Xinshida Motion Control System Application in Winding Machines for the Machine Tool Industry
2025-07-17
Xinshida Motion Control System Application in Winding Machines for the Machine Tool Industry
Project Background
Winding is a machine that wraps thread-like objects onto specific workpieces. In recent years, fully automatic winding machines have been developing rapidly. To meet the demands for high efficiency and high output, most fully automatic models now adopt a multi-head linkage design. Xinshi Da YunKong uses motion controllers and servo systems as the core control components of these machines, working in conjunction with robotic arms, pneumatic control elements, and auxiliary actuators to achieve functions such as automatic wire arrangement, automatic foot wrapping, automatic wire cutting, and automatic skeleton loading and unloading. These machines boast high production efficiency, significantly reducing reliance on manual labor, and deliver consistently stable product quality—making them ideally suited for processing environments with high production volume requirements.
Xinshida has developed a variety of solutions for fully automatic winding machines, including U-shaped winding machines, 8-axis hollow-structure winding machines, self-adhesive hollow coil winding machines, dual-needle brushless stator coil winding machines, and dual-flyer winding machines, among others.
1. Double flying fork winding machine
The typical winding structure of the double flying-fork winding machine is shown in the figure below. It consists of three rotating axes: the left flying-fork axis, the right flying-fork axis, and the rotary axis. All three axes are driven by motors connected via synchronous belts.
• Left and right flying fork shafts: Used to drive the copper wire in circular motion, winding it around the iron core.
• Rotating shaft: Used to rotate the iron core by a fixed angle, positioning the slot requiring winding directly beneath the flying shuttle shaft for winding.
2. Internal winding machine
The internal winding machine process mainly consists of loading, winding, wire arranging, wire stripping, soldering, and spot welding.
• Feeding process: Install the required coils and other components onto specific molds to facilitate automatic wire drawing during the winding process.
• Winding operation: Primarily involves securing the winding according to the mold’s shape;
• Cable arranging and winding actions: These are the two core actions of the entire machine; cable arranging is involved whenever winding is completed.
• Stripping process: Remove the enamel coating from the wire ends (typically using a wire stripper or laser stripping).
• Tin-fusing action: Prepares for subsequent spot welding;
• Spot welding process: Perform spot welding on the coil joints.
Customer needs
Simple parameter settings, enhanced production efficiency, and improved process accuracy.
Xinshida Solution
Proposal Description
The Xindashida winding machine solution supports simultaneous operation at multiple stations. By setting processing parameters through control software, the servo system responds to the motion planning instructions from the controller, precisely positioning the rotary axis and rapidly rotating the flying spindle to wind copper wire onto the iron core being processed. While winding the coil, subroutines handle loading and unloading as well as stripping the insulation coating, eliminating the need for the traditional single-operation mode and significantly enhancing the machine’s operational efficiency.
Winding Machine Control Software Interface
Scheme advantages
1. Integrated process program, rich in instructions, and easy to program.
The number of axes can be selected according to the actual process requirements. The system offers a rich set of instructions and supports secondary programming, making it easy to adapt to different machining products. It provides file-based management and can archive up to 40 files, thereby maximizing the principle of multi-functionality in a single machine. Parameter settings have been simplified—no need to memorize numerous parameters anymore; instead, you can simply search and set parameters based on key information.
2. Bus control, stable operation, high efficiency, and precise accuracy.
A bus-based control solution is available, enabling multi-axis interpolated motion control. This approach not only ensures smooth operation but also boosts production efficiency by 20% compared to conventional control methods. It eliminates the risk of pulse loss typical in traditional PLC systems. Additionally, when paired with vision inspection, it guarantees accuracy of ±0.1 mm or better.
3. Servo system self-tuning, anti-resonance
After extensive testing and analysis, Sigriner has customized a set of servo system parameters specifically tailored to the winding and molding process. The newly developed automatic tuning feature of the Ω6s series servo eliminates the need for manual adjustments, allowing customers to seamlessly optimize performance during operation. Additionally, its built-in adaptive filtering function automatically suppresses mechanical resonance that may occur during motion, reducing equipment commissioning time by 90%. The processing results are shown in the figure below and meet the customer’s ideal requirements.
Scheme Composition
The Xinshida winding machine solution primarily consists of a motion controller, servo drives, servo motors, an HMI, extended I/O modules, and a manual pulse generator. Users can choose from various configurations—including bus or pulse control—and options for 4-axis, 6-axis, or 8-axis systems. Additional I/O modules can be added as needed.
Topology of the Xindashida Motion Control Winding Machine Solution
Associated products
SC30 Series Standard PAC
SC50 Series High-Performance PAC
Singlina Ω6-A Servo Drive
OMP Series Motors
Project Results
The Xindashida Omega6 series AC servo system and the SC30 motion controller are a series of products jointly developed with great dedication by the Xindashida Central Research Institute and the Singlina team. These products are widely used in general industrial control applications. In addition to the excellent performance of the winding machine solution shared this time, which has been highly acclaimed by customers, they have also achieved remarkable results and consistently received positive feedback from users in fields such as industrial robotics, engraving machines, laser cutting, packaging, and dispensing. By successfully addressing numerous challenges—such as complex user solutions and high maintenance costs—these products demonstrate Xindashida’s exceptional performance and high reliability.
