Delta’s Pin Capacitor Winding Machine Solution Simplifies Development and Maintenance

Fulfills Multiple Applications and High-efficiency Stable Production



Capacitors, resistors, and inductors are the basic electrical components widely used in consumer electronics, industrial controls, automotive, electricity supply, and new energy applications for all types of high or lower-frequency circuits. Among these, aluminum electrolytic capacitors, which feature high electric capacity, are commonly used for high voltage power sources, such as for the power supplies of new energy vehicles.



Aluminum electrolytic capacitors are made of aluminum foil, insulation paper, and internal/external pins. By winding the layers into a roll to increase the contact area of foil and battery electrolyte, the electric capacity of the capacitor increases. The winding process is critical during production. Through real-time data transmission and tension control, it improves productivity as well as repeatability. In addition, with high demand and short supply, capacitor manufacturers are facing an urgent challenge that their core programs are overly reliant on senior developers. To overcome the situation, manufacturers are embracing digital and standardized methods and enhancing the flexibility of their production lines in terms of implementation and maintenance.



Delta has recently helped a well-known capacitor manufacturer in South China adopt its Pin Capacitor Winding Machine Solution. The client replaced its single-chip microcomputer with Delta’s highly integrated EtherCAT solution that supports motion control based on the CODESYS platform. The upgrade helps users edit programs flexibly and optimizes high repeatability production through tension control. To sum up, Delta provides the client with a total solution for high-efficiency production and flexible applications.



Delta’s Pin Capacitor Winding Machine Solution employs the PC-based Host Motion Controller AX-8 Series to transmit device information and control multiple motors through the standard Delta Servo System ASDA-B3 Series in real-time to produce capacitors by winding and unwinding. The controller also transmits the information to the Human Machine Interface DOP-100 Series for implementation management so admins at different levels can all fulfill onsite control and monitoring.





Delta’s Pin Capacitor Winding Machine Solution brings the following benefits to the client:



• Standardized platform & EtherCAT for easy development and maintenance

Delta’s Pin Capacitor Winding Machine Solution is based on the mainstream CODESYS motion control. It integrates the PC-based Host Motion Controller AX-8 Series to simplify the copy process for easy development and further system maintenance. Moreover, the solution adopts an EtherCAT Fieldbus structure for connecting the external encoders, stepper motors, and IO signals with expansion modules. The device information can also be transmitted to the Human Machine Interface DOP-100 Series and corporate IT systems to merge OT and IT and achieve visualization in a smart factory.



• High repeatability & low cycle time for efficient and stable production

Delta’s Pin Capacitor Winding Machine Solution is capable of high-efficiency and stable production. It offers a cycle time (CT) of 2.9 seconds with a product length of 600mm and a length error accuracy within ±0.5 mm. While the speed goes up to 1,000 mm/s, the solution maintains stable tension with low fluctuation of the swing rod.



• Highly automated & comprehensive functions for multiple applications

Delta’s Pin Capacitor Winding Machine Solution has comprehensive functions, such as auto calculation for the initial winding diameter when tension is on. It also features a code wheel control mode and an absolute positioning control mode to control winding length. In certain circumstances, it supports paper-first and 2-layer paper windings. Delta's devices are highly automated and can satisfy different implementation and maintenance requirements from multiple applications to boost continuous development and innovation. 



Delta’s Pin Capacitor Winding Machine Solution has improved its tension algorithm and control accuracy. Compared with conventional solutions, Delta's solution significantly increases productivity and winding effects. By adopting the standardized program platform, the solution simplifies development and maintenance by helping users avoid dependency on specific developers and edit programs individually. With power battery winding demand booming, Delta is strengthening its efforts in this and similar fields. Delta will continue to leverage its product capabilities to help clients build high-efficiency and high-quality manufacturing for tackling the new energy market.