{"id":3494,"date":"2020-12-28T07:07:03","date_gmt":"2020-12-28T07:07:03","guid":{"rendered":"https:\/\/www.fhopepack.com\/videos\/?p=3494"},"modified":"2026-10-27T15:15:56","modified_gmt":"2026-10-27T15:15:56","slug":"automatic-steel-wire-coiling-winding-machine","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/automatic-steel-wire-coiling-winding-machine\/","title":{"rendered":"Steel Wire Coiling Machine: Winding on a Collapsible Head"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong>\nAn automatic steel wire coiling machine takes continuous wire feed from upstream drawing or annealing lines, winds it onto an expandable segmented mandrel, performs cut-to-length separation, and transfers consolidated coils for strapping.\nThe accompanying operational video (duration: 72 s) details the mechanical sequence of a dual-mandrel coiling unit: high-speed winding, radial mandrel collapse, pneumatic coil-holding arm engagement, and automated reset.\nEngineered for heavy-duty industrial wire processing, this dual-head configuration supports line speeds from 200 to 800 m\/min and delivers up to 40 strapped coils per hour under continuous operation.<\/p>\n<\/blockquote>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/z4F8iqqQI4E\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<hr \/>\n<h2 id=\"table-of-contents\">Table of Contents<\/h2>\n<ul>\n<li><a href=\"#video\">Kinematic Sequence Breakdown of the Coiling Cycle<\/a><\/li>\n<li><a href=\"#cycle\">Cycle Phase Timeline<\/a><\/li>\n<li><a href=\"#how-it-works\">System Architecture: How the Wire Coiling Line Operates<\/a><\/li>\n<li><a href=\"#specs\">Technical Specifications &amp; Line Data<\/a><\/li>\n<li><a href=\"#takt\">Takt Time &amp; Output Kinematics<\/a><\/li>\n<li><a href=\"#selection-checklist\">Engineering Selection Checklist<\/a><\/li>\n<li><a href=\"#safety\">Machine Safety &amp; Electrical Standards<\/a><\/li>\n<li><a href=\"#engineering-faq\">Engineering FAQ<\/a><\/li>\n<li><a href=\"#next-step\">Project Sizing &amp; Quotation Workflow<\/a><\/li>\n<li><a href=\"#related-reading\">Related Reading<\/a><\/li>\n<li><a href=\"#sources\">Sources &amp; References<\/a><\/li>\n<\/ul>\n<h2 id=\"video\">Kinematic Sequence Breakdown of the Coiling Cycle<\/h2>\n<p>The coiling system consists of three main sub-assemblies: an expandable four-segment coiling mandrel mounted on the driven headstock, an articulated swinging transfer arm for coil consolidation and offloading, and a heavy-duty structural base frame housing the drive train. A column-mounted HMI console and multi-tier stack light provide real-time status indication.<\/p>\n<ol>\n<li><strong>0 to ~9 s \u2014 High-Speed Rotary Winding:<\/strong> The segmented mandrel rotates at synchronized line speed. The servo-driven traverse guide executes reciprocal pitch-controlled strokes, building precision layered wire windings onto the expanded mandrel barrel.<\/li>\n<li><strong>~12 s \u2014 Coil Completion &amp; Deceleration:<\/strong> As wire length approaches the pre-programmed target, the drive spindle decelerates smoothly to prevent outer-wrap slack and prepare for cut-off.<\/li>\n<li><strong>~15 to 42 s \u2014 Radial Mandrel Collapse &amp; Clearance Generation:<\/strong> The segmented coiling mandrel collapses radially inward (moving from expanded winding diameter to collapsed unloading clearance). This mechanical collapse relieves radial hoop tension from the wire pack, allowing axial release.