Instructions for Automatic Layer Winding Machine HRZU3000(B)
Automation of layer winding greatly can save the manpower and lower the skill level requirement for operators. In practice, one worker can run more than 4 automatic layer winding machines meantime.
However, it also raises requirements for the quality of plastic spools and welding wire.
| Item | Manual machines | Automatic machines |
| 1. For plastic spools | Both grooveless and grooved plastic spools can be used because workers can control the spacing between wires manually during bottom layer winding to ensure neat arrangement. | Bottom layer winding is fully automatic. Grooved plastic spools are mandatory to achieve a neat bottom layer, which ensures smooth winding of upper layers.Each wire diameter requires a matching grooved spool: φ0.8, φ1.0, φ1.2 each need dedicated grooved spools.Groove width is fixed when production completed, and each groove fits only a limited diameter range.
If wire diameter is larger or smaller than the groove pitch, defects such as gap, sinking, or jumping will occur as shown in the picture below:
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| No special requirements for the position or shape of the starting hole and finishing hole on the spool. | Strict requirements for the relative positions of the starting hole, finishing hole, and pin hole; also requirements for the shape and dimensions of the starting and finishing holes. Therefore, customized molds are required, and the mold cost is approximately USD 10,000 per set.We recommend using plastic spools produced by our cooperative mold manufacturer, which can greatly reduce production inconvenience caused by incompatible plastic spools and fully maximize the production efficiency of the automatic layer winding machine.
If customers insist on using their existing plastic spools, the spools must be sent to our company in advance for usability verification. |
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| 2. For Welding Wire | / | Wire ovality ≤ 0.005 mm.Diameter tolerance between start and end on the same bobbin ≤ 0.005 mm. |
| / | The applicable wire diameter range for the grooves must be continuously verified by the customer during production. Verified diameter tolerances in China:φ1.2 wire: ±0.005 mm；φ1.0 wire: ±0.004 mm；φ0.8 wire: ±0.003 mm
Wires out of tolerance will easily cause tangling during automatic winding. |
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| / | Wire linearity: Relaxation diameter ≥ 600 mm, Lay length ≤ 30 mm. |
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