Coil winding tension control

This paper analyzes the current coil-winding machine to determine the wire tension occurring at various locations along the winding apparatus. The goal is to make possible design improvements for better wire tension control at the armature to prevent wire breakage and to enable high-speed winding. A typical commercial winding machine was analyzed. The computer simulation result suggests design modification is needed. Three new design concepts are presented. In the new designs, the path of the flier end pulley is no longer fixed. This allows the flier arm to deflect in response to tension fluctuations to achieve a more uniform tension during the winding process.