<\/li>\n<li><strong>~45 to 51 s \u2014 Dwell &amp; Separation Phase:<\/strong> The mandrel remains fully collapsed with the completed coil suspended at dead center, verifying clearance before manipulator transfer.<\/li>\n<li><strong>~54 to 60 s \u2014 Transfer Manipulator In-Feed &amp; Mandrel Reset:<\/strong> The pivoting transfer arm swings 90\u00b0 inward to clamp the coil exterior. Concurrently, the mandrel core re-expands to its designated nominal winding diameter.<\/li>\n<li><strong>~63 to 69 s \u2014 Next-Coil Take-Up Engagement:<\/strong> The mandrel clamps the wire tail, accelerates back to line velocity, and resumes high-speed winding for the subsequent coil pack.<\/li>\n<li><strong>~72 s \u2014 Manipulator Retraction:<\/strong> The transfer arm withdraws the secured coil to the auxiliary staging position for automated ID strapping, returning to home standby.<\/li>\n<\/ol>\n<h2 id=\"cycle\">Cycle Phase Timeline<\/h2>\n<p>The 72-second clip captures a transition between successive coil lots:<\/p>\n<table>\n<thead>\n<tr>\n<th>Operational Step<\/th>\n<th>Timestamp Window<\/th>\n<th>Duration<\/th>\n<th>Mechanical Execution<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Precision Layer Winding<\/td>\n<td>0 to ~12 s<\/td>\n<td>~12 s<\/td>\n<td>Mandrel rotating at sync speed; servo traverse controlling coil build<\/td>\n<\/tr>\n<tr>\n<td>Mandrel Radial Collapse<\/td>\n<td>~15 to 30 s<\/td>\n<td>~15 s<\/td>\n<td>Internal toggle\/wedge links contract segments to collapse diameter<\/td>\n<\/tr>\n<tr>\n<td>Release Dwell &amp; Stabilization<\/td>\n<td>~30 to 42 s<\/td>\n<td>~12 s<\/td>\n<td>Full radial clearance maintained; coil core tension relieved<\/td>\n<\/tr>\n<tr>\n<td>Transfer Arm In-Feed<\/td>\n<td>~45 to 51 s<\/td>\n<td>~6 s<\/td>\n<td>Manipulator swings into axial alignment with mandrel centerline<\/td>\n<\/tr>\n<tr>\n<td>Coil Clamping &amp; Re-Expansion<\/td>\n<td>~54 to 63 s<\/td>\n<td>~9 s<\/td>\n<td>Mechanical jaws secure coil outer profile; mandrel returns to winding diameter<\/td>\n<\/tr>\n<tr>\n<td>Winding Resumption<\/td>\n<td>~63 to 69 s<\/td>\n<td>~6 s<\/td>\n<td>Wire tail clamped, spindle accelerates into synchronous speed<\/td>\n<\/tr>\n<tr>\n<td>Arm Retraction &amp; Offload<\/td>\n<td>~72 s<\/td>\n<td>\u2014<\/td>\n<td>Coil stripped axially to ID strapping station<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>Note: Data derived from 3-second frame-sampling intervals. The recorded cycle isolates the coil offload and mandrel reset sequence rather than total gross wind time.<\/em><\/p>\n<h2 id=\"how-it-works\">System Architecture: How the Wire Coiling Line Operates<\/h2>\n<p>A fully integrated steel wire coiling and packaging line combines continuous accumulation, precision winding, shearing, automated strapping, and exit logistics into a closed loop:<\/p>\n<ol>\n<li><strong>Vertical Tension Wire Accumulator:<\/strong> Buffers 5 to 20 m of wire using a motorized dancer assembly. It absorbs speed differentials between upstream drawing machines and coiler index cycles, preserving constant tensile force and preventing line trips.<\/li>\n<li><strong>Dual-Head Coiling Machine:<\/strong> Employs two independent segmented mandrels. While Head A completes high-speed winding and length metering via an optical encoder, Head B indexes to the strapping position.