Closed-Loop Process for Perfect Layer Winding

Prof. Dr.-Ing. Klaus Feldmann, Dipl.-Ing. Andreas Dobroschke

The production of perfect layer coils is extremely demanding. Several boundary conditions influence the build up of the coil significantly. The decisive process parameter for perfect layer coils is the angle of lag. It has to be kept within a tight tolerance zone. Due to fluctuations of both wire diameter and bobbin size it is not possible to ensure a constant angle of lag with a fixed programmed feed rate of the wire guide. Usually after 2 to 3 layers wound the feed rate of the wire and the feed rate of the wire guide differ so much that the angle of lag exceeds the permissible limits.

In order to realise an automated process for perfect layer coils an innovative winding system was developed at the Institute FAPS. It controls the angle with a closed-loop system by regulating the feed rate of the wire guide according to the actual angle. The angle of lag is measured by a CCD-Linesensor that is connected via USB to the control PC that calculates the required parameters for the closed-loop control. In this paper the development of the system is presented and experimental results are discussed.