Choosing the right coil winder for your project is a serious business. There are a lot of variables that need to be taken into consideration.
RothGreaves standard and custom coil winders offer a wide range of features, including spool tensioners, analog pitch compensators, and EasyWind software. All models also feature a manual controller dial.
Wire Size
The right wire size is one of the most important aspects of a coil winding project. A too-small wire will not provide enough power and could even be dangerous. A too-large wire will take up too much space and can prevent proper heat dissipation. A combination of factors usually determines the correct wire size.
Choosing the correct wire size is not always easy, especially for beginners. It involves a fair amount of math. There are two main systems used to determine the wire size. The American Wire Gauge (AWG) and Standard Wire Gauge (SWG) systems. The American system is typically how jewelry wire is sized in the United States and Canada, while the SWG system is often how wires are sized in Great Britain.
There are also different types of wires to choose from. The most common are aluminum and copper. Both are good conductors, but copper has a higher resistance to corrosion. There is also bare copper and tinned copper. Bare copper corrodes quickly, while tinned copper resists corrosion and is more durable.
In addition to deciding on the right wire size, you must consider the bobbin or winding form that will be used for your coil. The bobbin should be well-designed to hold the desired number of turns without interfering with the layering process. The bobbin must also be designed to prevent the wire from breaking or becoming tangled during winding.
A high-quality programmable winder should be able to handle various wire sizes. It should also be able to produce consistent tension throughout the entire winding process. Variable tension can cause the wire to stretch and break, which will result in production and quality control issues.
Depending on your needs, you can choose from a range of peripheral attachments for your programmable coil winding machine. These can include a tailstock, custom tooling, programmable tensioner, closed-loop tensioner, heat bonding, wire stripper, and de-reeler.
A programmable coil winder can also be equipped with an LCD display to make it easier to read the program settings. It can also be configured to show the piece count, winding speed, and current status. A programmable coil winder can also support a variety of languages and be controlled via an external computer.
Winding Speed
As with the wire size, the winding speed is another important factor to consider when selecting a single spindle coil winder. If the speed is too fast, the coil will have an uneven structure, while a slower speed will result in a more uniform coil. A good rule of thumb is to find the middle ground between these two speeds, as this will yield the best results. Ideally, you will test out the different speeds on a bobbin with wire before you start production on the machine.
All of the SCHLEICH single-spindle coil winders have the option to manually control the speed of both the bobbin and feeder motors, giving you maximum flexibility for your project. The manual controller is located in the Automated Coil Winding tab controls and allows you to adjust each of these parameters separately to find the ideal combination for your specific bobbin with wire.
If you want to get a little more advanced, all of our coil winders are capable of being fitted with a variety of standard PC-based CNC winder controls. These include both the Incremental Script engine and the Absolute Script Engine. The latter is able to store many more complex windings and can also be used for changing the pitch, traverse length, and Tension at a turn and degree level.
In addition to the different winding speeds, we offer a number of other options and peripheral attachments to our single-spindle coil winders that can make your project more efficient. For example, a nozzle-type coil spreading head can help you spread the wire evenly around the bobbin and prevent nicks or burrs while you’re working. We also have a range of tape attachments and cutters to help you secure your finished coil.
We even have a stacked bed winder that is designed to take up less space than a traditional single-spindle model. It is perfect for projects that need to wind a large number of coils quickly and can save you space on your manufacturing floor.
Coil Shape
Depending on the purpose of your coils, you may require different winding structures. For example, if you are creating electromagnets, the wires that make up the coil must be structured so that their cross-sectional areas are as small as possible. This ensures that the current that flows through the coils is as tight and efficient as possible. If the conductive material of your coils can be made smaller, it will also need less insulation.
The insulating materials used in electrical coils are a combination of several layers. The first layer is a metallic core that helps conduct the electricity that flows through the coils. This core is then wrapped in a layer of thin, insulated material. The type of material that is used depends on the type of coil, the current it will carry, and its temperature requirements. Coils are generally constructed with copper because they have the best electrical and physical properties.
A single spindle coil winder can support a wide variety of wire sizes, shapes, and gauges. It can also handle multiple spools of wire simultaneously. This makes it ideal for industrial applications that need to produce large quantities of high-quality coils.
Besides having a wide selection of options for your coils, you can also choose a single-spindle machine that offers various peripheral attachments to complete the entire process. This can include a tailstock, custom tooling, and a programmable tensioner. Choosing the right single-spindle coil winder can help you create the perfect coil for your project and increase the speed of production.
A programmable coil winder can also have a number of features to prevent errors during the coil production process. These features can include an online programming system, a cursor card foot function, and a display showing the winding progress.
A programmable coil winder can also feature a nozzle that attaches the wire to a flyer, a rotating device that fixes the coil in place. The nozzle also has a slit that allows the windings to be separated from each other quickly. This can be an advantage when you are using a wire with a low diameter since it will allow the coils to have more slots and a higher fill factor.
Automation
Whether your project involves the production of power transformers or various types of electrical appliances, it is imperative that you have high-quality coils. Coils play a key role in all electrical and electromagnetic applications, and a coil winder can help you produce tight and evenly wound coils for your products.
The coil winding process requires great precision and accuracy to ensure that your products meet the required specifications. A coil winding machine that is not properly calibrated or adjusted can result in uneven and inconsistent coils. Consequently, your product may not work correctly and could potentially be dangerous to use. A good coil winding machine should be able to accommodate different wire dimensions and shapes for your needs, including round, square, rectangular, and trapezoidal.
In addition to the coil dimensions and shape, you also need to consider the coil’s size and winding speed. A larger coil will require a bigger traverse unit, and the time it takes to complete one turn will be longer. This is why it’s important that you know what your requirements are prior to purchasing a coil winder.
You can find a wide range of single-coil winders that are available to purchase. Some machines are standalone units that can be used for flexible production, while others are designed to integrate into an automated production line. There are even models that can produce a variety of types of coils, such as SMPS coils and lighting equipment.
A single-spindle coil winder should be easy to operate and have a user-friendly interface. It should also be able to accommodate multiple taps and allow you to program different winding sequences. This way, you can make the most of your single-spindle coil winder and maximize its potential for success in your manufacturing business.
Another feature that is important in a single-spindle coil winder is the ability to perform a “start point” setting. This allows you to set the exact position where the wire will be spread out for each new layer of winding. This is particularly helpful if you’re producing multiple identical coils.
