Georg Wendler, Erlalngen

-
Optimized Winding of a Repeating Coil on a CNC Winding
Machine FVV 112 E
End dW"dlna

The application of :i programmable winding machine Iw20 I I

is demonstrated by the example of a repeating coil. Iw19 I

The CNC-program i:s shown in detail.

1. Winding task

The repeating coil has a trapezoidal coil arrangement

which is wound on a spool S18. The first layer
consists of two times 45 windings, wound with Iwn , A I
enamel-led copper wire of 0.30 mm diameter. Then a
50 micrometer thick Hostaphan foil is interleaved. I W _ I I
The windings (wire diameter 0.25 mm) 2a and 2b are
wound in the right and left halves of the spool and
also insulated with Hostaphan foil. The folowing
layers W3 to W20 (wire dia.0.08 mm) are shifted on
the left and right side by different amounts and w 1.2
ma
insulated with Tesa strips. The covering insulation
w11
consists of three wiindings of Tesa band.
Spool
kvl. Schema% secnoncli dew of the windlng shllctute

2. The winding machine

The CNC winding machine FW 112 E (table 2) has a

storage capacity of 1000 working cycles which can be
divided into 999 products; it is suitable for all winding
tasks. Wires from 0.01 to 2 mm diameter with a pitch
per spindle revolutilon of 0 to 60 mm can be wound
over a maximum wire laying width of 285 mm. The
winding speed (maximum winding diameter: 200 mm)
goes from 20 to 4000 "/min. Thanks to the
recirculating ball screw in the feed system, the
linearity error is lesa than 1 %.

The maximum speed of the machine is 16.000 rpm,

depending on the studded wheels.The display on the
CNC unit indicates: The relevant product number and
cycle, product name, nominal and actual number of
turns, wire dia., direction of pitch, direction of rotation
and instructions for the operator.

The keyboard is devided into figures keys, function

keys and operating keys. By using symbols for the
winding parameters programming can be carried out
indepently from any language.

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3. Program structure

The table below shows the entire program, entered in preprinted coding sheets. The program is explained by
the example of working cycle 6.1.

4. Principle of fixed-point programming of program step 6.1

The fixed point is variable. By the first program step (6.1), winding spindle and wire guide are positioned, so
that upon starting the process they will always be in the same place. The first winding (W1.1/W1.2) consists of
three working cycles:

Cycle 6.2 Wind winding W1.l from left to right.

Cycle 6.3 Position wire guide on the right reversal point (26 mm).
Cycle 6.4 Wind winding W1.2 from left to right.
The second winding (W2bW2a) is realized with the following working cycles:
Cycle 6.5 Position wire guide on the right reversal point (27,8 mm).
Cycle 6.6 Wind winding Wb2 from right to left.
Cycle 6.7 Position wire guide on the left reversal point (10 mm).
Cycle 6.8 Wind winding W2a from left to right.
With winding W3, the trapezoidal winding properly speaking starts:
Cycle 6.9 Position wire guide on the righ reversal point (26 mm).
Cycle 6.10 Wind winding W3 from right to left.
Cycle 6.1 I Wind windings W3 to W20 with winding type "trapezoidal automatically"

The left reversal point 10 mm and the right reversal point 26 mm as well as
shifting at the left side by 0.294 mm and shifting at the right side by 0.191 mm is
being programmed. The machine stops at the end of each layer and automatically
reduces the winding width. This way, a trapezoidal winding is carried out.
Inserting of intermediate insulation is done at the end of each layer, whereby the
speed of the machine is beeing controlled via the pedal operation unit during
inserting. After inserting the insulation material, the automatic operation is initiated
by the start key.

Cycle 6.12 Covering insulation 3 windings Scotch tape

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5. Operating exerience, economic efficiency

By using the winding machine FW 112 E for the manufacture of the repeating coil UF 1376, 13 minutes of
production time are saved. The present winding time amounts to 12 minutes, i. e. a rationalization of 52 %
could be achieved. This high percentage is due to the fact that all winding parameters are programmable,
so that set-up times in the conventional sense are avoided. As soon as the product number is called, the
machine will be ready for operation. The stops do no longer have to be adjusted mechanically: they are
programmable through the use of a pitch measuring system, the positioning of the wire guide guaranteeing
a repeat precision with a tolerance of max. 0.01 mm. The main spindle can be positionedwithan accuracy of
0.1 winding.

The fact that all wiriding parameters are programmed provides for a highly reproducible quality of the
wound products, which results in a drastic reduction of the waste rate.

The 52 % time savinlg enabled an increase of production from 15 repeating coils to 30 units (in 8 working
hours). Assuming that one winding minute costs approx. DM 0.60, and with 21 working days per month, the
amortization time of the winding machine amounts to approx. 6.5 months.

The author of this article

is Georg Wendler, managing director of! lndustielle Wickeltechnik GmbH, Erlangen.

