Industrial Automatic Coil Winding Machine

This project presents an industrial-grade automatic coil winding machine built around a PLC and HMI, designed to bring reliable, precise automation to Pakistan's manufacturing sector at an affordable price. Imported automated winding machines are prohibitively expensive, so this system was engineered from the ground up to deliver comparable industrial performance for winding transformer and solenoid coils at a significantly lower cost (up to ~50% cheaper than imported alternatives) while dramatically reducing winding time. The machine uses an AC servo motor for precise spindle rotation and a stepper motor for accurate wire distribution, coordinated by a programmable logic controller (PLC) with a human-machine interface (HMI) for user-friendly control. Operators can set the number of turns, wire thickness, and solenoid/transformer size; the PLC processes these inputs and commands the servo and stepper motors accordingly. The system achieves winding accuracy up to 0.0125 mm, delivering reduced manufacturing cost alongside improved productivity and precision.