The Autowinder AW1 consists of the following components:

Drive Unit
The drive unit consists of the traversing carriage for mounting of the laser sensor and the wire guide roller, a guide rail for guiding the carriage and a stepping motor as the drive.

Laser Sensor
The laser sensor consists of two sensor units. A guide roller is located symmetrically between the two sensor units. Thus the shape of the spool and the wire can be measured foreward in both directions.

The terminal is used for input, storage of winding data and for operating and display of winding data while running operation.

The controller controls and regulates the wire traverse. In the controller all data input via the terminal are stored, so that an operation is possible without a terminal.
Also, the controller has an interface via which a simple communication with a SPS is possible.
There is also the possibility to use the Autowinder via a simple switch. Thus, several Autowinder can be operated with only one terminal.



The sensor works on the principle of laser triangulation. It continuously measures the contour of the winding material as well as the spool flanges and transmits it to the controller. The controller itself determines the spool dimensions and the necessary reversal points of the traverse.

In case of winding mistakes at the flange (peak or valley), they are also detected and  regulated by steady correction of the reversal point. For this, the normal height of the current wire laying is compared with the height of the flange. If there is a difference, either a peak or a valley, the reversal point is accordingly moved to the inside or outside direction.

The control process is universal, because it always evaluates the current situation.

This has the following advantages:

  • it does not matter where the winding errors occur, if by overrun behavior of the wire, tolerances of the spool, deformed flanges, not adjusted wire guide rollers, asymmetry in vertical operation, etc.
  • any types of spools can be processed, such as cylindrical, biconical and spools with conical core.
Trouble winding on a A250/400 test spool before winding continues with the new traversing system
Condition of the test spool shown in the beside fig. after continued winding with the new traversing system

For proper function, the Autowinder must be installed parallel to the coil axis. Furthermore, the distance between the sensor and the spool axis is to be selected in the way that the smallest spool core as well as the largest flange lie in the measuring area.
By manufacturer the wire guide roller is positioned symmetrical between the two channels of the sensor, where the corresponding foreward moving channel is active.
This is a key design feature of the KMK Autowinder, because the sensor detects the temporary state of the winding as well as of the flange shortly prior to the actual point of contact between wire and spool and transmit it to the controller. The controller then immediately can make appropriate corrections already in the same winding layer.

The Autowinder offers two options for wire traversing: synchronous mode and constant mode.

In synchronous mode the wire traversing starts and stops together with the winder. The traversing speed is proportional to the spool rotational speed and thus generates a constant winding pitch along the entire spool. For this, a speed sensor for the spool speed is needed.

In constant mode the traversing is started and stopped manually and the traverse carriage travels between the reversal points back and forth at a constant speed.

The traversing system is operated by means of a practice-oriented hand device with a display and allows free programming of several winding places.

A stepper motor is used to drive the traverse. It has a high acceleration capacity, long lifecycle and can be operated affordably.

The KMK Autowinder can process copper wires and high-gloss wires. With modified control it is well suited in bunching machines!

Product movie

KMK-Getriebebau · Tel.: +49(0)431-641708 · kmk-kiel(at)
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