Automatische Stahldrahtwickelmaschine

Executive summary

An automatic steel wire winding machine takes wire from the drawing or rewinding line and lays it into a coil of set length, at constant tension, without the operator guiding it. Our winding machines combine a tension-controlled feed, a driven take-up and a length counter that slows the machine before the set length. This page explains the winding cycle, tension and speed control, coil sizing and what to check before you buy.

A blue framed winding machine feeds bright steel wire over an orange guide wheel into a vertical cage take-up on a geared, rotating base. The layers build evenly while the operator watches the panel with its speed displays and emergency stop.

Inhaltsverzeichnis

What the winder does

Drawn steel wire leaves the line on large carriers, but customers buy it in coils of a set weight or length. The winder rewinds it into those coils. Manual winding gives loose laps, wrong lengths and tangled coils at the pay-off. An automatic winder keeps tension steady, counts length and lays each turn in place, so the coil pays off cleanly at the customer.

The winding cycle

  1. Futter: wire comes from the pay-off or drawing block over guide wheels.
  2. Spannung: a tension unit keeps the wire tight, and a synchronous device matches take-up speed to line speed.
  3. Wind: the take-up turns while a servo traverse, or the cage geometry, lays the turns evenly.
  4. Graf: a meter counter measures length to 0.01 m and slows the machine before the set length.
  5. Cut and change: the wire is cut, the full coil is released and the next coil starts.

The PLC stores each reel specification, so a product change means loading a stored recipe, not resetting the machine.

Spool, flyer or cage take-up

Aufnehmen How turns are laid Am besten geeignet,
Spool with traverse spool turns, a servo traverse moves the wire across small coils of fine and medium wire
Flyer a rotating arm lays wire onto a still coil former twist-free coils for some cable and wire grades
Vertical cage wire is laid into a rotating cage on a vertical axis heavier coils that are lifted off and strapped

On our coiling line the servo traverse is linked to the winding head, so the pitch follows the wire diameter set in the recipe.

Tension and speed control

Too little tension gives a soft coil that collapses; too much stretches the wire or breaks it. On our steel wire coiling line, tension is set from a DC 24 V tension control cabinet. A synchronous device controls the take-up speed to avoid overstretch or wire break, and the machine stops at once if the wire breaks.

Typische Reichweiten

Artikel FHOPE steel wire coiling line (example)
Kabeldurchmesser 1.8 – 5.0 mm
Max Geschwindigkeit 500 m / min
Mittelhöhe 1,000mm
Spulengröße ID 400 mm, OD 500 mm, width 55 mm
Coilgewicht 10-30 kg
Ausgang 15–20 coils per hour (one head), 30–40 (double head)
Akku 5–20 m Draht
Längenzählung 0.01 m resolution

Larger coils and heavier wire, like the cage take-up above, are sized per project and confirmed at quote.

Coil mass and wire length

Coil mass (solid) = π/4 × (OD² − ID²) × width × steel density. For the 500 / 400 / 55 mm coil: π/4 × (0.5² − 0.4²) × 0.055 × 7,850 = 30.5 kg if packed solid (example only). Real coils have gaps between turns, so expect less.

Wire length = coil mass ÷ mass per metre. A 3 mm wire has 7.07 mm² cross-section, or 0.0555 kg/m. A 30 kg coil holds 30 ÷ 0.0555 = 540 m, which takes about 540 ÷ 500 = 1.1 min at full speed (example only).

Why an accumulator or two heads

Buffer time = accumulator length ÷ line speed. A 20 m accumulator at 500 m/min buys only 20 ÷ 500 × 60 = 2.4 s. That is enough to ride through a speed change, but not a coil change. For continuous drawing lines we use two winding heads: one winds while the other is emptied, which is why output doubles from 15–20 to 30–40 coils per hour.

Auswahl-Checkliste

  1. Wire diameter and grade?
  2. Liniengeschwindigkeit in m/min?
  3. Coil ID, OD, width and target weight or length?
  4. Single head or double head?
  5. Strapping, wrapping or weighing after winding?
  6. Pay-off type: drawing block, carrier or spool?

Sicherheit

The machine is designed to EN ISO 12100:2010 for risk assessment, EN 415-10 for packaging machine safety and EN 60204-1 for electrical equipment. The rotating take-up and running wire are the main hazards, so fence the winding zone with interlocked access or a light curtain. Keep limit switches at both ends of the accumulator and the emergency stop within reach.

Häufig gestellte Fragen zur Technik

Q: What wire sizes can it wind? A: Our steel wire coiling line handles 1.8–5.0 mm; other sizes are confirmed at quote.

Q: How accurate is the length? A: The meter counter reads to 0.01 m and slows the machine before the set length.

Q: What if the wire breaks? A: Wire-break detection stops the machine at once, and the synchronous take-up control is there to prevent the overstretch that causes most breaks.

Q: Can it strap the coil too? A: Yes, strapping with PET or PP strap at 2 or 4 points can follow, plus wrapping, weighing and labeling.

Nächster Schritt

  1. Bitte senden Sie uns Ihre Drahtstärke, Schnittgeschwindigkeit und Spulenspezifikation. an info@fhopepack.com.
  2. Wir haben Größe the winder, tension unit and downstream packing.
  3. Wir antworten innerhalb von 24 Stunden mit einem Vorschlag und einem Kostenvoranschlag.

Quellen

  • FHOPE quotation: automatic steel wire coiling and strapping machinery (2018)
  • FHOPE product page: steel wire winding and wrapping machine
  • EN ISO 12100:2010; EN 415-10; EN 60204-1
  • The steel wire winding machine shown above

Letzte Überprüfung: 21.09.2026

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