The coil winding technology, which refers to the process of winding wires around a core to create electromagnetic coils, is a crucial component in several industrial sectors. Round wire winding technologies, in particular, continue to play a central role in key industries such as automotive, electronics, and renewable energy.
Globally, the demand for round wire winding systems remains high, primarily driven by the expansion of electrification in emerging markets like light electric mobility. In these contexts, round wire winding still represents the best choice in terms of cost-performance ratio. It is also the most straightforward option for manufacturers transitioning to the production of electric motors.
Technological innovation has become a key factor in this sector. To this end, both the United States and Europe are heavily investing in solutions that enhance efficiency, precision, and production speed. Automated and semi-automated winding machines are increasingly sought after due to their ability to handle complex configurations and minimize human error.
GROB Italy stands out in the field with three advanced solutions, specifically developed to address its customers’ needs.
1. Flip: enhancing efficiency at high frequencies
One of the most effective innovations introduced by GROB Italy is the “Flip” technology. This solution reverses the mid-positioning of wires during winding, thereby compensating for eddy currents generated in the stator pack, which can negatively impact motor efficiency—particularly at high frequencies. By utilizing the “Flip” technology, motor performance can be significantly optimized. This solution is compatible with both flyer and template-based winding machines..
2. Antitwist: controlled winding for multiple wires
The “Antitwist” system is a patented innovation that enables the stratified winding of coils with multiple parallel wires using flyer technology. This solution addresses one of the biggest challenges in coil winding: the precise and organized handling of numerous parallel wires. The Antitwist system allows for the simultaneous control and management of up to 24 wires, a capability previously unattainable with this type of technology. This advancement not only improves manufacturing efficiency but also ensures higher-quality end products.
2. Leads Twisting: streamlining the insulation process
The “Leads Twisting” system, recently patented by GROB Italy, marks another milestone in the optimization of coil winding processes. This technology twists copper leads at the end of the winding process, just before cutting. By doing so, it facilitates manual insertion of the insulating sheath, allowing the operator to perform the task with greater speed and precision while minimizing errors. Improper insertion of the leads into the sheath can result in rejections during electrical testing, leading to additional costs and inefficiencies. The Leads Twisting system not only improves the quality of manual operations but also enhances the overall efficiency of the manufacturing process.