IWT lndustrielle Wickeltechnik GmbH, Germany

645

CIM SYSTEM in Winding
Techniques
Up to now, winding machines were programmed
individually. The introduction of CIM processes
reduces machine set-up times considerably and
adds greater flexibility to production. This article
describes how a continuous winding data flow
system was implemented in a large-scale
equipment factory. A PC-based CIM system now
takes the winding data created in the mainframe
to the winding machine.
CIM - also used for winding now
Providing CNC machine tools with programs by
means of CIM ( CO m p u t e r I n t e g r a t e d
M a n U f a c t U r i n g ) systems is the state of
the art in most fields of industrial production. In
winding technology, however, this was not com-
mon up to now, because, among other things,
program codes, interfaces and the respective
protocols are in most cases specifically designed
by the different manufacturers, so that they do
not correspond to any standard.
For this reason, a performance specification has
been prepared, based on the first stage of de-
velopment of a CNC package for winding ma-
chines. This specification as well as the
experience gained in the course of the realizati-
on of the project were integrated into the packa-
ge, so that now a practice-oriented standard CIM
software is available.
A PC as center of the hardware
The principal item is a usual PC with two eight-
fold transmission modules which are connected
with a parallel and a serial interface of the PC. In
the present case the PC is interconnected
through BAM (interface for video display termi-
nals) with the mainframe / server. This coupling
will be possible if the PC is equipped with the
corresponding access assembly.
winding machines of the series FW 3xX
are connected with the transmission modules.
8 machines type FW can be connected to each
module, the maximum configuration level being
at present 128 machines. Each individual ma-
chine is selected via the parallel interface
(Centronics), the winding program is transmitted
through the serial (V24/RS232C) interface of the
PC. The work documents are printed on the
spot. 646
All software functions necessary for
flexible operation
The CIM software is designed in modular con-
struction. It consists of the modules basic data,
winding program, transmission and taking over
of transformer data. The CIM software is con-
nected through file transfer programs with the
mainframe / server. The system is operated by
menu selection with operator guidance. After
starting the system, one of the modules or the
central computer is selected.
On the mainframe / server, the following
actions are possible:
-+Call or update of all winding programs loaded
since the last call,
+ Specific call of individual programs,
+ Work on the central computer, like on a
normal terminal.
The modules offer the following functions:
-+Mask-based creation or modification of a
winding program,
+ Transmission of winding programs from the
PC to the machines, from the machines to
the PC, from the PC to the printer or other
peripherals,
+ Deletion of winding programs: individually on
the hard disk, individually on the machine, all
programs on one machine, all programs on
all machines.
+ Machine occupancy: all data transmissions
are logged. The protocol is a continuous in-
formation on the current machine occupancy.
+ Machine directory: here, all connected
machines as well as the reserve channels are
managed (in our case: 12 + 4).
Of course, the winding programs stored on the
hard disk are also accessible at any time. They
are coded through a 40-digit, freely selectable
character string. This character string, i. e. the
program, can quickly and easily be searched and
called by means of a matchcode. Input errors,
transmission errors and machine messages are
automatically displayed by the system.
IWT .Wickdmoschinen
I
Drucker
 The unsatisfactory condition before the introduction of the CIM system, as a setting of tasks

The former data flow (below) shows in which way the control information was generated and how it got
to the machines: based on the technical specification and other technological data, the winding pro-
gram was createdl in dialog with the mainframe. It was printed as a "winding sheet", taken to the win-
ding machine together with the work documents, and keyed in by the operator into the machine
storage. Due to the more and more frequently changing types, the machine storages were no longer
sufficient for all the existing programs, so that after some time the same program had to be keyed in
again, which increased the set-up times. Furthermore, transmission errors frequently occurred. As
quite often the same program was used on several machines, it was necessary, before starting the
winding process, 1.0 check the data for their current status.

---

These problems led to the following requirements:

-+ Increased data continuity,
-+ Extended storage capacity,
--+ Shorter set-up times,
-+Simpler winding program transmission,
-+Exclusion of transmission errors,
-+Faster type change,
-+ Safe update of existing programs.
These tasks could only be mastered with a CIM system introduced for the 12 winding machines.

Rational, flexible CIM operation

Based on the technical specification (now stored on mainframe / sewer and generated with the help of
superset program:;) and other technological data, the winding program is created, stored and loaded in
dialog with the mainframe I sewer. The programs loaded are at regular intewals newly called from the
PC (due to pauses and other idle times). The work assembler distributes the programs in real time ac-
cording to the production orders to the machines. Workstation-specific program modifications are car-
ried out on the PC by duplicating and modifying the program and transmitting the copy. Thanks to its
great operator convenience, the system was well received by the workshop staff.
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Amortization in 1 year

In the special case described above, the system will be amortized after 1, year, exclusively through the
reduction of set-up times. If the following factors, which are difficult to evaluate:

-+ Shorter lead times,

+ Better quality,
-+ More flexible manufacture,
-> Documentation in real time,

were also taken into account, the amortization time would be even shorter.

Outlook
Due to the positive experience made with the system, also for other applications, the following exten-
sions are in the phase of realization:

-+ Text module: additional information concerning machine operation can be placed between the pro-
gram lines.

Meanwhile further modules in the CIM software have been developed which shifted functions of the
mainframe into the PC. For example, any transformer calculation programs available on the market
can be combined with the CIM software. This way, the calculated transformer data are automatically
converted into winding programs which then can immediately be wound on an IW machine. Further-
more, the winding programs of the different IWT winding machines can automatically be converted into
the requested machine type. With the help of a transmission plan, the requested production plan is
transmitted directly to the winding machine.

A further developmental step will be to get the ClM software running under “WINDOWS 95”.

The author of this article

Dipl.-lng. (FH) Georg Wendler, born in 1950, studied electrical engineering in Nurnberg.

IWT lndustrielle Wickeltechnik GmbH, Germany

648