* Specifications may vary
** Optional equipment
*** Expandable on request
² Approx. 400 KB (500 steps incl. comments)
³ Valid when spindle speed × traverse < 3600/min

🔧 Wire Tension – RWC301-V2-AG & RWC401-V2-AG

The diagram below illustrates the relationship between the winding radius and the resulting wire tension for the high-performance winding machines RWC301-V2-AG and RWC401-V2-AG.

Both models feature a robust, electronically controlled automatic 2-speed transmission. Unlike traditional belt-driven systems, shifting is managed dynamically by the control system depending on load and application:

• Gear 1: High torque at low speed – ideal for large wire diameters and high pulling forces
• Gear 2: Higher speed at reduced torque – suited for faster winding operations

These machines are optimized for wire diameters starting from 1 mm – suitable for round, flat, and edgewise-wound conductors. As the winding radius increases (e.g. with larger coils), the achievable wire tension decreases due to physical principles:

Power = Torque × Speed

Since the total machine power remains constant, an increase in speed results in lower torque – and thus reduced wire tension capability.

📈 Diagram Interpretation

• Green curves: RWC301-V2-AG – for medium to heavy-duty wire tension tasks
• Orange curves: RWC401-V2-AG – for maximum tension at large wire diameters
• Left Y-axis shows wire tension in Newtons (logarithmic scale, up to 15,000 N)
• Right Y-axis provides typical reference wire diameters up to 12 mm
• Wire tension decreases as winding radius increases

🧩 Practical Use

This diagram helps in selecting the appropriate drive configuration depending on:

• Target wire diameter (≥ 1.00 mm)
• Winding type: round, flat or edgewise
• Required tension range
• Coil size or winding radius

With automatic gear shifting, the RWC301-V2-AG and RWC401-V2-AG machines are ideal for high-performance winding in sensor and transformer production.

🔎 Note: On dual-spindle machines, the effective torque per spindle is halved. Actual wire tension also depends on the brake system and friction conditions.