Automatic Solenoid Coil Winding Machine Manufacturer in India

Why Automation for Solenoid Coil Manufacturing?

Before technical detail, understand the benefits clearly:

1. Consistency & Quality: Automation ensures identical winding geometry, uniform turns, and exact tap placements — critical for coil electrical performance (inductance, resistance).

2. Higher Throughput: Multi-spindle automatic machines increase production many times over compared to manual winding. 12–24 spindles run concurrently; cycle times drop dramatically.

3. Reduced Labor Cost and Human Error: One operator can supervise multiple machines/lines; rejects decrease.

4. Process Integration: Automatic transfer to soldering, pin bending, testing and packaging reduces handling damage and increases takt time.

5. Traceability & Test Data: Integrated testing (LCR, DC resistance) and CCD inspection provide quality logs and reduce field failures.

6. Scalability: Modular lines allow capacity growth (add spindles or additional soldering stations).

Given these advantages, choosing a Fully Automatic Solenoid Coil Winding Machine Manufacturer in India is a strategic investment for any serious OEM.

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High-Level Production Flow (End-to-End)

A modern fully automatic solenoid coil production line typically follows this sequence:

1. Auto bobbin feeding.
2. Terminal pin insertion (auto).
3. Loading onto mandrel → multi-spindle programmable winding (12 / 16 / 20 / 24).
4. Auto unload from winding turret → load into conveyor / transfer to soldering station.
5. Rotary dip soldering with auto flux dosing.
6. Pin bending / crimping / pressing.
7. Electrical testing (LCR / DC resistance / hipot where applicable).
8. CCD visual inspection for solder joint & winding faults.
9. Final unload into protective tray and packaging.

Below we deep-dive into each stage with technical detail — tooling, sensors, control logic, cycle timers, and engineering choices.

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Working Video of Solenoid Coil Production Line

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Detailed Machine Working / Process Flow (Main Section)

1. Auto Bobbin Feeding — First Mile of the Line
Purpose: Smooth, accurate, timed supply of empty bobbins into the production line with correct orientation.
Feeding methods:

• Vibratory bowl feeder with orienting tracks: ideal for high speed and varied bobbin profiles. Vibratory motion and specially designed tracks orient bobbins to the required position and hand them to an indexing conveyor.

• Rotary feeder / carousel: compact solution for small footprints; bobbins loaded into pockets and rotated to pick points.

• Pick-and-place robot from trays: flexible for varied bobbin geometries and changeovers.

Key components:

• Feed hopper with level sensor (ultrasonic / IR) and low-level alarm.
• Orienting track with mechanical guides to hold bobbin orientation.
• Pneumatic or servo-driven pick head or pusher to transfer bobbin to the loading station.
• Presence sensors (photoelectric, inductive) to confirm correct bobbin.
• Reject mechanism for malformed or upside-down bobbins.

Control & logic:

• Set feed rate to maintain continuous line flow.
• Interlocks ensure the winding turret or mandrel is ready before feed.
• Auto retry logic: if orientation not corrected within two attempts, push to reject bin to avoid downstream stoppage.

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2. Terminal Pin Insertion — Precision Mechanical Insertion

Purpose: Insert terminal pins into the bobbin terminals prior to winding. Correct insertion ensures soldering and final electrical contact reliability.

Approaches:

• Pneumatic insertion head: High speed with controlled stroke and force. Good for standard pins and long production runs.

• Servo or linear motor insertion: Greater control over insertion depth, force profiling, and variable pin types.

• Robotic insertion (SCARA/6-axis): Best for complex orientations or multiple pin positions.

Fixtures & tooling:

• Pin feed from a vibratory bowl or collated tape feeder.
• Insertion mandrel for supporting bobbin and ensuring alignment.
• Force sensor or load cell on the insertion tool to detect incorrect insertion, missing pins, or excessive resistance (which could indicate a broken pin or misalignment).

Sensors & checks:

• Optical sensor or mechanical detector to verify pin presence after insertion.
• Limit switches to monitor full stroke.
• Immediate reject path if insertion force exceeds pre-set limit.

Control routines:

• PLC coordinates pin feed and insertion timing with bobbin presence signal.
• Retry attempts: if insertion fails due to minor misalignment, the controller can attempt re-alignment and re-insert up to a defined number of times before rejecting.
• Option to mark feed time and insertion success in the traceability log.

