CUSTOM-BUILT WINDING SYSTEM:
FROM SITE ASSESSMENT TO FULL PRODUCTION
WINDING MACHINE UPGRADE FOR PRODUCTION SCALABILITY AND STANDARDIZATION
A long-standing client reached out to Cleveland Automation Systems® needing a replacement for an outdated, custom-built winding machine. Originally fabricated using miscellaneous bar stock and non-standard parts, the equipment lacked any formal documentation, relied on manual controls, and couldn’t support scaling production efficiently.
Operators described the system as “inconsistent” and “difficult to dial in,” with varying results depending on who was running it. Replacement parts were often unavailable, requiring custom fabrication, and any process adjustments had to be made by trial and error using physical potentiometers. As production demands grew, this legacy setup became a major bottleneck.
Following our on-site assessment, we identified several systemic issues: absence of recipe control, no digital feedback or data visibility, no documentation for maintenance or troubleshooting, and no long-term path for scaling or repeatability. If left unaddressed, these limitations would continue to increase downtime, limit throughput, and expose the business to unnecessary operational risk.
CAS developed a fully engineered winding system upgrade—from site assessment to install. The new winding machine features intelligent motion control, real-time data collection, recipe-based operation, and off-the-shelf components for simplified sourcing. It’s designed to support future expansion, reduce operator variability, and bring the process into alignment with modern manufacturing standards.
SOLUTION
FROM SITE ASSESSMENT TO ENGINEERED WINDING SYSTEM
At Cleveland Automation Systems®, every successful solution starts with a thorough on-site evaluation—and this project was no exception. During our initial Site Assessment, our engineering team captured dimensional data, wiring configurations, mechanical specs, and current process parameters. We also observed operator workflow and gathered feedback from floor personnel to ensure we understood both the technical and day-to-day challenges.
From there, we launched our Project Kickoff (PKO)—a collaborative engagement that brings the CAS team and client stakeholders together to align on objectives, priorities, and timeline. In this case, the client’s key goals included:
- Standardizing the winding process across operators
- Creating a modular system that could be duplicated or scaled
- Eliminating obsolete and hard-to-source components
- Adding data feedback and recipe control for consistency
CONCEPT & ENGINEERING DESIGN
Our Mechanical Design Team generated initial concept layouts—focused on core motion requirements (rotation and traverse), operator interface, and long-term serviceability. These concept sketches allowed for collaborative iteration between the client and our engineers, ensuring we addressed every nuance of the product being wound and the desired coil spacing.
Once the direction was approved, we entered the Design & Detail Phase, using SolidWorks to develop a full 3D model of the winding machine. This phase included:
- Manufacturing-ready fabrication drawings
- A detailed Bill of Materials (BOM) using only off-the-shelf components
- Custom fixture design for consistent product loading
- Flame control mechanisms where needed
BUILD, INTEGRATION, AND FINAL ASSEMBLY
After sourcing all required components, our internal team moved into Mechanical Assembly, including:
- Frame fabrication
- DC motor integration for both rotational and traverse axes
Control panel build and field wiring - Encoder mounting and flame head configuration
As with all CAS solutions, this system was built with serviceability and future adaptation in mind—no black boxes, no mystery parts, and everything well-documented for future support.
INSTALLATION & SITE ACCEPTANCE TESTING (SAT)
Once the system was fully assembled and tested at our facility, Cleveland Automation Systems® delivered and installed the equipment at the client’s site. Our goal during this phase was to ensure seamless integration with minimal disruption to operations.
We managed the entire installation process—including rigging, anchoring, final wiring, and software configuration—then moved directly into Site Acceptance Testing (SAT). This crucial step ensured that the system not only met the design specs but also aligned with how the client needed it to perform on the floor, in real time.
Key SAT Activities Included:
- Verifying axis speeds and movement tolerances
- Testing and fine-tuning the traverse-to-rotation synchronization for uniform coil spacing
- Configuring and validating recipe parameters for different product variants
- Calibrating the IO-Link encoder to measure rotations and linear travel
- Validating all alarms, interlocks, and fault responses via the Ignition HMI
By the end of SAT, operators were trained and comfortable using the new interface, the system was running cleanly, and the client had full confidence in its repeatability. This wasn’t just a machine—it was a fully integrated, production-ready winding solution.
SYSTEM REQUIREMENTS & SPECIFICATIONS
To deliver a fully functional winding and coiling system, Cleveland Automation Systems® engineered a solution that could handle multiple product types, reduce manual inputs, and deliver precise, repeatable performance.
Core Requirements Included:
- Component Standardization: Replace obsolete, hand-built components with off-the-shelf parts for easier sourcing and future maintenance.
- Recipe Management: Allow operators to select pre-set parameters (speed, length, spacing) via the HMI, reducing guesswork and ensuring consistency.
- Multi-Variant Production: Design the system to handle coiled products with different starting geometries (straight, bent, or mixed).
- Rotation & Traverse Coordination: Precisely synchronize the rotation and linear motion to control coil spacing and count.
- Motion Feedback & Validation: Capture total degrees of rotation and linear travel to ensure product specifications are met in real time.
- Scalability & Training: Provide documentation and system architecture that supports easy scaling, operator training, and spare parts management.
Meeting these requirements ensured the client had a machine that was not only reliable and accurate—but also flexible, operator-friendly, and future-proof.
HARDWARE & TECHNOLOGY INTEGRATION
To meet performance requirements while ensuring long-term maintainability, CAS specified a robust suite of industrial-grade hardware and software. Every component was chosen for its reliability, compatibility, and ease of sourcing—ensuring zero reliance on obsolete parts.
