Fully Automatic Magnetic Coil Production Line

Fully Automatic Magnetic Coil Production Line

Machine  introduction

The SIPU Fully Automatic Magnetic Coil Production Line is a high-precision, modular manufacturing system desiged for the mass production of electromagnetic components. Unlike single-purpose machines, this versatile platform integrates Pin Insertion, Winding, Soldering, Taping, and Testing into one continuous workflow.

Whether you are manufacturing heavy-duty Solenoid Valve Coils for hydraulics, high-voltage Ignition Coils for automotive engines, or precision Voice Coils for speakers, this machine delivers consistent quality and industry-leading speed (up to 4,000 PCS/H). It is the preferred choice for top-tier manufacturers aiming to replace manual labor with smart automation.

Magnetic Coil Winding Machine Application Areas

• Our machine is compatible with a wide range of bobbin structures and wire types, serving key industries:

• 1. Automotive Industry (Critical Safety Parts)

• Ignition Coils: Precise layering for high-voltage output.

• ABS Coils: Anti-lock braking system sensor coils.

• Fuel Injector Coils & Solenoid Coils.

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• 2. Industrial Automation & Fluid Control

Solenoid Valve Coils: Used in water valves, gas valves, and pneumatic cylinders.

• Relay & Contactor Coils: High-speed winding for power switching components.

• 3. Acoustic Components (Speaker Industry)

• Voice Coils (VCM): Precision winding for speakers, headphones, and buzzers.

• 4. Power & Electronics

• Inductor Coils: Common mode chokes and power inductors.

• Stator Coils: For brushless motors and stepper motors.

A Six-Step Automated Process

Step 1: Intelligent Feeding (Emphasis on Protection)

This system uses a custom-designed vibrating track for automatic sorting and feeding of spools. The smooth conveyor design prevents scratches, protecting raw materials and reducing pre-production waste.

Step 2: Precision Pin Insertion (Micron-Level Accuracy)

Terminals are inserted with micron-level precision, supporting complex L-shapes and 90° bends. This ensures perfect pin alignment, enabling reliable soldering and preventing post-assembly failures.

Step 3: 32-Spindle High-Speed Winding (Core Process)

Equipped with 32 synchronous shafts (maximum speed 20,000 RPM) and an active servo tensioner.

Wide Range: Handles wires from 0.02mm (sensors) to 0.45mm (solenoids).

Performance: Achieves perfect orthogonal winding (gap-free), supports throughput up to 4,000 pieces/hour, and maintains stable inductance values.

Step 4: Automated Termination (Soldering and )

Soldering: Leads are immersed in flux and solder baths to ensure strong solder joints without melting the plastic coil frame.

Step 5: Integrated Quality Control (Zero Defects)

All defective parts are rejected. Built-in testers measure resistance (R) and withstand voltage. Non-conforming parts are automatically rejected and placed in separate bins, ensuring 100% product conformity.

Step 6: Intelligent Unloading

Finished coils are automatically unloaded onto blister trays or conveyor belts. This automated process minimizes damage and speeds up the final packaging process.

 Key Features & Advantages

•Deeply Customized (Tailor-Made) Solution:

Unlike generic standard machines, this production line is engineered specifically for your unique product (e.g., Relay or Solenoid Coils). Every station—from feeding to soldering—is optimized for your specific bobbin structure and process requirements. This dedicated design ensures maximum stability and zero-defect output for mass production.

• High-Speed Servo System:

All axes (X/Y/Z) are driven by Panasonic/Mitsubishi Servo Motors, ensuring smooth motion and high repeatability compared to pneumatic cylinders.

• Active Tension Control:

Equipped with SIPU's proprietary Servo Tensioners, the machine actively feeds wire to prevent breakage, which is critical when winding 0.02mm fine wires for ABS or Voice coils.

• Industry 4.0 Ready:

The PLC system can store up to 1000 product recipes. It supports MES/ERP integration, allowing production managers to monitor output and yield rates remotely.

Technical Parameter

FAQ

Q1: Can this production line manufacture different types of coils (e.g., switching from Solenoid to Voice Coils)?

A: Since this is a fully automatic high-speed line, we design it as a dedicated solution for a specific product series to ensure maximum stability and efficiency (4,000 PCS/H).

While the winding technology is shared, the physical handling mechanisms for a Solenoid Coil and a Voice Coil are very different. Therefore, we do not recommend running vastly different products on the same line. However, for coils with the same structure but different dimensions, production switching is possible by changing the tooling fixtures.

Q2: My coil requires special processing like insulation taping or CCD inspection. Can you integrate this?

A: Yes. As an engineering-driven manufacturer, we can customize the line layout. We can integrate Automatic Taping Stations (for insulation), CCD Visual Inspection (for soldering checks), or even Robotic Palletizing stations based on your specific technical requirements.

Q3: How does the machine handle defective products during mass production?

A: The machine features an intelligent sorting system. The integrated tester checks Resistance, Inductance, and Voltage in real-time. If a coil fails any test, the system automatically routes it to a separate Reject Bin (NG slot), ensuring that only 100% qualified products reach the packing stage.