Machine Concept Overview
This machine is specially designed for automatic winding of small-size toroidal ferrite common mode choke inductors, where:
- Two different copper wires are wound
- Four terminal ends are generated
- Each winding is placed symmetrically on opposite sides of the toroidal core
Unlike single-head systems, this advanced model features:
✔ Dual independent winding heads
✔ Automatic ferrite core ring feeding through vibrator bowl
✔ Sequential two-side winding operation
✔ Maximum 3-meter copper wire length capability
✔ Suitable for 0.05 mm to 2.0 mm round copper wire
This machine is ideal for replacing manual toroidal winding processes that typically require 6–8 skilled workers.
Automatic Ferrite Core Ring Feeding via Vibrator Bowl
One of the most critical automation features is the vibrator bowl-based automatic core feeding system.
How It Works:
- Ferrite toroidal cores are loaded in bulk into the vibrator bowl.
- The bowl automatically aligns and orients the cores.
- A linear feeder transfers the core to the loading position.
- The robotic pick-and-place or mechanical arm loads the core into the winding station.
Benefits:
- Eliminates manual core handling
- Increases feeding consistency
- Reduces cycle time
- Enables continuous production
- Improves safety and efficiency
This feature makes the system suitable for true mass production environments.
Working Video :
Dual Head Winding System – Two-Side Common Mode Winding
Common mode chokes require two separate windings, generally wound symmetrically across the toroidal ring.
Working Principle:
- Head 1 performs the first winding on one side of the toroidal core.
- After completion, the core automatically indexes or transfers to Head 2.
- Head 2 winds the second copper wire on the opposite side.
- The result: two separate windings with four terminal ends.
This ensures:
✔ Balanced inductance
✔ Proper EMI suppression
✔ Symmetrical winding distribution
✔ High repeatability
The dual-head mechanism significantly improves output compared to single-head manual systems.
Maximum 3 Meter Copper Wire Winding Capability
This machine is engineered to handle winding operations up to 3 meters of copper wire length per winding cycle, depending on:
- Core size
- Turn count
- Wire diameter
This makes it suitable for:
- Small common mode chokes
- High-turn inductors
- Precision EMI filters
Wide Wire Size Compatibility (0.05 mm – 2.0 mm)
The machine supports a wide copper wire diameter range:
- Ultra-fine wire: 0.05 mm
- Medium range wires
- Heavy-duty wire: up to 2.0 mm
This flexibility allows manufacturers to produce:
- Miniature SMD common mode inductors
- Industrial-grade choke coils
- High-current toroidal inductors
Adjustable tension control ensures:
- No wire breakage
- No insulation damage
- Stable winding distribution
Ideal for Medium & Big Sizes Common Mode Choke Inductors
The system is especially optimized for:
- Medium & Big OD ferrite toroidal cores
- Compact EMI filter designs
- High-density PCB power modules
Medium & Big toroidal core winding is traditionally difficult and labor-intensive. Automation ensures:
- Accurate turn placement
- Uniform spacing
- Controlled tension
- Minimal rejection rate
Replacement of Manual Labor (6–8 Operators)
In traditional setups, small toroidal choke winding requires:
- Multiple manual operators
- Skilled labor
- Continuous supervision
- High rejection rates
This dual-head automatic system can replace approximately 6–8 manual workers, offering:
- Reduced manpower cost
- Higher production speed
- Consistent quality
- Lower fatigue-related errors
For high-volume production units, this leads to substantial cost savings.
High Productivity & Mass Production Capability
The machine is built for industrial output levels.
Production Advantages:
- Continuous automatic core feeding
- Sequential dual-head winding
- Automatic stop at preset turn count
- Fast model changeover
- Minimal downtime
This makes the machine suitable for:
- Export-oriented units
- OEM component manufacturers
- Large-scale EMI filter production
Complete End-to-End Fully Automatic Production Line Option
Beyond winding, we at Deptronics Technologies also provide a complete fully automatic production line solution, including:
1️⃣ Winding Station
Dual-head toroidal winding system.
2️⃣ Enamel Polish Removal
Automatic enamel stripping from terminal ends for solder readiness.
3️⃣ Soldering Station
Flux dipping and automatic dip soldering system.
4️⃣ Case Assembly
Automatic plastic case loading and insertion.
5️⃣ Case Fixing / Crimping
Secure mechanical fixing of housing.
6️⃣ Laser Marking
Branding, model number, batch code marking.
7️⃣ Testing Station
Automatic LCR testing for:
- Inductance
- Resistance
- Balance check
- Short/open detection
This transforms the system into a complete end-to-end smart manufacturing solution.
Technical Highlights
| Parameter | Specification |
|---|---|
| Core Feeding | Vibrator Bowl Automatic |
| Winding Heads | Dual Independent Heads |
| Winding Type | Two-Side Common Mode |
| Wire Size | 0.05 mm – 2.0 mm |
| Max Wire Length | 3 meters |
| Control System | PLC + HMI |
| Production Mode | Automatic |
| Application | Small Toroidal Common Mode Choke |
Quality Advantages
Automation ensures:
✔ Consistent turn count accuracy
✔ Stable inductance value
✔ Balanced dual winding
✔ Reduced human error
✔ High repeatability
✔ Lower rejection rate
This results in better EMI suppression performance in the final product.
ROI & Business Growth Impact
Investing in a dual-head automatic toroidal winding system delivers:
- Faster production cycles
- Reduced labor dependency
- Increased production capacity
- Higher customer trust
- Improved export competitiveness
For mass production manufacturers, ROI is achieved quickly due to manpower savings and productivity improvement.
Why Choose Deptronics Technologies?
At Deptronics Technologies, we specialize in:
- Custom-designed winding automation
- China-manufactured high-performance machinery
- Sample-based programming
- Installation & training support in India
- Long-term service assistance
We do not just supply machines — we provide complete production solutions based on your daily output targets and exact product design.
Future of Common Mode Choke Manufacturing
With increasing demand in:
- Electric vehicles
- Renewable energy
- Industrial automation
- Data centers
- Consumer electronics
Automated toroidal choke production is no longer optional — it is essential.
Manufacturers adopting automation gain:
- Scalability
- Precision
- Cost efficiency
- Competitive market advantage
Contact Us
For machine inquiries, pricing, or customization options, contact us today!
DEPTRONICS TECHNOLOGIES
📌 Contact Person: Deepanshu Saxena
📞 WhatsApp/ Mobile: +91-8800622761
🌐 Website: https://coilwinder.in/
📧 Email: [email protected]
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