> **Resumen ejecutivo**
>
> A high speed online automatic wire winding machine sits at the end of the drawing line and winds wire at line speed, so there is no intermediate spool and no second handling. The key is synchronisation: the winder must follow the drawing machine's speed and start/stop signals exactly. This page explains the online interface, the drive scope, throughput math and the checks before you order.
Bright wire runs along a blue bench over orange guide wheels to a tall orange winding column with a flared base. Below, a round blue turntable carries the growing coil while the operators stand clear of the running wire.
Índice
- Online or offline winding
- The online interface
- Drive scope: what must be supplied
- Throughput and coil time
- Coil change at speed
- Lista de verificación de selección
- Seguridad
- Preguntas frecuentes sobre ingeniería
- El próximo paso
- Lectura relacionada
- Fuentes
Online or offline winding
| Item | Online winder | Offline rewinder |
| :--- | :--- | :--- |
| Position | at the drawing line exit | separate station |
| Speed | follows the drawing machine | set by the rewinder |
| Handling | none between drawing and coil | spool or carrier moved by crane |
| Main risk | loss of synchronisation | extra handling damage |
| Best for | high-volume wire grades | many small orders and lengths |
Online winding removes one handling step. The price is that the winder becomes part of the drawing line: if it cannot keep up, the line slows down.
The online interface
The drawing machine's controller sends the winder two kinds of signal: a speed signal, so the take-up matches line speed, and start/stop signals, so both machines run and stop together. A synchronous device trims the take-up speed to keep tension steady, and the winder stops if the wire breaks. Our line PLCs link to other machines by hard-wired signals, Profinet or Ethernet; the exact signals and levels are agreed in the technical appendix before build.
Drive scope: what must be supplied
**A speed signal is useless without a drive that can act on it.** On one of our semi-automatic rewinder projects, the main motor was 22 kW. Its inverter, plus breakers, terminals, switches and an emergency stop, had to receive the drawing machine's signals, and the turntable drive had to be synchronised with the main motor. We supplied an additional inverter for the rewinding motor to close that gap. Write the full drive list into the contract, not just "motor".
Throughput and coil time
**Mass flow = line speed × mass per metre.** A 2.5 mm steel wire has 4.91 mm² cross-section; at 7,850 kg/m³ that is 0.0385 kg/m. At 500 m/min the line delivers 500 × 0.0385 = 19.3 kg/min, or about 1,155 kg/h (example only). A 250 kg coil then fills in 250 ÷ 19.3 ≈ 13 min, so about 4.6 coils per hour; the 30–40 coils per hour below applies to small 10–30 kg coils.
| Item | Steel wire coiling line | Cable winding line |
| :--- | :--- | :--- |
| Max line speed | 500 m/min | 200 m/min |
| Wire diameter | 1.8–5.0 mm | confirmed at quote |
| Heads | 1 or 2 | confirmed at quote |
| Output (double head) | 30–40 coils per hour, for 10–30 kg coils | confirmed at quote |
| Accumulator | 5–20 m | confirmed at quote |
Our steel wire coiling line reaches 500 m/min; our cable winding line runs at 200 m/min. The 500 ÷ 200 = 2.5 speed ratio is why steel wire winders need stronger tension control and faster coil change than cable winders.
Coil change at speed
The drawing line does not stop for a coil change, so the winder must:
- use two winding heads, so one winds while the other is emptied (our double-head line gives 30–40 coils per hour);
- or buffer wire in a 5–20 m accumulator, which at 500 m/min gives only 0.6–2.4 s, enough for an automatic cut and transfer but not a manual change;
- or cut and transfer to an empty former within the buffer time.
The right choice depends on coil time: a 13 min coil gives plenty of time; a coil that fills in under a minute needs two heads.
Lista de verificación de selección
1. Wire diameter, grade and drawing speed?
2. Coil weight or length target?
3. Signals available from the drawing machine controller?
4. Drive scope: main motor, inverter, turntable drive, panels?
5. Single or double head, and accumulator length?
6. Strapping or wrapping after winding?
Seguridad
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 running wire, guide wheels and turntable are the main hazards. Fence the winding zone with interlocked access or a light curtain, and wire the emergency stop into the drawing line's stop circuit so one button stops both.
Preguntas frecuentes sobre ingeniería
Q: How fast can it wind?
A: Our steel wire coiling line reaches 500 m/min; the speed for your wire is confirmed at quote.
Q: Does it need a signal from my drawing machine?
A: Yes, a speed signal and start/stop signals.
Q: What wire sizes?
A: Our steel wire line handles 1.8–5.0 mm; other sizes are checked per project.
Q: Can it run with an older drawing line?
A: Usually, if the drawing controller can send a speed signal; otherwise a speed encoder is added.
El próximo paso
1. **Send your wire size, drawing speed, coil target and drawing controller type** to info@fhopepack.com.
2. **We size** the winder, drive scope and interface.
3. **Respondemos en un plazo de 24 horas** con una propuesta y un presupuesto.
Lectura relacionada
- [Automatic wire coiler (product)](https://www.fhopepack.com/Wire-coil-wrapping-machine/automatic-wire-coiler.html)
- [Automatic cable winding and packing machine (product)](https://www.fhopepack.com/Cable-packing-machine/automatic-cable-winding-and-packing-machine.html)
- [Automatic steel wire coil packing machine (product)](https://www.fhopepack.com/Wire-coil-wrapping-machine/automatic-steel-wire-coil-packing-machine.html)
- [High speed steel wire rewinding packing machine](https://www.fhopepack.com/videos/high-speed-steel-wire-rewinding-packing-machine/)
- [Automatic steel wire winding machine](https://www.fhopepack.com/videos/automatic-steel-wire-winding-machine/)
Fuentes
- FHOPE project correspondence: semi-automatic rewinder linked to a drawing machine (2024)
- FHOPE quotation: automatic steel wire coiling and strapping machinery (2018)
- FHOPE product page: automatic cable winding and packing machine
- EN ISO 12100:2010; EN 415-10; EN 60204-1
- The online wire winding machine shown above
Última revisión: 20/10/2026
