Optimization for wire tensioners

The tensile force is one of the most important parameters during the winding process with a considerable impact on the quality of the coils produced. Electronic tensioners usual in trade are not able to compensate fluctuations of the tensile force satisfactorily, when bobbins with a non-circular cross-section are wound. In this case considerable fluctuations result from the accelerations taking place during the whole winding process. Two different approaches are presented in this paper to keep the tensile force within a restricted tolerance range in order to facilitate a perfect layer winding and to reduce the mechanical stress of the wire.