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3. Multi-Spindle Winding — 12 / 16 / 20 / 24 Spindle Configurations

Purpose: Simultaneous, repeatable winding across multiple spindles to multiply throughput.

Key architecture:

• Spindle bank: Array of spindles (12/16/20/24) arranged on a single turret or linear head. Each spindle has independent tension and control.

• Programmable winding head: Every spindle can execute defined patterns — single layer, bifilar, multilayer, taps at defined turns, and more.

• Mandrel / bobbin clamping: Pneumatic or servo clamps hold bobbin on mandrel during winding if required.

Winding patterns supported:

• Single winding (standard solenoid coil).
• Bifilar / multi-wire configurations.
• Layered winding with tape insertion in between layers.
• Lapped winding for uniform density.

Cycle time & throughput:

• Throughput depends on turns per coil, wire gauge, and spindle speed. For example, a 12-spindle machine winding 150 turns per coil at 12000 RPM effective lay speed can produce hundreds of coils per hour per spindle bank. Multi-spindle multiplies that throughput.

Monitoring & alarms:

• Wire break detection using IR/photoelectric or micro-switch tension loss detection.
• Over-current / drive alarms for servo faults.
• Wire guide position sensors to detect misfeeds.

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4. Auto Unload and Transfer to Soldering Station

Purpose: Smooth, synchronized transfer of wound bobbins from winding station to soldering module with minimal handling.

Transfer mechanisms:

• Robotic pick & place (6-axis or SCARA): Gentle picking, orientation correction, and transfer to conveyor or directly to solder pot fixtures.

• Linear conveyors with indexing plates: The winding turret unloads directly onto an indexing conveyor which moves coil pockets into the soldering station.

• Rotary transfer indexes: Circular plate with pockets that rotate to successive stations (winding → transfer → soldering).

Clamping & seating:

• Special grippers or vacuum noses ensure secure pick up without damaging wound coils. Soft jaws or rubber pads prevent wire abrasion.

Synchronization & buffer:

• Buffers (accumulation conveyors) help decouple winding cycle time from soldering cycle time, preventing line stoppages. PLC logic manages buffer levels and flow control.

Quality checks before transfer:

• Quick continuity check or loop test to ensure no open circuits before soldering.
• Presence & orientation sensors ensure correct seating for soldering.

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5. Rotary Type Dip Soldering with Auto Flux (Rotary Dip Soldering Station)

Purpose: Make robust solder joints for terminal pins to the winding tails. Rotary dip provides higher throughput and uniform soldering.

Rotary dip soldering layout:

• A rotary index table with fixtures (pockets) holds the coils and rotates them sequentially through stations:

  1. Flux dosing / spray: Precisely dispense flux to terminal/pin area.

  2. Preheat (optional): IR or convection preheating to drive off solvents and stabilize temperature.

  3. Solder dip: Dip the terminal area into molten solder pot.

  4. Cooling / wipe: Air knives or wipe station to remove excess solder and shape joints.

  5. Inspection (CCD or vision) immediate post-soldering.

Solder pot:

• Temperature control with PID controllers and thermal shielding to maintain stable solder bath temperature (e.g., 350–4000°C for Sn63/Pb37 or higher for lead-free solder).

• Flux residue control and skimming arrangement.

Solder joint quality controls:

• Wave height and dip dwell time programmable to avoid solder bridging.
• Air knives / wipers to create proper fillet and remove excess solder.
• Solderability sensors detect insufficient fillet or incomplete wetting.

Safety features:

• Fume extraction with local exhaust to control flux fumes.
• Interlocks to prevent operator access while solder pot is active.
• Thermal shields and emergency stop logic.

Throughput note: Rotary indexing allows continuous soldering of multiple coils per minute depending on index speed and dwell times. Pairing the rotary station with buffer conveyors optimizes overall takt time.

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6. Auto Pin Bending or Pressing

Purpose: After soldering, terminal pins often require bending or forming to final geometry (e.g., J-bend, crimp, right angle) for PCB mounting or connector assembly.

Mechanisms:

• Servo-driven forming station: High precision, programmable forming profiles, adjustable for different pin diameters and bending radii.

• Pneumatic press with forming die: Cost-effective for high volume, fixed geometry bending.

• Robotic forming tools: For complex bend sequences or multiple pins.