<\/li>\n<li><strong>Servo Traverse Mechanism &amp; Portal Shear:<\/strong> Coordinates traverse pitch with wire diameter to maintain flat, uniform coil sidewalls. Upon reaching preset length, a rigid hydraulic\/pneumatic portal shear executes a clean square cut.<\/li>\n<li><strong>Through-the-Eye Automatic Strapping Unit:<\/strong> Feeds high-tensile polypropylene (PP) strap directly through the inner diameter (ID) of the coil, applying friction-weld seals at multiple radial intervals.<\/li>\n<li><strong>Downstream Unloading System:<\/strong> Discharges finished, strapped coils to walking beams, downenders, or automated turnstiles.<\/li>\n<\/ol>\n<table>\n<thead>\n<tr>\n<th>Sub-Assembly<\/th>\n<th>Engineering Function<\/th>\n<th>Primary Benefit<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Tension Accumulator<\/td>\n<td>Buffers 5\u201320 m wire; maintains tension within \u00b15%<\/td>\n<td>Zero shutdown of upstream drawing lines<\/td>\n<\/tr>\n<tr>\n<td>Dual Expandable Mandrels<\/td>\n<td>Alternate continuous winding and offloading<\/td>\n<td>Eliminates indexing downtime; doubles throughput<\/td>\n<\/tr>\n<tr>\n<td>Length Encoder &amp; Servo Traverse<\/td>\n<td>Optical metering down to 10 mm; dynamic stroke adjust<\/td>\n<td>Precise coil weight and flat sidewall formation<\/td>\n<\/tr>\n<tr>\n<td>Heavy-Duty Portal Cutter<\/td>\n<td>Guillotine blade cut at full deceleration<\/td>\n<td>Clean end condition; zero wire snagging<\/td>\n<\/tr>\n<tr>\n<td>Automated Radial Strapping<\/td>\n<td>Through-the-ID strapping (3 to 6 positions)<\/td>\n<td>Structural bundle integrity during transport<\/td>\n<\/tr>\n<tr>\n<td>Coil Transfer Manipulator<\/td>\n<td>Axial coil stripping via pneumatic clamp<\/td>\n<td>Eliminates manual handling; protects surface finish<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h2 id=\"specs\">Technical Specifications &amp; Line Data<\/h2>\n<table>\n<thead>\n<tr>\n<th>Parameter<\/th>\n<th>Operational Range \/ Value<\/th>\n<th>Engineering Notes<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Wire Diameter Range<\/td>\n<td>1.2 mm to 8.0 mm (Customizable)<\/td>\n<td>Low, medium, and high carbon steel, galvanized or annealed<\/td>\n<\/tr>\n<tr>\n<td>Maximum Line Speed<\/td>\n<td>200 to 800 m\/min<\/td>\n<td>Synchronized via closed-loop dancer feedback<\/td>\n<\/tr>\n<tr>\n<td>Production Capacity<\/td>\n<td>40 coils\/h (Dual-Head) \/ 20 coils\/h (Single-Head)<\/td>\n<td>Dependent on coil weight, wire gauge, and strapping cycles<\/td>\n<\/tr>\n<tr>\n<td>Centerline Elevation<\/td>\n<td>1,000 mm from finished floor<\/td>\n<td>Standard ergonomics for cross-line integration<\/td>\n<\/tr>\n<tr>\n<td>Electrical Rating<\/td>\n<td>380 V \/ 440 V, 3-Phase, 50\/60 Hz<\/td>\n<td>Inverter-driven spindle motors with dynamic braking units<\/td>\n<\/tr>\n<tr>\n<td>Accumulator Buffer Length<\/td>\n<td>5 to 20 m capacity<\/td>\n<td>Tuned to line speed and mandrel switchover duration<\/td>\n<\/tr>\n<tr>\n<td>Strapping Material<\/td>\n<td>Polypropylene (PP), 10 mm \u00d7 0.8 mm<\/td>\n<td>Optional polyester (PET) or steel strap on request<\/td>\n<\/tr>\n<tr>\n<td>Strapping Configurations<\/td>\n<td>3, 4, or 6 radial straps<\/td>\n<td>Symmetrically spaced through coil core<\/td>\n<\/tr>\n<tr>\n<td>Joint Weld Efficiency<\/td>\n<td>75% to 80% of base strap tensile strength<\/td>\n<td>Thermally regulated friction vibration weld<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h2 id=\"takt\">Takt Time &amp; Output Kinematics<\/h2>\n<p>Line takt time governs line balance with upstream wire processing