Automated Production Line for Automotive Solenoid Coils

Winding Equipment We Trust — Tested in Our Own Production

The process utilizes an automated assembly line workflow encompassing winding, welding, and inspection. A robotic handling arm automatically grasps the bobbin and loads it into the winding machine; upon completion of the winding process, resistance welding is automatically performed to bond the enameled wire to the terminal pins. Following the welding stage, a CCD vision system conducts inspections to verify flatness and resistance values.

Winding MaterialCopper / Enameled / Litz / Aluminum / Flat / Self-bonding / etc

Winding Precision± 0.01mm

Winding TurnsCustomizable (1T – 10,000T)

Minimum Order QtyCustomizable

Lead Time7–15 business days

Payment TermsT/T, L/C, Western Union

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Typically responds within 24 hours · Free samples available

30+ Years Experience

ISO Certified Factory

Shipped to 30+ Countries

Dual-station winding operation.

Supports terminal wrapping; winding can be performed in both vertical and horizontal orientations.

Ensures precision winding without wire crossovers or stacking defects.

Automated flatness inspection via CCD vision. Compliant parts proceed to manual re-inspection; non-compliant parts are automatically diverted to a locked NG bin.

Rapid changeover with fully interchangeable quick-change fixtures.

Termination: Pneumatic shearing/snapping with dedicated scrap collection.

7-inch LCD touchscreen with visual teaching for WYSIWYG programming.

(Merged with item 4).

Locked NG bin prevents unauthorized reuse of defective parts.

Electrode life counter with pre-warning alerts for tip dressing or replacement.

Controlled process ensures zero weld spatter or missed welds.

Automated resistance testing with auto-sorting of NG parts.

AC servo-driven spindle and X-Y-Z axes for high-speed, precision positioning.

Ergonomic control panel with dedicated Start and Emergency Stop buttons.

WHY WISRSUN?

❖ The motion controller is paired with a specialized closed-loop intelligent fine-tuning dense-winding control technology. Its patented closed-loop wire-laying sensor utilizes digital sampling technology, offering robust anti-interference capabilities, precise control, and superior wire-laying performance.

❖ Closed-Loop Tension Control: The controller is capable of programming and monitoring every dual-motor active servo tensioner within the system, and monitors and uploads the tension status of the entire production process in the form of data.

Applications

Smartphones & 3C Electronics

Automotive Electronics

Industrial Sensors

Precision Instruments

Audio Equipment

Wireless Charging

Our standard MOQ is 500 pcs for most coil types. For first-time customers or prototype evaluation, we accept small trial orders of 10-50 pcs. MOQ may vary by product complexity. Contact us for a specific quote.

Yes. Samples are available within 5-7 business days after engineering confirmation. A nominal sample fee applies, which is credited toward your first mass production order.

You can email drawings such as PDF, DWG, or STEP files, or fill out our inquiry form. If you do not have drawings, a written description or physical sample is also acceptable.

We can wind wire as fine as 0.01mm using Zongheng CNC precision winding machines with automated tension control.

Yes. Our special-shaped coil series handles non-circular and irregular geometries. Submit your drawings and our engineering team will assess feasibility.

Standard options include bare copper wire, enameled copper wire, and Litz wire. Custom alloy or coated wire options are available on request.

Yes. Provide your target inductance, frequency, and DC resistance requirements, and we will calculate and wind to specification.

WIRESUN is ISO 9001 certified. Products can ship with test reports and COA. Third-party inspection can be arranged upon request.

All coils are wound on CNC machines with precision control. Each production batch undergoes electrical testing, including inductance, DCR, and impedance checks.

Standard documentation includes packing list, commercial invoice, Certificate of Analysis, and electrical test report. RoHS/REACH documents are available upon request.

We ship worldwide. Regular destinations include Southeast Asia, Europe, the Americas, the Middle East, and Russia. Express and sea freight options are available.

Standard terms are 30% T/T deposit upon order confirmation and 70% balance before shipment. L/C is accepted for larger orders, and Western Union is available for sample fees.

Standard products usually take 15-20 business days. Complex custom coils generally take 20-30 business days. Final lead time is confirmed at quotation stage.