Quality checks:

• Vision or mechanical gauge to verify bend angle & clearance.
• Resistance / continuity check post-bend to ensure no damage to internal windings.

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7. Testing — Electrical & Functional Validation

Purpose: Ensure each coil meets electrical parameters — DC resistance, inductance, Q factor (if required), insulation resistance, and continuity. Testing eliminates defects early and provides traceability.

Types of tests:

• DC Resistance (DCR): Low resistance measurement using four-wire (Kelvin) method for precision.

• Inductance (L) & Q factor: Using LCR meters or bridge testers for frequency-dependent validation.

• Insulation resistance / Hipot (where necessary): High voltage test for dielectric integrity (typically for safety-critical coils).

• Continuity test: Quick pass/fail for open circuits.

• Functional test: For complete solenoid assemblies, actuation and stroke tests may be included on the line.

Automatic sorting:

• Failures are routed to reject bins for rework or scrap.

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8. CCD Check (Computer Vision / Optical Inspection)

Purpose: Visual verification of winding quality, solder fillet, pin position, and presence of foreign materials. CCD cameras detect surface defects faster than manual inspection.

Common CCD checks:

• Solder joint fillet presence & wetting – check for insufficient solder, bridging or cold solder joints.

• Pin position & bend accuracy – ensure pins are within tolerance on x/y axis.

• Winding neatness – detect loose turns, wire crossing or smashed insulation.

• Label & marking verification – check product codes, orientation marks.

System architecture:

• High-resolution CCD cameras with telecentric lenses for distortion-free measurement.
• Illumination systems: ring lights, backlights, and diffusers to get consistent images.
• Image processing algorithms and pattern matching to identify defects; configurable thresholds per product family.

Integration into workflow:

• CCD systems mounted post-soldering and post-bending stations for in-line inspection.
• Reject logic: immediate diversion to rework station if defect identified.
• Data logging of images for audit and troubleshooting.

Benefits: Lower false rejects compared to human inspection, consistent 24×7 performance, immediate feedback to process owners.

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9. Unload into Tray for Product Safety & Packaging

Purpose: Final handling to ensure product protection and ease of downstream packaging and shipping.

Tray types & methods:

• ESD safe trays with pockets sized to coil geometry, preventing movement and scratching.

• Blister trays for additional mechanical protection.

• Tape & reel options for electronic assembly customers (if required).

Unloading solutions:

• Pick & place robot to accurately place coils into trays with correct orientation.

• Gravity chute into fixed trays for simple operations (less precise, but cost effective).

• Indexing conveyor with tray pockets that accept finished coils as they arrive.

Safety & QA:

• Part presence sensor in each tray pocket to ensure completeness.
• Tray level sensor to avoid overflow.
• Packing labels and batch codes printed or applied automatically for traceability through laser printer.

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Optional Add-Ons & Assembly Line Extensions

A real strength of a fully automatic solenoid coil manufacturing machine line is the ability to offer integrated assembly solutions beyond coil winding. Deptronics and similar manufacturers provide modular add-ons:

1. Riveting & Mechanical Part Assembly

• Auto rivet feeding and rivet insertion stations for mechanical fastening (for solenoid plunger caps or assembly housings).
• Press stations with force sensing to avoid deformation.
• Spiral screwdrivers and nut-feeding modules for small mechanical assemblies.

2. Complete Subassembly Cells

• Combine coil winding, soldering, pin forming, rivet assembly and final mechanical housing insertion in a single autopilot line.

3. Conveyorized End-of-Line Packaging

• Automated cartoning and labelling for direct dispatch to OEM assembly lines.

These add-ons make the line a one-stop solution for customers looking to move from manual or semi-automatic processes to fully automated production, reducing touch points and increasing reliability.

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Productivity, Example Calculations

Manufacturers ask: “How fast will this pay back?” Below is a worked example to estimate throughput and simple ROI. Numbers are illustrative — actual values depend on product specifics and local costs.

Assumptions (example product):

• Machine configuration: 12-spindle winding machine with rotary dip soldering.
• Coil spec: 500 turns, wire gauge AWG 35.
• Winding cycle per 12 coil : 30 seconds.
• Additional processing (soldering + bending + testing): 03-04 seconds per coil (line balanced).
• Effective takt time per 12 coils (line): 35 seconds
• Operating hours per day: 16 hours (two shifts).
• Operating days per year: 300.

