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Automatic Transformer Coil Winding Machine | PLC & Servo Control, Auto Wire Feeding, for Rectangular & Round CoilsPrecision Automation for Transformer & Reactor Coil WindingEngineered for transformer manufacturers demanding repeatable coil quality and minimal labor input, this Automatic Coil Winding Machine integrates PLC servo control, auto wire feeding, and tension-adjustable wire distribution into a single high-rigidity platform. Purpose-built for rectangular coils used in amorphous and open-core transformers — where axial and radial tightness directly determine electromagnetic performance and thermal stability. The system combines a high-efficiency gear mechanical speed regulation drivetrain with variable frequency stepless control, delivering smooth acceleration, precise speed holding, and responsive braking (F-class insulated motor). Wire feeding is driven by imported ball screw and linear guide for ±0.1mm placement accuracy, synchronized seamlessly with the winding spindle via dedicated circuit. Tension is adjustable for both round and flat wire; pneumatic clamping adapts to varied workpiece profiles. With a high-resolution touchscreen HMI and top-mounted control box, operators can set wire pitch, speed ramps, and layer count per recipe — reducing setup time and eliminating manual counting errors. Whether producing distribution transformer windings, reactor coils, or amorphous core assemblies, this machine ensures consistent layer density, zero wire overlap, and damage-free insulation placement. Built for 24/7 operation with full OEM/ODM support. 
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Product Description
1. Product OverviewThis automatic winding machine is purpose-designed for the production of small to medium-sized electromagnetic coils, with specialized capability for rectangular coil geometry used in amorphous alloy transformers, open-core transformers, distribution transformers, and reactor windings. The machine integrates a winding host, automatic wire feeding system, layer insulation supply device, round/flat wire distributor with adjustable tension, pneumatic clamping, PLC control, servo drive, and touchscreen HMI into a single unified platform. Unlike general-purpose winders, this machine prioritizes axial and radial coil tightness — the critical factor in transformer efficiency, short-circuit withstand, and thermal performance. Rectangular coils, which are prone to corner-loosening and layer slippage on conventional equipment, are wound with consistent inter-layer pressure via synchronized servo wire placement and tension control. 2. Key Specifications
3. Core Design Advantages① Rectangular Coil Specialization — Axial & Radial Tightness Rectangular coils require precise corner tension management to prevent layer loosening — a known weakness of generic winding machines. This machine's servo wire distributor adjusts feed rate dynamically through corners, maintaining consistent tension and placement pitch. Result: uniform inter-layer pressure, zero gap formation, and coils that hold shape during vacuum casting and handling. ② PLC + Servo Control with Touchscreen HMI PLC controller stores winding recipes by coil type. Operators set turns, pitch, speed ramps, and layer count on the high-resolution touchscreen. Recipe recall ensures identical coil geometry across batches and shifts. Manual fine-tuning is available during winding for real-time correction. Reduces operator skill dependency and setup scrap. ③ Imported Ball Screw & Linear Guide — ±0.1mm Accuracy Wire feeding carriage travels on precision-ground ball screw and linear guide rails (imported components). This eliminates backlash and ensures wire is placed exactly on pitch, layer after layer. Critical for flat wire windings where even 0.2mm deviation causes overlap or gap defects. ④ Dual Wire Compatibility — Round & Flat The tension-adjustable wire distributor handles both round magnet wire and flat rectangular strip. Tension is calibrated per wire dimension and material (copper/aluminum). Pneumatic clamping secures the wire end during start and cut, preventing slippage. One machine covers multiple product lines without hardware changeover. ⑤ Mechanical Gear + VFD Stepless Speed Control High-efficiency, low-noise gear transmission paired with variable frequency drive delivers stepless speed adjustment across a wide range. Start and stop slopes are preset to prevent wire shock and layer displacement during acceleration/deceleration. F-class motor insulation supports continuous operation in industrial environments. Responsive braking stops the spindle instantly on cycle completion or fault. ⑥ Automatic Layer Insulation Supply Integrated insulation feed device places layer paper/tape automatically between winding layers. Synchronized with spindle rotation and wire feed, eliminating manual insertion and ensuring consistent insulation coverage — essential for distribution transformer dielectric performance. ⑦ Seamless Process Synchronization A dedicated control circuit links wire feeding speed, spindle RPM, and insulation feed rate in real time. The three subsystems adjust proportionally throughout the winding cycle, preventing wire pile-up, stretching, or insulation misalignment. This is the core technology enabling single-operator multi-machine supervision. ⑧ Ergonomic & Maintenance-Friendly Design Top-mounted desktop control box places HMI within easy sightline. Direct-coupling bobbin mount enables quick coil removal and reload. Removable side panels provide service access. Pneumatic system uses standard global fittings for easy maintenance. 4. Typical Applications
5. Quality Assurance & Service
6. Ordering Information
→ Contact our engineering team for a quotation, technical datasheet, coil sample photos, or factory video.
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