Delta Reveals Winding Machine Control Solution for High-Speed Winding and Stable Tension Control

As factory automation advances to smart manufacturing, outstanding equipment performance, precise control, and expandable architecture has become crucial to all industries. Coil winding technology, for instance, keeps evolving with better functions, higher speed and greater precision for applications in electrical engineering, transmission, mechanical manufacturing, and more.

An ideal winding machine must organize the wires in order and evenly on H-wheels regardless of the material of the coil or the number of layers it may consist of. Delta provides an integrated solution for winding machines based on its years of experience and advanced automation products. It ensures steady tension control for different wire materials, such as copper, aluminum, iron, aluminum-plastic, and copper-plastic wires, and others, to achieve excellent winding performance with higher efficiency while saving energy, labor and time.

This solution features several of Delta's industrial automation products. The standard programmable logic controller (PLC) and human machine interface (HMI) for control and user interface precisely manage the servo drives and motor drives for winding, unwinding and tension control. This solution also applies multiple High-performance Compact Drive MH300 Series to implement high speed and stable winding. The MH300 Series is 40% smaller than its previous generation and can achieve an open-loop output frequency of 2000 Hz. Its Safe Torque Off (STO) provides an emergency stop function to keep operators and equipment safe.

Delta's total solution benefits customers in three aspects:

•　Highly stable tension control for reliable high-speed operation
The MH300 Series high-performance compact drive used in this solution implements automatic coil diameter calculation and two-stage PI control for stable tension control and high-speed machine runtime (up to 23 m/s).

•　Easy hands-on deployment with high versatility
High operation performance and stable tension control under VF mode of the MH300 Series eliminates the need for PLC programs and is suitable for various winding machines.

•　High efficiency, and energy & cost saving
The winding and unwinding inverters share the same DC-bus, so the potential energy generated during AC motor drive operation can be transformed into electricity and used by the motor drive for unwinding. This does not require a braking resistor and simplifies the system, saving cost for system building and energy consumption.

Delta's competitive and complete winding machine control solution fulfills the need for stable and rapid winding with a well-managed tension balance. It advances equipment reliability, winding performance and efficiency, and is suitable for fully automatic and semi-automatic winding machines, precision servo winding machines, toroidal winding machines, hollow coil winding machines, and more.