Resistance welding and optical quality control of copper coils

Individual Systems by AUTFORCE

We had the opportunity to prove our competence in the field
of individual plants with a winding plant for copper coils.

The project

An existing winding plant for copper coils was integrated into a new, digitally connected plant. The aim of the project was to convert the existing plant so that it could be used for the production of different types of magnetic coils. The coils are transferred to further process steps and undergo optical quality control after being resistance welded. It was particularly important for us to make the best possible use of the existing equipment and to implement an optimal automation solution on the available production area.

Our services ranged from the mechanical design to the mechanical construction, the risk analysis, the electrical planning, the control cabinet construction, the electrical installation, the control programming, as well as the supply of the hardware.


  • plant consisting of three units: Separation unit, winding machine and resistance welding station including camera checks.
  • cycle time: 10 seconds
  • fully automated system with an autonomy time of 30 minutes (after which the feed pots have to be filled again by the operators)
  • currently the plant is designed for two types, but a third type has been included in the planning
  • compact, ergonomic design
  • low set-up effort
  • flexible reference part mode implemented for camera system verification
  • reuse of components from the old plant
    (base frame, rotary indexing table, conveyor belt)


Thanks to the compact, ergonomic design, the available space was used in the best possible way.


The system can be expanded to include additional types with little effort.


A large part of the components of the existing plant were reused. (base frame, rotary indexing table, conveyor belt)

Minimize errors

Seamless quality assurance by using camera inspection minimizes the error rate of your production.

Step 1

The robot removes the coils wound by the winding machine and places them in a transfer nest by using a double gripper. This transfer nest then loads the rotary indexing table.

Removal of the coils

Welding of the coil formers

Step 2

At the rotary indexing table, the contacts of the coilformers are welded with a welding head.

Step 3

Am Rundtakttisch werden die Kontakte der Spulenkörper mit einem Schweißkopf verschweißt. The welding contacts are then checked for accuracy and quality by two Keyence cameras.

Camera inspection

Coil former removal

Step 4

In the next step, the coil formers are removed from the rotary indexing table via a transfer nest and then deposited in the IO or NIO rack via robot. The removal of the horde is done by a conveyor belt.

Are you interested in an individual plant?

Let’s talk!