Wire Winding Machine Control Solution

SC Series Motion Controller

A wire winding machine is a device that winds linear material onto specific workpieces. Most electrical products require wound coils made of enameled copper wire (commonly known as magnet wire). From coil design and parameter analysis to CNC programming, automatic compensation technology, adaptive diagnosis and control throughout the entire winding process, and detection of motion interference in the wire guiding section, every step relies heavily on automation, materials science, mechanics, stacking theory, and testing theory.

Wire winding machines possess all the advantages of CNC equipment—high speed, high precision, high flexibility, and a high degree of automation. Advances in the electronics industry continue to place higher demands on the CNC and servo drive systems used in winding machines. High-speed, high-precision interpolation breaks down complex automatic winding trajectories into precise servo control commands. When winding highly complex coils, winding programs consist of numerous fine adjustment routines. Besides ensuring continuous execution of micro-segment programs during high-speed operation, the system must also predict the current coil state in real time based on spindle dynamics to meet high acceleration requirements. This demands that the controller be capable of high-speed, high-precision interpolation and preprocessing of micro-segments, precise acceleration/deceleration control, advanced position prediction, direct interpolation of complex paths, and high-speed data transmission.

CODESYS enables development of sophisticated motion controllers. By integrating motion control and logic control into a single platform, CODESYS combines both within its IEC 61131-3-compliant CODESYS programming system and CODESYS real-time runtime software, forming the CODESYS Motion CNC Robotics Toolkit. This toolkit supports everything from simple single-axis control to advanced CNC and robotic control. The CODESYS motion control functionality includes a graphical DIN 66025 editor (supporting G-code), CNC libraries, and all necessary function blocks for CNC programming, offering comprehensive interpolation capabilities ranging from linear to spline interpolation. CODESYS motion control features powerful path planning capabilities, including CNC tool radius compensation, support for virtual and logical axes, and visualization with online 3D path display and planning.

CODESYS provides fully open interfaces and programming templates for libraries, enabling users to perform deep secondary development based on their industry-specific know-how and integrate proprietary algorithms.

Many controller manufacturers have developed wire winding machine controllers based on the CODESYS software. Below, we present a control solution combining motion controllers and servo systems for wire winding applications.

Winding System Solution

Fully automatic winding machines are a relatively new type of equipment developed in recent years. To meet the demands of high efficiency and high output, fully automatic models typically adopt multi-spindle联动 designs. This winding machine control solution uses the SC series motion controller and servo system as the core control unit, working in conjunction with robotic arms, pneumatic control components, and execution accessories to achieve automatic wire guiding, lead wrapping, wire cutting, and automatic loading/unloading of bobbins. The motion controller is developed on the CODESYS software platform, featuring rich interface options and outstanding overall performance, meeting diverse application requirements.

This motion control-based winding solution supports simultaneous multi-station operations. Processing parameters are configured via control software, and the servo system responds to motion planning commands from the SC series motion controller. The rotary axis achieves precise positioning while the flyer axis rotates rapidly, winding copper wire onto the core to be processed. During winding, subroutines simultaneously handle loading/unloading and漆 removal (insulation stripping), avoiding traditional single-operation modes and significantly improving machine efficiency.

Wire Winding Machine Control Software Interface

The winding machine solution primarily consists of a motion controller, servo drives, servo motors, HMI, extended I/O modules, and a handwheel pulse generator. The system topology is shown below:

System Topology of the Motion-Controlled Winding Machine

The control core of this solution comprises the SC motion controller and the Sigriner Ω6s series AC servo system, offering the following advantages:

Integrated process programming with rich instruction sets and easy programming
Bus-based control for stable operation, high efficiency, and accurate precision
Servo system self-tuning and resonance suppression

Finished Product

The SC30 motion controller, developed on the CODESYS software platform, is widely used in general industrial control applications. In addition to receiving customer approval in the winding machine application presented here, it has also achieved excellent results and consistent user satisfaction in industrial robotics, engraving machines, laser cutting, packaging, dispensing, and other fields, successfully helping users solve complex challenges and reduce maintenance costs.