Electronic Components Industry Solutions

Introduction

Precision and consistency are the lifeblood of the electronic components industry.
Relays and solenoid valves are core components in industrial control, automotive electronics, home appliances, and communication equipment. The precision and consistency of their coils directly determine the reliability and service life of these components. A minor tension deviation or uneven winding can be amplified into failure or malfunction in the final product.
Xiamen SIPU Mechanical has spent years specializing in relay coils and solenoid valve coils, developing tailored precision winding solutions for each product category.

Our equipment addresses four major pain points:

² Unstable tension leads to significant deviations in coil dimensions and resistance parameters, affecting product reliability

² Poor consistency in mass production results in high defect rates

² Complicated product changeovers and high debugging costs make it difficult to adapt to multi-variety, small-batch production

² Scattered processes—winding, adhesive coating, soldering—result in low overall efficiency

Our solutions deliver comprehensive improvement:

² Precision tension control (±0.02N) ensures every coil turn is tight and uniform

² Servo-driven digital parameter settings enable rapid switching between close-wound and spread-wound modes

² Multi-station automation integrates winding, testing, and adhesive coating

² SPC quality traceability system enables complete recording and tracking of production data

Latching Relay

Solenoid Valve

Product Categories

1. Relay Coil Winding Equipment

Relays are core switching components in industrial control, automotive electronics, communication equipment, and IoT devices, with stringent requirements for coil dimensional accuracy, resistance consistency, and winding density. Among them, latching relays rely on a permanent magnet structure to maintain their working state. The winding directly affects magnetic flux matching, engagement, and release behavior—making them far more technically demanding than ordinary relays.

SIPU provides:

l High-precision servo-driven winding machines, compatible with wire diameters from 0.02mm to 2.0mm

l Closed-loop tension control system with fluctuation within ±0.02N, ensuring stable coil dimensions and resistance

l Multi-station automatic loading/unloading structure significantly improves production cycle time for high-volume manufacturing

l Compatible with multiple relay bobbin specifications; quick product changeover with high flexibility

l Customized equipment and process solutions available for latching relay coil requirements

Typical applications: Signal relays, power relays, industrial control relays, automotive relays, smart meters / security systems with latching relays, and more

2. Solenoid Valve Coil Winding Equipment

Solenoid valve coils are widely used in fluid control, hydraulic transmission, and pneumatic automation. Different operating environments impose vastly different performance requirements: water valve coils are exposed to water and moisture long-term and must have excellent waterproofing and sealing properties; hydraulic valve coils are immersed in high-pressure hydraulic oil and must resist oil, high temperatures, vibration, and have long service life; pneumatic valve coils prioritize response speed and continuous operating stability.

SIPU provides:

l Support for free switching between close-wound and spread-wound processes to meet different heat dissipation and structural design requirements

l Optional integration of adhesive coating, soldering, electrical performance testing, and collection processes for fully automated production lines

l Full-process SPC quality traceability system with complete production data retention and full product traceability

l Process development tailored to different operating conditions: waterproof structures for water valves, oil-resistant processes for hydraulic valves, high-speed winding solutions for pneumatic valves

Typical applications: Water meter and water purification equipment solenoid valve coils, hydraulic machine tools and construction machinery hydraulic valve coils, pneumatic control solenoid valve coils for automation equipment, general industrial solenoid valve coils, and more

Lathing Coil

Valve Coil

Case Studies

Case 1: Full-Automatic Winding Solution for Latching Relay Coils

Project background:
A leading domestic relay manufacturer encountered winding process bottlenecks when expanding into high-end latching relay product lines. Latching relays are widely used in smart meters and security control systems, achieving on/off switching through magnetic flux changes. They demand extremely high precision in winding tension, turn count, and positioning consistency. Minor process deviations can cause engagement or release failures, directly affecting the safety of end equipment.
The customer's existing semi-automatic equipment lacked sufficient precision, resulting in poor batch consistency and high defect rates—unable to meet the supplier qualification standards of high-end clients.

