AUTOMATIC COIL WINDING MACHINE

Abstract

The article deals with the design of a fully automated coil winding machine for stator winding of a motor used in submersible pumps. The conventional coil winding machine winds copper wire onto a former (winding fixture). The former is attached to the sliding arm which is actuated manually. However this machine usually has material tension limitations, operator intervention and low productivity and as motors are the basic need for all operation requiring automation, the stator winding becomes the growing and essential process in automation solutions. The machine winds the coil within the slots of the former. The length of the former is 9.2 cm. The number of slots and windings per slot are customized. The winding is done by suitable methodology using various components. The three phase geared induction motor actuates the rotation of sliding arm with suitable belt and pulley arrangement. Proximity sensor is used to count the number of turns of the sliding arm. The machine winds the coil of 110 turns per minute at 120 rpm. Shifter assembly consists of series of nylon pulleys to maintain tension and linear alignment. The ball screw mechanism is used for precise slot shifting, and it is driven by stepper motor. The machine is controlled by the PIC16F877A microcontroller. The required number of turns and slots is given as input through a keypad which is displayed in a LCD. After the process is over, it is notified through a buzzer. The approximate cost of the developed machine is reduced very much.