Automatic Contactor Coil Winding Process
The machine is engineered to perform the winding process in a controlled and repeatable sequence.
1. Bobbin Loading : The contactor coil bobbins are positioned on the 12 spindle holders. Depending on the machine configuration, bobbin loading can be manual or integrated with an automatic loading system.
2. Wire Feeding : Copper wire is supplied through individual wire feeding and tension-control systems. The wire passes through the required guides and tensioning mechanism before reaching the winding spindle.
3. Controlled Winding : The 12 spindles rotate simultaneously while the winding traverse mechanism guides the copper wire across the bobbin. The PLC and servo-controlled system maintain the programmed winding parameters to achieve consistent coil geometry and turn distribution.
4. Turn Count Control : The winding program controls the required number of turns for each coil. Encoder feedback provides accurate spindle movement and helps maintain repeatability between production cycles.
5. Wire End Cutting : After completion of the programmed winding operation, the wire is automatically cut and secured according to the configured process.
6. Automatic Taping : After winding, the finished coil is transferred to the automatic taping attachment. The taping unit applies insulation tape around the coil according to the programmed taping requirement. Tape length, overlap and application movement can be adjusted according to the coil design.
7. Finished Coil Unloading : After the taping operation is completed, the finished coils are unloaded for further assembly, inspection or packing.
Working Machine Videos :
Automatic Taping Attachment
The integrated taping attachment is an important feature of this machine for applications where the wound contactor coil requires additional insulation or mechanical protection.
Instead of manually removing the wound coil and transferring it to a separate taping operation, the taping attachment allows the process to be incorporated into the automated production sequence.
The taping system can be configured according to the customer’s coil design, tape specification and required number of layers.
Typical parameters that can be controlled include:
- Tape length
- Number of tape layers
- Tape overlap
- Taping speed
- Taping position
- Start and end position
This integrated approach helps reduce manual handling and provides more consistent tape application from coil to coil.
Precision Wire Tension Control
Consistent wire tension is critical in contactor coil manufacturing. Excessive tension can damage or stretch fine copper wire, while insufficient tension can result in loose turns, uneven layers and inconsistent coil geometry.
The 12-spindle machine therefore incorporates individual wire tension-control arrangements for stable wire feeding during high-speed winding.
Depending on the application, the machine can be configured with magnetic tensioners or servo-based tension-control systems.
The objective is to maintain stable wire movement throughout the winding cycle and achieve repeatable coil construction across all 12 spindles.
Servo-Controlled Winding System
The winding system uses precision servo motors for controlled spindle rotation and traverse movement.
The winding program can define:
- Number of turns
- Winding speed
- Acceleration and deceleration
- Traverse movement
- Winding direction
- Layer transition
- Start and stop position
This allows the machine to be configured for different contactor coil designs without changing the complete machine architecture.
Multiple production recipes can also be stored in the HMI for different coil models, allowing operators to select the appropriate program during production.
PLC and HMI-Based Operation
The machine is operated through an industrial PLC and touchscreen HMI. The operator can monitor and adjust production parameters from the HMI while machine status, alarms and process conditions are displayed in real time.
Typical HMI functions include:
- Recipe selection
- Turn-count setting
- Winding speed adjustment
- Taping parameters
- Spindle operation monitoring
- Alarm indication
- Production counter
- Manual/jog operation
- Parameter management
This makes the machine suitable for repeat production as well as multiple contactor coil models.
Wire Break Detection and Production Monitoring
For continuous production, wire-break detection is essential. If a copper wire breaks during the winding process, the machine can detect the abnormal condition and stop or interrupt the relevant operation according to the programmed sequence.
The operator can then correct the wire condition and resume production.
Additional monitoring and inspection systems can also be integrated depending on customer requirements.
