CNC Custom 600mm Coil Winding Machine
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About
The 600mm CNC Coil Winding Machine is a popular custom machine build that we can make for customers that need that extra winding area for longer cores.
Being a custom build means that it is not a stocked item and there will be a lead time that can vary depending on how many machine builds we have on the go.
Please feel free to email us on info@ukcnc.net for prices and more details.
Within this page we layout the different options that are available.
We have used our 3D renders as they show the options in more details than photos.
Standard 600mm Coil Winder
The picture above show the Standard 600mm Custom CNC Coil Winding Machine
The Standard 600mm CNC Coil Winding Machine features:
- Aluminium Profile frame with electronics enclosed.
- All of the aluminium plates come with a really attractive finish, as well as bead blast and oxidisation treatment.
- 600mm travel between chucks
- Wire range 0.01mm – 0.5mm (bigger wire sizes supported for single layer)
- 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.
- Resolution of 0.36 degrees (0.001 turn)
- 16mm diameter C7 grade Ballscrew.
- Feeder mounted on precision low profile rails with a resolution of 0.0003125mm.
- Adjustable easy flow wire guide using ceramic pulleys, felt pad adjuster and nozzle holder.
- Rotating Tailstock that can be locked on precision low profile sliding rail.
- Precision ER25 chucks with low runout and includes two sets of collet sizes 3-16mm
- Set of Ruby Tipped Nozzles 0.3mm, 0.6mm, 0.8mm and 1.2mm
- Set of extra pads and support arms for nozzle holder.
- Choice of stand alone Magetic WireTensioner.
- Windows software to control the machine via USB.
- 110v-240v AC 50/60Hz
- Safety Limit Switches and Emergency Stop button
Tailstock Options
Standard
The Standard Tailstock runs along low profile rails with high precision bearings.
The Tailstock is fitted with the same ER-25 Chuck as the Bobbin motor and supports core sizes or workpiece holding adapters from 1mm-16mm.
The chuck is mounted in two sets of bearings and rotates freely.
Other Features include a locking handle to fasten in place and a Proximity Limit switch sensor which is wired through drag chain.
Dual Motor
Dual Motor upgrade.
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 synchronised via the controller and will be wired through a drag chain to keep it all nice and tidy.
This Upgrade Includes the same features as the standard tailstock but with extra plates and an integrated motor.
Tensioned Dual Motor
Another option we can offer for customers that have chosen the Dual Motor option is the Tension Tailstock.
This tailstock has a index pin and rail for locking the tailstock in place and also a extra tension system that uses a ballscrew and handle to apply the require torque against the core.
Ideal for longer cores that could whip when being wound.
Feeder Options
Standard
The Standard Wire Feeder Guide is mounted on a set of rails that allows it to be moved away or towards the core/bobbin that is mounted in the chucks. This can then be locked off in place using the handle.
The wire path follows along the Porcelain pulley and through the felt pad that cleans the wire and can be used for applying tension to the wire.
It then exits through a Ruby Tipped Nozzle and out onto the core/bobbin you are winding.
The nozzle holder has two slots for using support arms that may be need for very long, small cores.
This is designed to be used with a stand alone tensioner that sits behind the machine on the work bench.
We offer four different models of the tensioner which can be chosen by the customers when ordering.
MTCSS covering wire sizes 0.03mm—0.07mm 4g—40g
MTCS covering wire sizes 0.04mm—0.14mm 10g—120g
MTCM covering wire sizes 0.08mm—0.25mm 50g—400g
MTCL covering wire sizes 0.12mm—0.35mm 80g—600g
MTCLL covering wire sizes 0.14mm-0.40mm 100g-800g
Integrated Spool & Tensioner
This has the same features as the Standard Wire Guide but also has a built in spool holder and tensioner stand.
This will move along with the feeder plate and is an alternative to the stand alone tensioner that can take up more room on the bench.
3rd Axis with Integrated Spool & Tensioner
This has the same features as the Standard Wire Guide but also has a built in spool holder and tensioner stand and also a motorized 3rd Axis.
The motorized 3rd Axis moves the wire guide away or towards the core/bobbin that is mounted in the chucks.
This is fully controlled via the software and has a built in limit sensor for homing.
Additional Options
Control Panel
Usually all the control buttons for Starting, Stopping, Pausing and Homing are controlled in the software by clicking on the buttons or using keyboard shortcuts.
The control panel brings those buttons out of the software and onto the machine where a operator may be happier to do repeat winding without having to go back to the computer screen.
Profile box to suit the frame on mounting plate with Eaton M22 Series quality buttons and Emergency Stop button.
Servo Motor Upgrade
On the standard machine we fit Closed Loop Stepper Motors, but we still get customers that prefer the higher cost Closed Loop Servo Motors.
The main advantage to using the servo motors over the stepper motors is the noise level is much lower and the torque ratio is better at higher speeds.
Our servo upgrade motors are the Clearpath motors that are from the SDHP range.
ClearPath-SDHP servo systems have 8-15 times the power of similar sized steppers, and more power than many similar sized servos due to the vector sinewave torque control and high energy rare-earth magnetics.
When installing the ClearPath motors we also use the recommended power supplies cables from the ClearPath range.
We can offer the servo upgrade for both the standard machine configuration and the dual bobbin option.
C5 Ballscrew Upgrade
We offer two options for the Ballscrew that is used to driver the Wire Feeder.
Ballscrews are available in different lead accuracy classes
C7 rolled in included in the price of the standard machine.
Rolled C7 ballscrew maximum lead deviation 0.050 over 300 mm
C5 ground which would be a Extra cost.
Ground C5 ballscrew maximum lead deviation 0.018mm over 300 mm
Top Range 600mm Coil Winder
Above you can see pictures of the top of the range 600mm CNC Coil Winder that has all the extra options fitted.
We can of course make much longer machine which include 1000mm, 1500mm, 2000mm between chucks.
Also other options such as probes and sensors can be incorporated into the design and also safety hoods with sliding doors or light curtains depending on your companies health and safety needs.
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
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
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.
Software Customisation
We can also customise the software with your own company logo and also setup operator screens that hide the settings.
Each Operator Screen has a padlock icon that is password protected. Clicking on this will unlock the full features of the software.
Here are a few examples of Operator Screens.
The image shows the cut down Standard Scripting engine where the operator simply loads the saved script and presses Start.
This image shows the cut down Absolute Scripting Engine where the operator simply loads the saved .CSV file and presses Start.
This image shows the cut down Automated Coil Winding Tab where the operator simply loads the saved Bobbin and presses Start.
Below you can see some of the variants of previous completed 600mm Coil Winder builds.
Please feel free to contact us for more information or official quote.
