CNC 200mm Coil Winding Machine – MK6

From £3,250.00

Select a Free Nozzle for guiding wire.
Select a free Collet set for the ER25 chucks.
Dual Bobbin Motors
We recommend a Dual bobbin motor for larger heavier bobbins that need the extra torque or for smaller cores less than 4mm to prevent any twisting when winding.
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Recommended Accessories
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Tensioners
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Additional Nozzles
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Additional Collets
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About

Just like previous models, the MK6 is ideal for anyone who needs to produce small quantity runs of coils or custom one-off coils.

A vast range of different coils can be wound for electronic projects.

Extra options are now included with the fully built machine that used to be offered as extras on the MK4, but most customers purchased these extra options anyway, so we thought that we may as well build them in now as standard items such as C5 precision ballscrew and ES/Limit kit.

A number of new features have been added to the MK6 , these include a new 3rd Axis that allows the wire guide on the feeder to be moved back and forth in software, safety cover hood, push buttons that interact with the software and upgraded onboard PSU.

Machine Build Features

  • High grade C5 ballscrew is used along with precision C5 bearings combined with anti-backlash couplers on each axis.
  • Low profile Hiwin style rails for smooth running with no unwanted side movement.
  • All of the aluminium plates come with a really attractive finish, as well as bead blast and oxidisation treatment.
  • Using solid, thick 10mm plates creates a stable frame that increased accuracy, none of your cheap thing plates to make the machine look fancy used in this design!
  • All machines are now fitted with Closed Loop motors on both feeder and bobbin assembly. This increases the torque, accuracy, speed and no loosing steps.  Speeds of above 2000 RPM are possible but as usual we always play safe and recommend 2000 RPM as the max speed !
  • CE certified and RHOS compliant. Declaration included in setup manual.
  • Built in safety features such as Emergency Stop, Limit switches and Safety hood.
  • Precision ER25 chucks with low runout compared to drill chucks.
  • Rotating Tailstock that can be locked on precision low profile sliding rail.
  • Easy flow wire guide using ceramic pulleys, felt pad adjuster and nozzle holder.
  • Low cost, accurate machine which allows full control of each Axis down to degree level, to suit your winding pattern using our Scripting Engine within the software.
  • Free windows software to control the machine via USB.
  • Automated options for traditional winding and also two different Scripting Engines that allow Incremental recipes to be created or Absolute recipes.
  • Comes with the new ARM Controller MKIII board and the latest firmware.
  • This is controller is a custom designed to work with our Coil Winding machines and is not available from any where else.

Extras

Dual Bobbin Motors

With most bobbins, you simply mount one end of the bobbin in the chuck that is rotated by the main Bobbin Motor and the other end in the revolving tail stock.

But If you have a delicate core to wind that may twist when being wound then the Dual Bobbin Motor is an option that will stop that and make it a lot more easy to do.

Both motors are synchronized via the controller and we will wire it in on new orders, along with a drag chain to keep it all nice and tidy.

A couple of videos showing Dual Bobbin motors in action.

Dual Motor 0.5mm Mandrel winding
  • Core Diameter: 0.5mm
  • Wire size: 0.0762mm (13 AWG approx)
  • Winding Pitch: 0.085mm
  • Winding speed: 1500 RPM
  • Total Windings: 1765
Dual Motor 2.04mm flat wire
  • Core Diameter: 2.04mm
  • Wire size: 0.1mm x 0.3mm Flat stainless steel
  • Winding Pitch: 0.5mm / 1mm
  • Winding speed: 500 RPM
Dual Motor 3mm flat wire
  • Core Diameter: 3mm
  • Wire size: 0.1mm x 0.3mm Flat stainless steel
  • Winding Pitch: 0.5mm / 1mm
  • 3mm Mandrel Winding speed: 1200 RPM

Nozzles

We supply ruby tipped nozzles in the following sizes. 0.3mm 0.6mm 0.8mm 1.2mm.

Spool Cone Kit

The machine comes with a 10mm top bar that allows small spools to be mounted and also used as a guide for vertically mounted spools.

With the Spool Cone Kit it allows bigger spools to be mounted. Inside the cones it has needle bearings for smoother running.

Wire Tensioner

The machine comes with a very simple felt wire tension system to keep the price down.