Typical Machine Specifications
| Parameter | Specification |
| Machine Type | Automatic Contactor Coil Winding Machine |
| Number of Spindles | 12/16/20/24 |
| Winding System | Servo Controlled |
| Wire Tension | Magnetic / Servo Type |
| Winding Direction | CW / CCW |
| Control System | PLC + HMI |
| Spindle Pitch | Application dependent |
| Copper Wire Range | Approx. 0.02–0.60 mm |
| Power Supply | AC 220V, 50Hz |
| Air Pressure | Approx. 4–6 kg/cm² |
| Taping | Automatic Taping Attachment |
| Tape Application | Programmable |
| Production | Application dependent |
| Optional Features | Automatic Loading, Unloading, Testing, Terminal Processing |
Final machine specifications are customized according to the contactor coil drawing, bobbin dimensions, wire specification, turn count and production requirements.
Advantages of Multi-Spindle Contactor Coil Winding Machine
High Production Output : Twelve coils are processed simultaneously, significantly increasing production capacity compared with single-spindle or manual winding systems.
Consistent Winding Quality : Servo-controlled winding and controlled wire tension help maintain consistent winding geometry and turn distribution across production batches.
Integrated Taping : The automatic taping attachment eliminates a separate manual taping operation for compatible coil designs, reducing handling and improving process consistency.
Reduced Labour Dependency : A single operator can supervise the machine, manage material loading/unloading and monitor production instead of performing each winding operation manually.
Faster Production : Parallel operation allows manufacturers to achieve high output within a compact production footprint.
Recipe-Based Production : Different coil models can be stored as individual programs in the HMI, simplifying model changeover and reducing setup errors.
Reduced Manual Handling : Combining winding and taping into one automated process reduces movement of unfinished coils between different workstations.
Scalable Automation : Additional automation such as automatic bobbin loading, unloading, electrical testing, terminal processing or inspection can be integrated depending on production requirements.
Applications
The machine is primarily designed for manufacturing:
- Contactor coils
- Motor starter coils
- Electromagnetic coils
- Relay coils
- Solenoid coils with compatible bobbin geometry
- Other small magnetic coils requiring automated winding and insulation taping
It is particularly suitable for manufacturers requiring continuous, high-volume production with consistent coil quality.
Why Choose Multi- Spindle Machine?
For manufacturers producing large quantities of the same or similar contactor coils, the 12/16/20/24- spindle configuration provides an effective balance between production capacity, machine footprint and automation.
Instead of relying on multiple individual winding machines and separate manual taping stations, the integrated system brings the major operations into one controlled production platform.
The result is a more organized manufacturing process with:
12 coils per winding cycle → controlled winding → automatic cutting → automatic taping → finished coil
This process reduces unnecessary material handling and creates a more repeatable production workflow.
Customized Automation for Contactor Coil Production
Every contactor coil is not identical. Bobbin dimensions, wire diameter, turn count, winding pattern, tape specification and terminal requirements can vary from one product to another.
For this reason, the machine can be engineered according to the customer’s actual coil drawing and production requirements.
Before finalizing the machine configuration, important parameters such as:
- Bobbin drawing
- Copper wire specification
- Number of turns
- Winding height
- Coil dimensions
- Tape material and width
- Number of tape layers
- Required production capacity
- Loading/unloading method
are evaluated to determine the appropriate tooling and automation configuration.
Deptronics Technologies – Coil Winding Automation Partner
Deptronics Technologies provides automatic coil winding machines and production automation solutions for transformer, relay, solenoid, contactor and other electromagnetic coil applications.
- Strong expertise in coil winding, soldering, and production line automation.
- Proven installations in leading transformer and inductor factories in India
- Quick local response and after-sales service.
- Tailor-made solutions for every client’s product and production requirement.
With Deptronics Technologies, you don’t just buy a machine — you gain a complete automation partner dedicated to your success.
Contact Us
For machine inquiries, pricing, or customization options, contact Deptronics Technologies today!!
DEPTRONICS TECHNOLOGIES
📌 Contact Person: Deepanshu Saxena
📞 WhatsApp/ Mobile: +91-8800622761
🌐 Website: https://coilwinder.in/
📧 Email: [email protected]
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