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The armature winder is a development of 3-axis needle winding technology that has been customised for manufacturing DC armatures.

This machine uses a PC, with three phase-locked servo drives and proportional cable tension control to wind the product. It provides consistent quality products without operator intervention. The winding pattern is stored on the PC hard disk and can be edited, using the installed software to create patterns for new products.

The invention of the 'hedgehog' to control the wire loops for commutator terminations was key to the process. The armature winder uses high power, brushless servos, belt drives and linear slides to provide tensions of up to 1000N at 10g acceleration and phase locked speed of 4 m/s. This is achieved whilst guiding the needle and wire in the stator slot with only 0.2 mm clearance.

Products from 25mm diameter to 200mm and up to 600mm long can be wound on the machine.