For smaller wires the spool of wire can be sat on it’s side and the wire will then be threaded over the top bar and into the back of the Feeder assembly. It will then go across a porcelain guide wheel, through a set of felt tensioners and through the ruby nozzle.

In the picture the tensioner is mounted on it’s own stand and stands back from the machine. On both setups the wire comes off the spools that are mounted vertically and thread up through the wire tensioner. The wire then enters the back of the feeder assembly and out through the ruby nozzle. On the second picture the ruby nozzle has yet to be fitted.

We are now stocking Magnetic Wire Tensioner Kits and they can be purchased on our Online Shop.

Video showing Winding with tensioner
  • Wire size: 0.05mm
  • Winding speed: 1500 RPM
  • Total Windings: 5000

Spare Felt Pads & Support arm

We are now offering a Spare Felt Pad kit that also includes a support arm for customers winding thin or flexible cores.

This includes:

4 x 25mm pads with metal backing
4 x 20mm pads with metal backing
1 x Support Arm for the 200mm nozzle holder.

Rubber Holding Cones

Set of Rubber cones for holding bobbin former cores or spools that need rewinding.

Cone diameter is 10mm at the tip and 25mm at widest point.
11mm-10mm Collets are needed for holding in the chucks.

Guitar Pickup Adapter Plate

We now have a Guitar Pickup bobbin plate for people to use with the 200mm Coil Winding machine.

This bobbin plate is exactly the same as the one supplied with the CNC Guitar Pickup Mini Coil Winder and has the same multiple M4 tapped holes to mount various guitar pickup bobbins.

The main difference is that the middle hole is 8mm diameter and we can supply it with a 8mm shaft and collet.

Software

All of our Coil Winding machines are controlled via the USB port of a PC running Windows, along with our custom software that is supplied FREE.
We have no plans in the future to charge for the software and all updates will remain FREE!

We have been asked why we do not offer a dedicated built in touch screen to run the machine and the simple answer is that we can add more features by developing for a dedicated computer and it is easier for our customers to update new releases as our software is always being updated and kept upto date.
We have customers that have mounted a low cost tablet to their machine that is running Windows OS or loaded the software on a Single Board Computer (SBC) along with a touch screen. Then simply connected a USB lead to our controller.

The software has been written to run on a PC with Windows operating system. It will happily run on low spec systems and will work on windows XP and up to Windows 10.
Minimum Screen Resolution for the software is 1024 x 768 or larger.

When starting the software you’ll select the coil winding profile for your machine. This will change certain parameters within the software to match the machines resolution. Below is a short list of the different settings.

  • Mini Coil Winder MK4/5 – Belt system pitch is 0.0125mm resolution steps with a minimum pitch of 0.0250mm recommended.
  • Mini Coil Winder MK6 ballscrew model resolution of 0.0025mm with a minimum pitch of 0.0050mm recommended.
  • 200mm Coil Winder – 0.0003125mm resolution steps with a recommended minimum pitch of 0.005mm recommended.
  • Quad Coil Winder – Belt system pitch is 0.0005mm resolution steps with a minimum pitch of 0.005mm recommended.
  • 600mm Coil Winder & Custom – The resolution will be set within the required specification. Contact us for more information.

Automated Coil Winding Tab

As you can see above it has a dedicated database and GUI for Bobbins/Pickups where you can load and save your own. You simply enter the width, number of windings and wire size.

The software will then calculate the nearest layer count based on the pitch you choose so you can see how close you are to the original.






For the Guitar Pickups section the software comes with a populate button that will load the built in database with a default set of common guitar pickup bobbins.

For Scatter Winding, please Click Here

Standard Scripting Tab

The Scripting Engine allows us to have more control over the coil winding process by allowing you to create a series of commands to control bobbin windings and feeder movement.

These commands can be built up and saved as a script for later use.

Creating the commands is very simple by using the GUI interface to choose the options you want for each new command and press the Add Command button

Absolute Scripting Tab

The Absolute Scripting Engine takes advantage of the Flash Memory that comes with the Coil Winder ARM Controller MKII/MKIII board and can be used for buffering loads of small commands.

This removes any small delays that can be caused by the USB communications latency.

Unlike the Standard Scripting Engine which is Incremental positioning for each command, this is absolute positioning on each command.

It can be used for doing variable pitches not only down to turn level but down to degree level.

