Fully Automatic Ignition Coil Production Line

 Abstract:

SIPU delivers a turnkey solution for Automotive Ignition Coils. Our innovative "Dual-Channel Converging" layout integrates Primary/Secondary winding, soldering, CCD inspection, and final assembly into one high-speed line.

1. Product Overview

The Ultimate Turnkey Solution for Automotive Ignition Systems.

The SIPU Fully Automatic Ignition Coil Production Line is a high-end manufacturing system designed for the automotive parts industry. Addressing the complex process of "Primary + Secondary + Assembly," we pioneered the "Dual-Channel Converging" design.

Integrating over 10 automation stations, the system seamlessly combines pin insertion, precision winding, automatic soldering, CCD visual inspection, and final assembly. It solves the traditional problems of large footprint and unbalanced cycle times.

2. Key Process Flow

Channel A: Primary Coil

• Bobbin Loading & Pin Inserting: Dual-bowl feeders automatically insert pins into the primary bobbin. 

• Precision Wire Winding: Precision winding of thick copper wire with auto-stripping and cutting. 

• Terminal Soldering: Fluxing and soldering of the primary terminals.

• Channel B: Secondary Coil

• High-Speed Winding: Utilizing 2 Winding Machines simultaneously to balance the long cycle time of fine wire winding.

• Wire Soldering: Precision dipping ensures connection reliability.

• CCD Inspection: Visual check for coil and solder joint quality. 

• Final Assembly Zone

• Convergence: Primary and Secondary coils meet at the central station.

• Auto Assembly: Robotic arms assemble the coils with the outer case. 

• Heavy-Duty Unloading: Finished products are tested and stacked onto large-capacity trays. 



Primary Coil




Secondary Coil



Final Product

3. Key Features & Advantages

Dual-Channel Layout 

• Space Saving: By arranging machines face-to-face, we save 30% of factory floor space compared to linear layouts.

• Cycle Time Balance: The parallel processing of primary and secondary coils eliminates bottlenecks.

Heavy-Duty Unloading System

• Ignition coils are bulky and heavy. We engineered a robust Tray Stacking System capable of handling heavy loads smoothly, a significant upgrade from standard light-duty unloaders.

Automotive-Grade Precision

• Equipped with Active Servo Tensioners and Closed-loop Control, ensuring consistent resistance and inductance for every coil to prevent engine misfires.

Intelligent Quality Control

• CCD Cameras: Detect soldering defects and coil quality.

• Electrical Test: Integrated Resistance, Inductance, and High-voltage testing with auto-reject for NG parts.

4. Technical Parameters

5. FAQ

Q1: Is this production line limited to manufacturing a single specific product?

A1: No, the line features a flexible Modular Design. While the main structure is stable, the tooling is adaptable. By simply changing the customized winding fixtures (jigs) and calling up pre-stored programs, you can switch production between different ignition coil models or handle different wire diameters (ranging from 0.03mm to 1.0mm) efficiently.

Q2: How does the "Dual-Channel Converging Layout" improve production efficiency?

A2：Traditional lines often face bottlenecks because fine-wire winding takes much longer than assembly.
SIPU solves this by using a Dual-Channel Design with multiple high-speed winding machines working in parallel.

• Parallel Processing: Primary and Secondary coils are wound simultaneously on separate stations.

• Cycle Time Balancing: The multiple winding units ensure that coils are ready exactly when the assembly robot needs them, eliminating waiting time and maximizing daily output.

Q3: Do you provide on-site installation for such a complex integrated line?

A3：Absolutely. This is a complex Turnkey Solution. SIPU provides Global On-Site Installation Services. Our senior engineers will travel to your factory to handle the mechanical assembly, software debugging, and provide comprehensive training to your staff until the line runs smoothly.