What Is an Automatic Winding Machine?
An automatic winding machine is an industrial machine that enables the automatic winding of materials in wire, cable, or strip form with defined tension, speed, and layer arrangement. These machines precisely control parameters such as the number of turns, layer structure, wire diameter, and winding geometry, ensuring standardized and repeatable results.

The main objectives of automatic winding machines are:

• High-precision and balanced winding

• Increased production speed

• Minimization of operator-related errors

• Ensuring quality and standardization

• Long-term and uninterrupted production

DMR Tekno develops application-specific automatic winding solutions with these objectives at the core.

DMR Tekno’s Automatic Winding Approach
When designing automatic winding machines, DMR Tekno adopts an application- and process-oriented engineering approach. Each winding application has different requirements; wire diameter, winding speed, tension tolerances, and product geometry vary from project to project. Therefore, instead of standard machines, custom-engineered solutions tailored to specific needs are offered.

DMR Tekno’s approach is based on the following core principles:

• High winding precision

• Stable and vibration-free mechanical structure

• Advanced automation and control

• Easy operation and maintenance

• Long-lasting and reliable system design

This approach ensures that automatic winding machines can be used safely across different industries.

Working Principle of Automatic Winding Machines
Automatic winding machines perform the winding process fully automatically according to predefined parameters. The basic working principle consists of the following stages:

Material Feeding:
The wire or cable is fed into the machine in a controlled manner from the feeding unit.

Tension Control:
During winding, wire tension is continuously monitored and controlled using precise sensors and mechanisms.

Winding Motion:
The winding head or bobbin carrier performs the winding operation with defined speed and axis movements.

Layer and Turn Counting:
The number of turns, layer arrangement, and positions are monitored by the automation system.

Completion and Unloading:
Once winding is completed, the product is automatically unloaded or transferred to the next process.

DMR Tekno automatic winding machines manage all these steps with high precision.

Critical Parameters in Automatic Winding Machines
The success of automatic winding systems depends on accurate control of several technical parameters.

Wire Diameter and Material Type
Different winding characteristics are required for copper, aluminum, or special alloys.

Tension Control
Critical to prevent wire breakage or loose winding.

Winding Speed
Ensures a balance between production capacity and quality.

Winding Pattern
Straight, cross, or special winding patterns affect product performance.

DMR Tekno optimizes these parameters specifically for each project.

Mechanical Design and Durability
Mechanical stability directly affects winding quality in automatic winding machines. Vibration, axis misalignment, or imbalance can cause winding errors and product losses.

In DMR Tekno automatic winding machines:

• High-rigidity body design

• Precision linear guides and bearing systems

• Low-vibration drive mechanisms

are used to create a long-lasting and stable structure.

Winding Head and Mechanisms
The winding head is one of the most critical components of automatic winding machines. DMR Tekno designs custom winding heads for different applications.

Features of winding heads include:

• Precise axis control

• Stable operation at high speeds

• Compatibility with different wire diameters

• Easily adjustable structure

This flexibility allows different products to be manufactured on the same machine.

Automation and Control Systems
DMR Tekno automatic winding machines are equipped with advanced PLC- and HMI-based automation systems. These systems ensure precise and repeatable control of winding parameters.

Advantages of the automation infrastructure:

• Control of winding turns and speed

• Recipe-based production

• Minimization of operator errors

• Data logging and reporting

• Remote monitoring and intervention capability

These features support standardization in production processes.

Energy Efficiency
Automatic winding machines must be designed for long-term and continuous operation. DMR Tekno optimizes motor and drive selections to minimize energy consumption.

Energy efficiency approach:

• High-efficiency motors

• Intelligent speed and torque control

• Minimal mechanical losses

This approach reduces operating costs while contributing to environmental sustainability.

Industry Applications

Electrical and Electronics
Provides high precision in coil, transformer, inductor, and motor windings.

Automotive
Suitable for mass production of electric motors, sensors, and cable assemblies.

Energy
Offers reliable winding solutions for generators, transformers, and power systems.

White Goods and Industrial Products
Widely used in motor and electromechanical component manufacturing.

Laboratory and Industrial Type Automatic Winding Machines
DMR Tekno develops automatic winding machines at different scales.

Laboratory Type

• Compact structure

• High precision

• Ideal for R&D and prototype production

Industrial Type

• High production capacity

• Design suitable for continuous operation

• Integration into production lines

Manufacturing, Assembly, and Testing Processes
DMR Tekno automatic winding machines undergo detailed quality controls during the manufacturing phase. After assembly, machines are subjected to comprehensive testing.

Test processes include:

• Winding precision

• Tension stability

• Mechanical balance

• Automation functions

These tests ensure trouble-free product delivery to the field.

Commissioning and Training
Installation and commissioning of the machine are carried out by the DMR Tekno technical team. Operators are provided with detailed training on operation, maintenance, and safety.

After-Sales Support
DMR Tekno considers after-sales support an integral part of automatic winding machine projects.

Services provided:

• Technical service

• Remote support

• Spare parts supply

• Software updates

• System revisions

Advantages of DMR Tekno Automatic Winding Machines

• High-precision winding

• Project-specific design

• Advanced automation infrastructure

• Long-lasting mechanical structure

• Long-term technical support