equipment:<\/p>\n<p><code>Takt Time = 3600 s &divide; Target Hourly Output<\/code><\/p>\n<ul>\n<li><strong>Dual-Head Configuration (40 coils\/h):<\/strong>\n<code>Takt Time = 3600 &divide; 40 = 90 s per coil<\/code><\/li>\n<li><strong>Single-Head Configuration (20 coils\/h):<\/strong>\n<code>Takt Time = 3600 &divide; 20 = 180 s per coil<\/code><\/li>\n<\/ul>\n<h3>Kinematic Validation<\/h3>\n<p>Consider a wire drawing line operating at a linear velocity of 600 m\/min winding a 900 m coil pack:<\/p>\n<p><code>Winding Time (t_wind) = (Coil Length &divide; Linear Velocity) &times; 60<\/code>\n<code>t_wind = (900 m &divide; 600 m\/min) &times; 60 = 90 s<\/code><\/p>\n<p>In a <strong>Dual-Head configuration<\/strong>, <code>t_wind<\/code> (90 s) matches the 90-second takt. Head A winds wire continuously while Head B executes mandrel collapse, coil stripping, ID strapping, and re-expansion within that same 90-second window.<\/p>\n<p>In a <strong>Single-Head configuration<\/strong>, strapping and handling time (approximately 90 s) occurs sequentially after winding, yielding:<\/p>\n<p><code>Total Cycle Time = t_wind + t_handling = 90 s + 90 s = 180 s<\/code><\/p>\n<p>This kinematic constraint explains why single-mandrel setups operate at half the capacity of dual-mandrel lines.<\/p>\n<h2 id=\"selection-checklist\">Engineering Selection Checklist<\/h2>\n<ul>\n<li><strong>Wire Feed Characteristics:<\/strong> Grade, tensile strength (MPa), and inlet diameter range.<\/li>\n<li><strong>Upstream Line Speed:<\/strong> Continuous output speed (m\/min) and emergency stop ramp duration.<\/li>\n<li><strong>Target Coil Geometry:<\/strong> Inner core diameter (ID mm), outer diameter (OD mm), coil build height (width mm), and target mass (kg).<\/li>\n<li><strong>Head Architecture:<\/strong> Dual-mandrel continuous winding (\u2264 40 coils\/h) vs. single-mandrel non-continuous system (\u2264 20 coils\/h).<\/li>\n<li><strong>Strapping Specifications:<\/strong> Radial strap count (3, 4, or 6), seal type (friction weld vs. mechanical seal), and strap width\/thickness.<\/li>\n<li><strong>Take-Away Interface:<\/strong> Direct discharge to gravity roller table, chain conveyor, tilting downender, or C-hook overhead monorail.<\/li>\n<\/ul>\n<h2 id=\"safety\">Machine Safety &amp; Electrical Standards<\/h2>\n<p>High-speed wire coiling machines combine heavy rotational inertia, high-tensile wire tension, and multi-axis automated clamping. Perimeter interlocks and dedicated safety logic prevent operator exposure during high-speed rotation and mandrel manipulation:<\/p>\n<ul>\n<li><strong>Wire Break Mitigation:<\/strong> Sudden wire fractures upstream trigger the accumulator&#8217;s multi-switch dancer limit sensors within 50 ms. Dynamic braking resistors arrest spindle rotation immediately, mitigating loose wire whipping.<\/li>\n<li><strong>Pinch-Point &amp; Crush Safeguards:<\/strong> The collapsing mandrel segments and pivoting transfer manipulator are guarded behind fixed physical fencing and interlocked perimeter access doors.<\/li>\n<li><strong>Maintenance Lockout (LOTO):<\/strong> Complete isolation and zero-energy state verification must precede manual wire restringing, shear blade servicing, or strap head maintenance.<\/li>\n<li><strong>Regulatory Harmonization:<\/strong>\n<ul>\n<li><strong>ISO 12100:2010:<\/strong> Risk assessment and risk mitigation hierarchy.<\/li>\n<li><strong>EN 415-10:2014:<\/strong> Packaging machines \u2014 General safety requirements.