In the electronics and electrical industry, coils, as core components, their quality directly affects the performance of terminal products. The circular 8-shaped continuous winding vertical winding machine launched by Yeyi Automation Technology (Suzhou) Co., LTD., with its leading high-precision winding technology, helps enterprises increase the product yield rate to over 99%, standing out in the market competition. What exactly is the mystery behind this technology? Next, we will provide you with a deep analysis.
Yeyi Automation Technology (Suzhou) Co., Ltd. was established on July 21, 2015. It is a high-tech enterprise specializing in the research and development and production of industrial automation equipment. The company has gathered senior technical talents in the field of power equipment. With the concept of "people-oriented and technological innovation", it continuously breaks through the technical bottlenecks of winding equipment. The circular 8-shaped continuous winding vertical winding machine, as its star product, integrates multiple patented technologies and innovative designs, and has become a benchmark equipment in the field of high-precision winding.
First, the precision mechanical structure lays the foundation for high precision
The high precision of the Yeyi circular 8-shaped continuous winding vertical winding machine primarily stems from its precise mechanical structure design. The equipment adopts high-precision grinding grade linear guides and lead screw transmission systems. The straightness error of the guides is controlled at the micrometer level, and the pitch error of the lead screw is extremely small, ensuring the smooth operation of the moving parts during the winding process, and the transmission error is almost negligible. For instance, when winding precision transformer coils, this high-precision transmission system can ensure that the spacing between each turn of the coil is uniform, avoiding the problem of unstable electromagnetic performance caused by spacing deviation.
The winding head and the mold are both key to high-precision winding. The winding head of the Yeyi vertical winding machine is specially designed and made of high-strength and high-rigidity materials. Combined with precise processing techniques, it ensures extremely small radial runout during high-speed rotation. Its molds incorporate innovative designs. The patent for "A Multi-Form vertical Winding Coil Combination Mold" approved on January 20, 2025 (with the authorization announcement number CN222354933U) includes various coil forming molds such as elliptical and square. Through the innovative application of the first wire mold and the lower support transfer mold, it can precisely guide the winding trajectory of the wire. Whether it is circular, square or irregular-shaped coils, high-precision forming can be achieved, reducing coil defects caused by mold errors from the source.
Second, the intelligent control system achieves precise regulation and control
In addition to the hardware foundation, the intelligent control system equipped on the Yeyi Lishan winding machine endows the equipment with a "smart brain". This system adopts advanced numerical control technology and high-performance processors, capable of real-time monitoring and precise control of key parameters such as speed, tension, number of turns and Angle during the winding process at the millisecond level.
In terms of winding speed control, the system can automatically generate speed curves according to the process requirements of the coils. When winding multi-layer coils, at the starting layer and the ending layer, the system will automatically reduce the speed to ensure that the wires fit closely and prevent loosening or collapse. In the middle layer, the speed is increased to ensure production efficiency. Meanwhile, the servo motor drive system equipped with the equipment works closely with the control system. The servo motor has an extremely fast response speed and can quickly execute the instructions of the control system, achieving a smooth transition of speed and ensuring a stable and orderly winding process.
Tension control is an important factor affecting the accuracy of winding. The Yeyi vertical winding machine is equipped with a high-precision tension sensor, which can sense the changes in wire tension in real time and feed the data back to the control system. Once the tension fluctuates, the control system will immediately adjust the tension regulating mechanism to keep the tension always within the set range. When winding wires of different diameters and materials, this intelligent tension control function can effectively prevent problems such as wire stretching deformation, wire breakage or coil loosening caused by improper tension, ensuring the tightness and consistency of the coil.
Third, both process optimization and quality monitoring system are implemented simultaneously
Yeyi Automation Technology not only focuses on technological innovation of the equipment itself, but also further ensures the product yield rate through process optimization and a quality monitoring system. In terms of craftsmanship, the company's technical team conducts in-depth research on the winding process characteristics of different types of coil products and formulates personalized winding solutions. From the winding sequence, winding direction to the planning of the number of winding layers, every detail has been repeatedly tested and optimized to ensure the scientificity and rationality of the process plan.
The quality monitoring system provides a double guarantee for high-precision winding. During the production process, the built-in online detection device of the equipment conducts real-time detection of the number of turns, size, appearance and other aspects of the coil. Once problems such as turns deviation, uneven wire diameter or surface defects are detected, the detection device will immediately issue an alarm and automatically shut down to prevent the further production of defective products. Meanwhile, Yeyi has also established a complete finished product inspection process, using high-precision inspection equipment to conduct comprehensive performance tests on coils, including inductance testing, resistance testing, withstand voltage testing, etc., to ensure that every coil leaving the factory meets strict quality standards.
In addition, Yeyi provides customers with comprehensive technical training and after-sales service. Through professional training, operators can master the high-precision winding technology and process standards of the equipment proficiently, reducing the impact of human operational errors on product quality. A well-established after-sales service system can respond promptly when equipment malfunctions, solve problems in a timely manner, ensure the continuous and stable operation of the equipment, and thereby guarantee that the product yield rate remains at a high level all the time.
The Yeyi circular 8-shaped continuous winding vertical winding machine, with its precise mechanical structure, intelligent control system, optimized process plan and strict quality monitoring system, has achieved high-precision winding through multiple measures, raising the product yield rate to over 99%, an industry-leading level. For enterprises that pursue high-quality and high-efficiency production, the Yeyi vertical winding machine is undoubtedly a reliable partner for achieving outstanding manufacturing, helping them gain the upper hand in the fierce market competition and create greater value.
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