upgrades or replacement of winding heads, feeding devices and other components.

2. Winding Head Assembly (Core Execution Unit)

The winding spindle is driven by a high-precision servo motor, with a stepless adjustable speed range (usually 50-1200rpm), and the spindle runout is controlled within 0.005mm. The fixture system includes pneumatic chucks or mechanical chucks for fixing inductor bobbins/magnetic cores, which can adapt to workpieces of different sizes (diameter 0.5-50mm), and the clamping force can be adjusted by air pressure or torque. The wire arrangement mechanism is equipped with ball screws or linear guides, controlled by servo motors for lateral movement to achieve uniform wire arrangement. The wire arrangement precision can reach ±0.01mm, supporting single-layer, multi-layer dense winding or sparse winding modes. The wire breakage detection device has built-in optical fiber sensors or pressure sensors, which immediately trigger shutdown when the wire breaks, avoiding empty winding or product scrapping.

3. Feeding Device

The spool bracket can install 1-4 spools, supporting different spool diameters (commonly 300-500mm). Some models have spool braking function to prevent wire loosening. The wire guide wheel set is composed of multiple ceramic or tungsten steel guide wheels to reduce wire wear. The groove diameter of the guide wheel matches the wire diameter (error ≤0.01mm) to ensure smooth wire transportation. The wire feeding motor adopts a stepper or servo motor, and the wire feeding speed is linked with the winding spindle speed to achieve synchronous speed regulation, avoiding wire accumulation or pulling.

4. Tension Control System (Key Precision Guarantee)

The core component is a magnetic powder tensioner or pneumatic tensioner, with a tension adjustment range of 0.01-5N. Some high-precision models can achieve 0.005N fine adjustment. The real-time feedback mechanism monitors the wire tension through tension sensors, transmits signals to the control system, and automatically adjusts the tensioner output, with an error controlled within ±5%. The tension compensation function presets compensation parameters for wire elastic deformation, avoiding uneven coil tightness caused by tension fluctuations during winding.

5. Positioning and Sensing System

The servo positioning module: the lateral and longitudinal movement of the winding head is driven by servo motors, combined with grating scales or encoders, with a positioning precision of ±0.001mm. The turn count detection counts through the spindle encoder, with a turn error ≤±1 turn, supporting automatic shutdown at the preset number of turns. Some models can set segmented winding by the number of turns. The bobbin positioning sensor uses photoelectric or laser sensors to accurately identify the pin position of the inductor bobbin, ensuring alignment of the winding starting point with an error ≤0.1mm.

6. Numerical Control and Human-Machine Interaction System

The control system mostly adopts PLC or special CNC system, supporting G-code programming or graphical programming, and can store more than 1000 sets of winding parameter programs for easy batch production call. The operation interface is equipped with a touch screen (commonly 7-15 inches), which can intuitively set parameters such as the number of turns, wire arrangement spacing, winding speed, tension value, and real-time display the operating status (rotational speed, completion progress, fault alarm). The fault diagnosis function has a built-in fault database, which can automatically identify problems such as abnormal tension, sensor failure, and motor overload, and display solutions.

Detailed Explanation of Core Working Principle (Whole Process)

1. Pretreatment Stage

According to the specifications of the inductor coil, the operator selects the appropriate fixture and guide wheel, installs the inductor bobbin on the chuck of the winding head, and locks it. Lead the enameled wire (or other wires) from the spool, pass through the wire guide wheel set and tensioner in turn, and finally fix it on the pin or starting slot of the inductor bobbin. Input winding parameters in the touch screen: number of winding turns (1-10000 turns per group), wire arrangement spacing (0.01-5mm), winding speed (50-1200rpm), tension value (0.01-5N), number of winding layers (1-100 layers), etc., and save it as an exclusive program.

2. Automatic Winding Stage

After starting the equipment, the numerical control system sends instructions, and the wire feeding motor and winding spindle start synchronously. Under the action of the tensioner, the wire maintains a constant tension and is uniformly transported to the winding head. The winding spindle drives the inductor bobbin to rotate at high speed, and at the same time, the wire arrangement mechanism moves laterally according to the preset spacing to uniformly wind the wire on the bobbin. During the process, the turn count detection sensor counts in real time, and the positioning system dynamically corrects the winding trajectory to avoid wire overlapping or deviation. For multi-layer coil winding, the system will automatically switch the wire arrangement direction. After completing one layer, it raises the winding height (the lifting amount matches the wire diameter), and then performs the next layer of winding to ensure tight fit between layers.

3. Finishing and Connection Stage

After reaching the preset number of turns, the winding spindle and wire feeding motor decelerate and stop. The wire breaking device automatically cuts the wire (cutting precision ≤±0.5mm). Some models can synchronously complete the welding (such as spot welding, tin dipping) or tape fixing of the wire end. The fixture automatically loosens, and the finished coil is transferred to the blanking area through the unloading device (pneumatic ejection or conveyor belt transportation). The equipment can automatically reset to prepare for the winding of the next workpiece (no need to reset parameters in continuous production mode).

4. Real-Time Regulation Mechanism

The tension control system monitors the wire tension throughout the process. If the tension is too high (close to the wire breaking threshold), the system will automatically reduce the winding speed and wire feeding speed, and adjust the tensioner to reduce the output; if the tension is too low, it will increase the tension value to avoid loose coils. The sensor real-time monitors the equipment operating status. If abnormalities such as loose bobbins, wire breakage, and motor overload occur, it immediately triggers shutdown and alarm. The screen displays the fault type and processing suggestions to prevent equipment damage or unqualified products.