Winding Machine

Case Study: SIPU Full-Automatic Line for HVAC Valve Coils

1. Project Overview

This custom solution is designed for mass production of HVAC solenoid valve coils, widely used in air conditioning systems, refrigeration equipment, and smart HVAC control valves. SIPU developed a fully automated line with two winding stations, integrating soldering, visual inspection, performance testing, and automatic tray loading to meet the customer’s high-volume and high-quality requirements.

2. Core Process & Equipment

  • Dual-Station High-Speed Winding

    Two SIPU precision winding machines work in parallel, supporting continuous high-efficiency production. The servo-controlled winding ensures uniform tension and consistent coil shape, even for fine-gauge enameled wires.

  • Rotary-Station Soldering

    The coils are automatically transferred to the rotary soldering station, where the leads are securely soldered under precise temperature and time control, minimizing cold joints and improving electrical contact reliability.

  • CCD Visual Inspection

    After soldering, a high-resolution CCD camera inspects both the coil winding quality (turn count, alignment) and solder joint integrity (tackiness, position, no missing solders), eliminating defective units at the early stage.

  • Electrical Performance Testing

    Each coil undergoes automatic resistance and inductance testing, ensuring compliance with the customer’s specifications. Unqualified products are automatically rejected.

  • Automatic Tray Loading & Packaging

    Passed coils are automatically sorted and loaded into trays, ready for direct assembly into HVAC valves, with zero manual handling required.

3. Key Benefits for the Customer

  • Higher Production Efficiency

    Dual winding stations and continuous line flow increase output by over 60% compared to manual or semi-automatic processes, meeting large-volume OEM orders on time.

  • Consistent & Traceable Quality

    Every coil goes through automated inspection and testing, reducing human error and providing full production traceability for each batch.

  • Reduced Labor & Operating Costs

    One operator can manage the entire line, cutting labor costs and minimizing the risk of operator-related defects.

  • Space-Saving Integrated Design

    The compact line layout optimizes floor space while maintaining smooth material flow, ideal for both new and existing factory environments.

4. Application Fields

This line is widely applicable to:

  • HVAC system solenoid valve coils

  • Refrigeration and air conditioning control components

  • Automotive thermal management valve coils

  • Household appliance electromagnetic coils

Contact SIPU to discuss your custom coil production line requirements, whether for HVAC, automotive, or industrial applications.


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