Solution:

SIPU Mechanical custom-designed a dedicated servo winding machine for latching relay coils with the following core configurations:

l High-precision servo tension control system with stable fluctuation within ±0.02N, ensuring uniform tension on every turn

l Multi-axis coordinated positioning mechanism precisely locks winding position with accuracy up to ±0.02mm, matching product magnetic flux design requirements

l Digital turn-counting module combined with tension curve recording system provides complete data retention for each product, supporting quality traceability

l Multi-station automatic loading/unloading mechanism enables fully automated winding, inline testing, and finished product discharge

l Equipment reserved with data interface for integration with the customer's MES system, enabling real-time production data upload

Project outcomes:

ü First-pass yield rate significantly improved from 82% to over 98.5%

ü Equipment production capacity reached approximately 1,600 pieces per hour with significantly improved efficiency

ü Customer successfully passed supplier audits of multiple international electrical equipment manufacturers and secured long-term bulk orders

ü Equipment has been running stably for over 8 months, with tension accuracy consistently maintained within ±0.02N

Case 2: Full-Automatic Winding Solutions for Water Valve and Hydraulic Valve Solenoid Coils

Project background:
A European fluid control system manufacturer operates in both civilian water supply equipment and industrial hydraulic equipment, requiring two types of solenoid coils for different operating conditions. Previously relying on external coil suppliers, the customer faced ongoing challenges: unstable quality, unreliable delivery schedules, and inability to customize according to needs.

The two product types present distinctly different process challenges:

l Water valve coils: Long-term immersion in water and exposure to moisture; waterproofing, moisture resistance, and air-tightness are core quality criteria

l Hydraulic valve coils: Long-term immersion in high-pressure hydraulic oil with high temperatures and high-frequency vibration; requires oil resistance, structural strength, and long-term operational reliability

Solution:
Water valve coil dedicated solution:

l Precision servo winding system with full-process digital tension control ensures dense and uniform coil structure

l Integrated automatic adhesive coating, resistance and turn-to-turn testing, and collection processes—winding to testing and collection in one seamless operation with automatic rejection of defective products

Hydraulic valve coil dedicated solution:

l Oil-resistant and high-temperature-resistant dedicated winding process with tension compensation algorithm to offset thermal expansion differences between magnet wire and metal bobbins

l Equipped with inline testing interface for automatic electrical performance testing of each coil after winding

Project outcomes:

ü Both solutions passed customer acceptance testing and entered mass production smoothly

ü Customer recognized our process customization capability and equipment stability, establishing long-term cooperation

ü Equipment has been running stably to date, with customer's overseas orders growing continuously

 Technical Advantages

Global After-Sales Service

Electronic components industry demands high equipment uptime and strict delivery schedules. We provide comprehensive after-sales support to global customers:

Ø On-site installation and commissioning — Professional engineering team completes equipment installation, commissioning, and acceptance at customer factory

Ø Process parameter customization — One-on-one equipment calibration based on customer product parameters for optimal matching

Ø 7×24-hour remote technical support — Rapid fault diagnosis and resolution to ensure stable equipment operation

Ø On-site training — Equipment operation, routine maintenance, and basic troubleshooting training

Ø Spare parts supply — Common spare parts kept in stock with fastest 48-hour global shipping

Summary

In relay and solenoid valve manufacturing, coil precision and production consistency are the cornerstones of product quality.
SIPU Mechanical has spent years specializing in relay coil and solenoid valve coil winding, delivering tailored mass-production solutions for all types of relays, latching coils, water valves, hydraulic valves, and pneumatic solenoid valves through precision tension control, flexible equipment platforms, and efficient full-process automation.
Choosing SIPU means choosing a winding equipment partner that understands processes, understands mass production, and can be relied on for the long term.

FAQ

1. What types of coils can SIPU's equipment handle?

 We specialize in relay coils and solenoid valve coils—including latching relays, water valve coils, hydraulic valve coils, and pneumatic valve coils. Whether close-wound or spread-wound, we can tailor the solution to your product.

2. Can we get a custom machine? 

Yes. Every machine is built around your coil specifications. Share your samples or drawings, and we'll evaluate and come back with a proposal.

3. How long until delivery? 

Single machines: 30-60 working days after parameters are locked. Complex turnkey lines take longer—we'll give you a specific timeline during the proposal stage.

4. What if something breaks? 

7×24 remote support is available. For major issues, we can dispatch engineers on-site. Common spare parts ship within 48 hours.

5. Do you install and commission overseas? 

Yes. We handle the full process—installation, commissioning, process calibration, and operator training—until your line is running smoothly.