Common Inductor Winding Machine

Common Inductor Winding Machine with real-time access to the MES system via Ethernet, combined with low-power environmental design and comprehensive monitoring of spot welding processes, it provides an "efficient, energy-saving, and flexible" intelligent winding solution for full-series common-mode inductors such as 2012/3416.

Performance

● The Common Inductor Winding Machine leads the industry in stability, allowing one operator to manage 10 machines simultaneously, saving 90% labor costs compared to traditional equipment.

● It adopts an aluminum vibrating bowl for automatic feeding, with 8 stations (detection, winding, spot welding, waste wire adsorption, unloading, etc.) operating in tandem. The cycle time for a single product is ≤3 seconds, requiring no manual intervention throughout the process.

● Built-in storage of 20 model parameters enables one-click recall during model changes. It is compatible with full-series products such as 2012/3416, with a model change time ≤5 minutes, making it suitable for small-batch and multi-variety production scenarios.

● Using a 12-divider indexing for positioning, the wire arrangement is uniform without overlapping. It is compatible with wire diameters of 0.025-0.12MM (typical value 0.03-0.09MM), and the error in the number of winding layers is ≤±1 turn.

● The spot welding temperature control accuracy is ±5℃, ensuring consistent solder fusion.

● The pressure control error is ≤±2%, and the flatness uniformity of solder joints is ≥98%.

● The service life of the spot welding head is counted in real time, and an automatic alarm prompts replacement when due to avoid abnormal wear.

● The feeding station is equipped with built-in visual inspection to instantly reject defective workpieces such as missing materials or deformation, with a front-end defect interception rate ≥99%.

● The Ethernet module uploads production capacity, yield, equipment status and other data in real time, seamlessly connecting to the MES system to support remote parameter adjustment and production report generation.

● It automatically enters sleep mode during non-operation, reducing energy consumption by 40% compared to similar equipment.

Features

● The bus control technology, PLC program and touch interface are completely independently developed, with strong anti-interference capability and a equipment failure rate <0.05 times/1,000 hours.

● Modular structure and easy-to-dismantle design reduce maintenance time by 60%, allowing ordinary technicians to complete daily maintenance.

● Supports customized angled lead winding to meet special pin angle requirements and reduce downstream processing steps.

● The specially made winding fixtures and spot welding heads are made of wear-resistant materials, with a service life of over 500,000 times, and the consumable cost is 30% lower than the traditional solution.

● The graphical touch interface supports visual parameter settings, and new employee training time is ≤1 hour; it real-time displays the winding trajectory and spot welding status for convenient on-site monitoring.

● The fully enclosed protective cover with emergency stop device complies with CE safety standards to eliminate human-machine interaction risks.

Highlights

● The "1 person 10 machines" operation mode refreshes the industry's production capacity limit. The floor area of a single device is only 1.2㎡, and the unit area production capacity is 5 times higher than that of traditional segmented equipment.

● The 12-station divider realizes parallel "winding-spot welding" operations to avoid single-station bottlenecks, with a comprehensive efficiency improvement of 30%.

● The first dynamic monitoring system for the service life of spot welding heads, combined with pressure-temperature dual-loop control, reduces the solder joint defect rate to 0.1%, far exceeding the industry average (0.5%).

● Supports winding of ultra-fine enameled wires, breaking the lower limit of wire diameter of similar equipment to meet the needs of high-end inductors such as 5G communications and medical equipment.

● Provides lifetime free software upgrades to support the expansion of new model parameters; standard remote diagnosis function allows engineers to optimize parameters through the cloud to ensure long-term optimal operation of the equipment.

Product parameters