<\/li>\n<li><strong>ISO 13849-1 (PLd \/ Cat. 3):<\/strong> Dual-channel safety circuit architectures for emergency stop and access gate interlocks.<\/li>\n<\/ul><\/li>\n<\/ul>\n<h2 id=\"engineering-faq\">Engineering FAQ<\/h2>\n<p><strong>Q: What is the maximum linear entry speed for the dual-head coiling system?<\/strong>\nA: Nominal speeds range from 200 to 800 m\/min, determined by wire tensile class, coil weight, and traverse pitch stability.<\/p>\n<p><strong>Q: Can the mandrel handle variable internal coil diameters (ID)?<\/strong>\nA: Mandrels are engineered for specific nominal IDs (e.g., 300 mm, 400 mm, or 500 mm). Modular bolt-on segment shoes allow rapid field conversions between standard industry diameters.<\/p>\n<p><strong>Q: How does the system prevent slack when cutting wire at high speeds?<\/strong>\nA: The line decelerates along a synchronized S-curve; the vertical dancer accumulator absorbs upstream wire flow while a dedicated pneumatic snubber clamps the tail against the mandrel prior to portal cutting.<\/p>\n<p><strong>Q: What type of strapping heads are utilized for through-the-eye bundling?<\/strong>\nA: Industrial friction-weld strapping heads feeding 10 mm to 12 mm PP straps through an indexing strap track, achieving joint efficiencies of 75% to 80%.<\/p>\n<h2 id=\"next-step\">Project Sizing &amp; Quotation Workflow<\/h2>\n<p>We engineer steel wire coiling lines tailored to exact plant footprints and metallurgical criteria:<\/p>\n<ol>\n<li><strong>Submit Line Parameters:<\/strong> Send drawing exit speed, wire diameter, finished coil dimensions (ID\/OD\/Width), and daily throughput targets to <strong>info@fhopepack.com<\/strong>.<\/li>\n<li><strong>Technical Engineering Proposal (48 Hours):<\/strong> Receive a customized machine footprint drawing, dual vs. single-head cycle simulation, and accumulator sizing calculation.<\/li>\n<li><strong>Plant Layout &amp; Integration Audit:<\/strong> Our packaging systems engineers verify take-away conveyor centerline clearances, electrical drops, and safety fencing envelopes for turn-key commissioning.<\/li>\n<\/ol>\n<h2 id=\"related-reading\">Related Reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Wire-coil-wrapping-machine\/automatic-wire-coiler.html\">Automatic Steel Wire Coiling and Strapping Machine Technical Overview<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Wire-coil-wrapping-machine\/Automatic-steel-wire.html\">Horizontal Steel Wire Winding and Strapping Systems<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Wire_coil_packing_machine.html\">Automated Wire Coil Packaging and Stretch Wrapping Solutions<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/automatic-steel-wire-rod-coil-compressing-with-strapping-machine\/\">Wire Rod Coil Compacting Presses with Integrated Strapping Heads<\/a><\/li>\n<\/ul>\n<h2 id=\"sources\">Sources &amp; References<\/h2>\n<ul>\n<li>Line Data and Engineering Architecture: <a href=\"https:\/\/www.fhopepack.com\/Wire-coil-wrapping-machine\/automatic-wire-coiler.html\">FHOPE Automatic Steel Wire Coiling &amp; Strapping Division<\/a><\/li>\n<li>Dynamic Cycle Analysis: On-site verification based on 3-second frame timing data<\/li>\n<li>Operational Demonstration: <a href=\"https:\/\/www.youtube.com\/watch?v=z4F8iqqQI4E\">FHOPE Official YouTube Channel<\/a><\/li>\n<li>Safety and Machinery Directives: <a href=\"https:\/\/www.iso.org\/standard\/51528.html\">ISO 