3D Coil Winding Simulator

We have also added a 3D Coil Winding Simulator to the software.

Sorry to say this simulator will only run on Windows 10 but the rest of the software will work fine on Windows XP and upwards.

The simulator allows you to check your coil shape before winding.

Manual Winding

Here you can use the dial on the controller box and manually control the speed of the bobbin motor while guiding the wire by hand. This allows the machine to be used as a traditional winding machine.

But also you can now manually control the speed of both the bobbin motor and the feeder motor by using the Automated Coil Winding tab controls.

If using the Manual Controller from the Automated Coil Winding Tab then it is not recommended to run the machine full time with the manual speed controller. This is just to be used as a calibration tool, which will let you determine the best speed for winding the particular bobbin with wire you are using.

Once you have found a speed that suits the bobbin and wire combination then you should switch to automatic mode for full winding.

Below are some more screenshots of different areas of the software and the standard scripting engine. There is a video further down showing the capabilities of scripting with a variable pitch being wound.

You are welcome to download the software and install from our website in the download section

Downloads

Windows 10/IoT UWP Application

This UWP application is currently in BETA and as so is limited to only the automated winding for the time being.

But the beauty of this software is it can be deployed to a SBC Board running windows 10 Core such as the Raspberry pi, this completely removes the necessity of having a full computer rig to communicate with your coil winder.

All information regarding the UWP Application can be found here – UWP Software

Coil Winder ARM Controller MKIII

We have developed a new controller board that uses a fast Arm Cortex M4 processor and brings many enhanced features to the machine.

All machines dispatched from September 2022 onwards will be supplied with the new Arm Controller MKIII.

The new ARM Controller MKIII controller still has all the features of the original MKI/MKII controllers but with the following enhancement’s:

  • Manual controller dial now built in on PCB.
  • Support for 3rd Axis
  • 8 Inputs with 3 of them dedicated for Limit/Homing and Emergency Stop.
  • Higher speed pulse trains.
  • Opto Isolated inputs can be switched to use 5/12 Volts.
  • On board Flash memory that can be used to buffer upto 130000 commands. This allows for very small movements to be sent to the  controller with no delay between them from the software’s new Absolute Scripting Engine and build up some fancy windings.
  • Fram memory also on board for Flash memory optimization algorithm.
  • Firmware now upgraded by flicking a switch and existing USB port. No more JTAG programmer needed. 
  • JST sockets for each dedicated wiring loom to plug into that makes for better contact and keeps things tidier.

Examples

Wave winding coils from Jerry.

He made up a special attachment that went in place of the nozzle. The attachment fed the wire in nice and close to the bobbin and applied a slight pressure down on the bobbin as it was wound. No bonding wire or glue was used and it self supported as it was wound.

Absolute scripting example

Here is a video showing lots of small movements building up a sensor coil with variable pitch be executed at per wind and degree level.

Variable pitch

Because the new machine uses dual motors and a combination of our custom software/firmware, we can do perfect interpolation between each axis, which lays down the wire very precisely.

As you have full control of the Bobbin motor and Feeder motor down to degree level, you can perform some fancy winding’s and also do variable pitch as shown in the video below.

Some of the videos are a few years old now and showing the older machine model. But the speed and accuracy remains the same and if anything the newer models have increased accuracy.

Also the older machine had open loop motors, but the new models for the last couple of years now have the quieter closed loop motor.

One of customers sent us a video of the 200mm CNC Coil Winding Machine at work with speeds of 2500 RPM

Here are a couple more videos of Jerry again, he is showing some modifications he has made for Bifilar winding using a custom nozzle holder.

CNC Coil Winder Dual Winding Modification
CNC 200mm Coil Winder Winding of multiple self supporting coils with the universal winding pattern.
Software/Firmware

Free Firmware upgrades and Free Windows Software.
Dimensions of base plate (L x W)

700mm x 300mm
Weight

Approx. 20Kg
Maximum Stepper motor RPM

2000 RPM (1500 RPM recommended MAX)
Power Supply

24V 16amp power supply
Maximum bobbin diameter (Height)

110mm
Wire range

0.01mm – 0.5mm (bigger wire sizes supported for single layer)
Feeder max resolution

0.0003125mm
Max feeder travel

approx. 200mm
Warranty

12 Month return to base warranty.

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