Address

10 Street Name, City Name

Country, Zip Code

Get in touch

970-461-1348

inside.sales@mdsusa.net

Gigatron - Coil-Winding Feeder

Wire - Constant Tension Feeding device

Advanced High Tech Solutions for Coil and Motor Winding Process Control

Gigatron is one of the latest results from BTSR INTERNATIONAL, a worldwide leading company in the design of high tech solutions and innovation development in a wide variety of industrial sectors.

Gigatron the Ultimate in Wire Constant Tension Feeding.

Gigatron represents a revolutionary new generation Wire Constant Tension Feeding device, unique in terms of functionality and performance, capable of adjusting with utmost accuracy the tension of the wired in motor and coil winding processes.

An innovative Solution based on the BTSR Dual-Drive Feeding System, Tension Profiler Function and Double Loop Control System bringing new and unique measurable benefits in terms of TOP Quality Control and Production Efficiency in coil winding processes.

MAIN BENEFITS

TOP Quality Standards Goal

is ensured by the highest coil winding quality and repeatability, thanks to BTSR ‘Double Closed Loop’ Technology guaranteeing the most accurate and precise wire tension control.

TOP Versatility

is guaranteed by Fully programmable parameters according to the wire requirements and possibility to dynamically modify the wire control tension according to the operating stage (‘Tension Profiler’ Function).

TOP Process Production Efficiency

is enhanced by dramatic reduction of wire breakages

TOP Productivity

is guaranteed by the capability to work at the maximum possible process speed.

Minimized Labour Costs

is possible thanks to the user-friendly programming options.

A wide application range

is possible thanks to the wide wire tension and diameter range of Gigatron

Centralized programming and monitoring

is possible thanks to MATRIX TOUCH COIL controller which will allow to program and control Gigatron units and monitoring the whole process production status also in graphical form.

Features

Advanced Digital Display for real-time operational information reading.
Ergonomic Keys for easy operation and synchronized alarm signaling
Automatic Compensation Arm for wire 'Storage and Release'
Dual Drive Feeding System for controlling and maintaining a constant winding feeding tension
Wire pretensioner cleaner and high accuracy tension sensor load cell
MATRIX TOUCH COIL allows to memorize, load, visualize and control even in graphic way the wire tension, speed and wire consumption (LWA)

Technical Features

Display tension range 0 grams – 20.000 g (cN)
Programmable tension range 200 g ÷ 18.000 g (cN)
Wire diameter 0,08 ÷ 1,5 mm - 40 ÷ 14,5 AWG
Wire diameter range: From. 0,12 Up to 2,25 mm 36,5 up to 11,2 AWG
Feeding speed range 0 ÷ 12,5 m/s - 0 ÷ 750 mt/min
LWA function: exact wire consumption measuring (Length Wire Absorption) with resolution of 1 mm
AUTO-LWA and alarm range setting Tension LWA ± 1 % upto ± 25 % Meter LWA ± 0,1 mt up to 10 mt
OEM machine computer interface Standard : RS485, Canbus Optional : Profinet, Ethernet IP, Ethercat Other on demand
Power supply voltage 48VDC ± 10%
Overall Dimensions (mm) 600 L x 126 W x 170 h
Minimum Air Pressure 4 bar
Weight: 14.3kg

APPLICATIONS

Main Application Processes

Single flyer winding (STATOR MOTORS)
Needle Winding (BRUSHLESS MOTORS)
Double Flyer (ARMATURE MOTORS)

Main Manufacturing Sectors

Automotive
Power tools
Transformer industry
Electric bicycle

Gigatron Product PDF

DOUBLE CLOSED CONTROL LOOP (BTSR Patent)

MOTOR TORQUE (BTSR Patent)

1st closed loop

Total Input Controls

Operated by the motor control force (Torque). Detects and adjust any input wire tension variation caused by:

• Input tension variation (full/empty feeding bobbin)

• Input wire entanglement

LWA Length of Wire Absorbed (BTSR Patent)

2nd closed loop

Total Output Controls Operated by means of multiple motor controls, Speed/Wire consumption.

Detects and monitor:

• Any dimensional variation of coil formers.

• A wrong wire dimension (diameter/AWG).

• Accumulation of dirtiness inside the wire guide

• Damage of the wire guide.

• Any mechanical variation or friction on the contact points after the tension feeder device (Minitron - Megatron - Gigatron).

• Wire passing through the wire guides with different angles and frictions (wrong thread-up).

CONSTANT TENSION VALUE GUARANTEED

Output Wire Tension (LIGHT BLUE color) is kept constant at the set value, despite of input wire feeding tension variations (RED color) and/or wire speed variations (GREEN color) during the working process.

MATRIX TOUCH COIL TERMINAL

Centralized programming and monitoring is possible thanks to MATRIX TOUCH COIL controller which will allow you to program and control MINITRON - MEGATRON - GIGATRON units and monitoring the whole process production status also in graphical form.