Working Principle of the Solenoid Coil Winding Machine
The entire operation runs in a continuous, automated loop. Here is the step-by-step working principle:
- Bobbin Loading: Empty bobbins are placed onto the feeding tray. Depending on the setup (semi-auto or fully auto), the machine’s fixture mechanism positions the bobbins onto the spindles perfectly aligned for winding.
- Initial Anchoring: The wire guide nozzles descend and automatically wrap the start of the copper wire around the bobbin’s initial terminal pin.
- Simultaneous Layering: The servo-driven spindles rotate at high speeds while the traverse system moves horizontally. This distributes the copper wire evenly, layer by layer, exactly according to the programmed recipe.
- Auto Stop & Cut: Once the precise turn count is reached, the spindles halt with ±0.1-degree accuracy. The nozzles wrap the final terminal pin, and the pneumatic cutter severs the wire.
- Auto Unloading & Reset: The finished solenoid coils are automatically ejected into a collection tray, and the spindles instantly reset for the next batch, minimizing idle time.
Working Video of Solenoid Coil Winding Machine
Key Functions of the Solenoid Coil Winding Machine
This automated system covers the entire winding process from empty bobbin to finished coil, requiring minimal human intervention. Its core functions include:
- High-Speed Multi-Spindle Winding
Depending on your production volume, the machine can be configured with 12, 16, 20, or 24 spindles. All spindles operate in parallel at speeds up to 12,000 RPM, allowing you to manufacture hundreds of coils in the time it takes a manual worker to finish one. - Advanced Tension Control System
Solenoid coils require flawless wire tension to maintain correct magnetic fields and electrical resistance. The machine uses advanced magnetic tensioners (with optional closed-loop servo tensioners) to constantly monitor and adjust the pull on the copper wire, preventing wire snapping or loose layers. - Automatic Pin Wrapping and Cutting
The system automatically guides the wire to the bobbin’s terminal pins, wraps it securely at the start, completes the required layers, wraps the final pin, and uses pneumatic scissors to cut the wire cleanly. - Broad Wire Compatibility
The machine is highly versatile, capable of handling fine copper wires (from 0.05 mm) up to thicker industrial gauges (up to 0.5 mm). - Smart PLC Touchscreen Interface
Operators do not need complex programming knowledge. The HMI touchscreen allows users to easily input bobbin dimensions, turn counts, winding direction (CW/CCW), and traverse pitch. Programs can be saved and instantly recalled for repeat orders.
Technical Specifications
To give you a clear view of its capabilities, here are the professional technical specifications for the multi-spindle solenoid winder:
| Specification | Details |
| Number of Spindles | 8 / 12 / 16 / 20 (Customizable) |
| Spindle Drive Motor | High-Torque AC Servo Motor |
| Wire Diameter Range | 0.05 mm – 0.6 mm |
| Maximum Bobbin Size | Up to 30 mm swing diameter |
| Spindle Pitch | 50 mm – 72 mm |
| Maximum Speed | Up to 10,000 RPM (varies by coil design) |
| Winding Direction | Clockwise (CW) / Counter-Clockwise (CCW) |
| Tension Control | Magnetic Tensioners (Servo optional) |
| Power Supply | AC 220V, Single Phase, 50Hz |
| Air Pressure Requirement | 4 – 6 kg/cm² |
| Optional Attachments | Auto taping, wire twisting unit, enamel remover, robotic auto-loading |
Cycle Time & Production Capacity
When manufacturing solenoid coils for automotive valves or appliance relays, speed is just as important as accuracy. A standard 12-spindle machine boasts incredibly short cycle times. Depending on the wire thickness and turn count, a full cycle typically completes in 25 to 40 seconds.
This translates to a massive production capacity of 1,200 to 1,500 coils per hour. For a factory running a standard 8-hour shift, a single machine can comfortably yield up to 12,000 flawless coils daily, vastly outperforming traditional methods.
Return on Investment (ROI) Analysis
Upgrading to an automatic multi-spindle machine transforms your factory’s profitability. Let’s look at the financial impact of replacing manual winding with a 12-Spindle Automatic Machine:
- Labor Savings: A standard manual line requires 10 to 12 operators to produce 1,200 coils an hour. The automatic machine requires only 1 operator, saving upwards of ₹1,50,000+ per month in wages alone.
- Zero Rejection Waste: Manual winding often yields a 5-10% rejection rate due to human error. The automatic machine brings defect rates to under 1%, saving thousands in wasted copper and bobbins.
- Payback Period: Thanks to the immense savings on labor and scrap—combined with a massive boost in hourly output—the typical ROI payback period for this machine is just 10 to 12 months.
After the first year, the drastic reduction in production costs goes directly to your bottom line.
Why Choose DepTronics Technologies for Coil Winding Automation?
Investing in an industrial automated production line requires more than just buying a machine—it requires a reliable engineering partner. DepTronics Technologies is recognized as one of India’s most trusted suppliers for automated coil winding and relay production line machines.
Here is why top manufacturers across India trust us:
- Pan-India Support: We provide complete installation, operator training, and on-site troubleshooting across all major industrial hubs in India.
- Local Spare Parts Availability: We maintain a local inventory of essential spare parts, ensuring your production line never faces long downtimes.
- Tailored Customization: Every machine is programmed and configured strictly according to your specific bobbin design, wire gauge, and production volume.
- Expert Engineering Team: Our service engineers hold deep expertise in automating relay and solenoid manufacturing setups.
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]
For mass production of relay coils, check our “Automatic Production Line for Mass Manufacturing of Relay Coils”
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