12100:2010 Safety of Machinery<\/a>, <a href=\"https:\/\/www.nen.nl\/en\/nen-en-415-10-2014-en-191845\">EN 415-10:2014 Safety of Packaging Machines<\/a><\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 2026-10-05<\/p>","protected":false},"excerpt":{"rendered":"<p>Executive summary An automatic steel wire coiling machine takes continuous wire feed from upstream drawing or annealing lines, winds it onto an expandable segmented mandrel, performs cut-to-length separation, and transfers consolidated coils for strapping. The [&hellip;]<\/p>","protected":false},"author":1,"featured_media":3522,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Steel wire coiling machine: winding on a collapsible head","_seopress_titles_desc":"How our steel wire coiling machine winds wire on a collapsible head and hands the coil on, with clip timing, line data, a takt check and safety notes.","_seopress_robots_index":"","_seopress_robots_follow":"","_seopress_robots_imageindex":"","_seopress_robots_snippet":"","_seopress_robots_primary_cat":"none","_seopress_robots_breadcrumbs":"","_seopress_robots_freeze_modified_date":"","_seopress_robots_custom_modified_date":"","_seopress_robots_canonical":"","_seopress_social_fb_title":"","_seopress_social_fb_desc":"","_seopress_social_fb_img":"","_seopress_social_fb_img_attachment_id":0,"_seopress_social_fb_img_width":0,"_seopress_social_fb_img_height":0,"_seopress_social_twitter_title":"","_seopress_social_twitter_desc":"","_seopress_social_twitter_img":"","_seopress_social_twitter_img_attachment_id":0,"_seopress_social_twitter_img_width":0,"_seopress_social_twitter_img_height":0,"_seopress_redirections_value":"","_seopress_redirections_enabled":"","_seopress_redirections_enabled_regex":"","_seopress_redirections_logged_status":"both","_seopress_redirections_param":"","_seopress_redirections_type":301,"_seopress_analysis_target_kw":"","_seopress_news_disabled":"","_seopress_video_disabled":"","_seopress_video":[],"_seopress_pro_schemas_manual":[{"_seopress_pro_rich_snippets_type":"custom","_seopress_pro_rich_snippets_custom":"<script type=\"application\/ld+json\">{\"@context\": \"https:\/\/schema.org\", \"@graph\": [{\"@type\": \"FAQPage\", \"@id\": \"https:\/\/www.fhopepack.com\/videos\/automatic-steel-wire-coiling-winding-machine\/#faq\", \"mainEntity\": [{\"@type\": \"Question\", \"name\": \"How fast does the steel wire coiling line run?\", \"acceptedAnswer\": {\"@type\": \"Answer\", \"text\": \"At 200 to 800 m per minute, with about 40 coils per hour on two heads or 20 per hour on one.\"}}, {\"@type\": \"Question\", \"name\": \"How is the coil strapped?\", \"acceptedAnswer\": {\"@type\": \"Answer\", \"text\": \"With PP strap, 10 mm wide and 0.8 mm thick, through the coil ID in 3 to 6 places.\"}}, {\"@type\": \"Question\", \"name\": \"What happens if the wire breaks?\", \"acceptedAnswer\": {\"@type\": \"Answer\", \"text\": \"The accumulator stops the machine at the same moment, and limit switches at both ends guard its travel.\"}}]}, {\"@type\": \"VideoObject\", \"@id\": \"https:\/\/www.fhopepack.com\/videos\/automatic-steel-wire-coiling-winding-machine\/#video\", \"name\": \"Steel Wire Coiling Machine: Winding on a Collapsible Head\", \"description\": \"An automatic steel wire coiling machine winds wire from the drawing line onto a coiling head, cuts it at the set length and releases a tight coil for strapping. 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