Throughput calculation:

• Coils per hour  = 1100-1200 coils per hour.
• Daily output = 1100 × 15 = 16,500 coils per day.
• Annual output = 16,000 × 300 = 4,800,000 coils per year.

Note: This is a simplified example. Real payback calculations must factor in:

• Raw material costs (copper wire, bobbins, terminals, solder).
• Labour savings vs previous manual process.
• Energy costs.
• Maintenance and consumables.
• Floor space and utilities.

Even with conservative assumptions, well-organized automated lines typically pay back within 6–24 months depending on production volumes and product complexity.

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Case Studies / Use-Cases (Representative)

Case A — Automotive Solenoid Supplier (High Volume):
Configured a 24-spindle winding machine with dual rotary dip soldering stations and inline CCD inspection. Achieved a 4× throughput increase and reduced rejects by 70% within three months post-commissioning.

Case B — Appliance Manufacturer (Medium Volume, Multiple SKUs):
Used a 12-spindle modular line with quick-change fixtures. Reduced manual labour by 65% and achieved consistent DCR within ±1% tolerance across 10 SKUs.

Case C — Contract Manufacturer (Small Batch Custom Orders):
Installed a 16-spindle machine with robotic pick & place for flexible batch sizes; recipe management enabled quick changeover between customer families.

These real-world use cases demonstrate typical benefits from a Fully Automatic Solenoid Coil Winding Machine Manufacturer in India.

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Frequently Asked Questions (FAQ)

Q1: Which spindle configuration should I buy — 12, 16, 20 or 24?
A: Choose based on volume and floor space. 12/16 suits medium volumes and offers lower capex. 20/24 are for high volume. Also consider wire gauge and cycle time — more spindles help when winding time dominates.

Q2: Can the machine handle different bobbin sizes?
A: Yes — with quick-change mandrels and adjustable fixtures. Deptronics provides changeover kits and recipes for multiple sizes.

Q3: How is wire break detected and handled?
A: Through tension sensors, optical detectors and wire guides. On detection, the machine pause and sounds alarm.

Q4: Is lead-free solder supported?
A: Yes. Temperature profiles, solder pots and flux selection are configured for lead-free alloys.

Q5: What is the typical lead time for a full production line?
A: Varies with customization — typically 50 to 70 working days for standard line configurations; longer for highly custom automation.

Q6: Do you provide trials or sample runs before purchase?
A: Reputable manufacturers usually offer prototype runs, sample processing and FAT (Factory Acceptance Test) before shipment.

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Why Choose Deptronics Technologies — Your Indian Manufacturer & Partner

As a Fully Automatic Solenoid Coil Winding Machine, Deptronics offers:

• Tailor-made solutions: Machines designed for the exact bobbin geometry and functional requirements.

• Strong service footprint in India: Commissioning, spare parts, and trained technicians available across all over India major industrial regions.

• End-to-end assembly & testing integration: From bobbin feeding to tray unloading — a single integrator saves time and aligns responsibility.

• Transparent ROI modeling: Deptronics helps customers estimate throughput, cost per piece, and payback before purchase.

• Training & documentation: Comprehensive O&M manuals, operator training and safety documentation.

• Continuous improvement: Deptronics offers line optimization after initial deployment (tuning recipes, reducing rejects).

Deptronics understands Indian manufacturing realities — variable supply chains, space constraints, and skill levels — and engineering solutions accordingly for Relay Coils also.

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How to Procure & Implement — Roadmap

1. Requirement capture: Provide coil specifications, sample bobbins, wire gauge, expected monthly volumes and quality specs.

2. Proposal & layout: Deptronics provides line layout, machine spec sheet, cycle time estimates and ROI.

3. Factory Acceptance Test (FAT): Sample coils are run and customer approvals obtained.

4. Shipment & Installation: Line shipped, installed onsite by Deptronics engineers.

5. Commissioning & training: Operators trained, recipes finalised and first production batches validated.

6. Performance tuning & support: Data driven improvements and AMC.

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If your business is ready to take the next step toward solenoid coil production excellence, contact DepTronics Technologies today and transform your manufacturing line into a world-class automated setup.

DEPTRONICS TECHNOLOGIES
Contact : Deepanshu Saxena
Mobile : +91-8800622761
WhatsApp : https://wa.me/918800622761
Email : [email protected]