Key Technologies Deployed:
- DC Motors with Variable Speed Drives
Enabled precise control of both rotational and traverse motions. Operators can now adjust speed directly from the HMI—eliminating manual potentiometers and improving setup efficiency across product types. - IFM IO-Link Encoders
Provided real-time measurement of rotation degrees and linear distance. This feedback loop ensures consistent coil spacing and accurate production of varying geometries. - Allen Bradley CompactLogix PLC
Delivered centralized control using CAS’s standardized code libraries and AOIs. This allowed for scalable programming, simplified troubleshooting, and seamless integration with other systems. - OnLogic Industrial Panel PC
Hosted the Ignition Perspective HMI, giving operators an intuitive interface to input recipes, monitor performance, and adjust motion parameters on the fly.
By combining proven hardware with flexible software architecture, CAS ensured the system was not only tailored to the client’s current process—but adaptable for future needs.
SOFTWARE & CONTROL STRATEGY
The software stack for this machine was built to prioritize precision, repeatability, and operator ease—all within a standardized CAS framework for long-term support and scalability.
Control Architecture Highlights:
- Standardized PLC Logic
CAS deployed internally developed code libraries and reusable AOIs within the Allen Bradley CompactLogix platform. This allowed for robust motion coordination, simplified diagnostics, and streamlined future updates or system expansions. - Ignition Perspective (Inductive Automation)
Served as the backbone of the HMI. This web-based platform allowed for:- Real-time visualization of coil progress, motor speeds, and sensor feedback.
- Direct input of product-specific recipes (speed, pitch, travel distance).
- Logging and storage of production data for traceability and quality control.
- Recipe Management System
Operators can easily load, adjust, and store coil-specific parameters through a user-friendly touchscreen interface. The recipe structure allows for complete control over:- Start/end lengths
- Coil pitch and spacing
- Travel speeds
- Flame length (if active)
By standardizing the codebase and empowering operators with visual, intuitive controls, the system created a more responsive, data-driven workflow—reducing setup time, minimizing operator error, and supporting consistent product quality.
OUTCOMES & MEASURABLE BENEFITS
The completed system didn’t just meet expectations—it redefined what was possible for the client’s coiling process.
Key Results:
- 100% Elimination of Obsolete Components
Every component—from motors to encoders to control panels—was replaced with readily available, off-the-shelf technology. The client can now order spares without chasing down legacy parts or relying on tribal knowledge. - Up to 60% Faster Setup Time
What previously required manual speed adjustments and trial-and-error positioning is now controlled through saved digital recipes. Operators can change products and start production with just a few taps. - Increased Product Consistency
The use of IO-Link encoders and integrated feedback loops enabled precise monitoring of both rotation angle and travel distance, resulting in tighter coil spacing tolerances and reduced scrap. - Improved Operator Confidence
With intuitive HMI controls and real-time visibility into machine status, the learning curve for new operators dropped significantly, and day-to-day interaction became safer and more predictable. - Scalability for Future Growth
Because of the modular software design and standardized hardware platform, the client now has the ability to:- Expand to multiple coil sizes or product SKUs
- Integrate additional downstream automation
- Enable remote diagnostics or IIoT functionality in the future
The result? A purpose-built, production-ready coiling machine that not only solved immediate reliability issues but also gave the client a future-proof platform to build on.
CUSTOMER BENEFITS & TESTIMONIALS
Beyond the technical success of the build, the impact on the client’s daily operations was immediate and tangible.
What the Client Gained:
- Operational Uptime and Reliability
With all obsolete components eliminated and system diagnostics built in, unplanned downtime has been significantly reduced. Operators no longer rely on manual adjustments or makeshift repairs to keep production moving. - Ease of Use & Training
The touchscreen HMI reduced training time for new staff. The client described the system as “surprisingly intuitive,” with one operator saying, “I can run this whole setup with just a few inputs. It does the hard part for me.” - Inventory & Maintenance Planning
The clean bill of materials, developed collaboratively during the design phase, gave the client full visibility into every component used—enabling faster ordering, better stocking decisions, and simplified preventive maintenance scheduling. - Confidence in Future Expansions
The client now sees this machine as a template for other production areas. Thanks to the modular, scalable design, they’re considering expanding this format to other product lines—a testament to the success of this system.
“This is the kind of equipment we’ve always wanted—built for us, but with flexibility for what’s next.”
— Engineering Manager, Client Team
TECHNOLOGIES & VENDOR PARTNERS
Delivering a reliable, scalable, and serviceable automation solution required a thoughtful selection of hardware, software, and supplier support.
KEY TECHNOLOGIES USED
- Allen Bradley PLC
Powered the core control logic using CAS’s standardized codebase and AOIs (Add-On Instructions), ensuring seamless integration with future automation modules. - IFM IO-Link Encoder
Enabled precision tracking of rotational degrees, linear distance, and product placement—crucial for coiling consistency. - OnLogic Industrial PC
Served as the HMI platform, providing a rugged, industrial-grade interface with fast data access and high uptime performance. - Ignition Perspective (Inductive Automation)
Delivered a modern, browser-based HMI for recipe management, real-time control, and remote monitoring capabilities. - SolidWorks
Used for detailed mechanical modeling and documentation, including fabrication drawings and exploded views for assembly and maintenance.
VENDOR & PARTNER CONTRIBUTIONS
- Rockwell Automation
Provided the PLC architecture and platform tools central to the control logic. - Rexel
Sourced major components with strong lead time reliability.
Contacts: Kristopher Franz & Melanie - IFM
Supported encoder integration and application engineering.
Contact: Mike Bruckner - Ignition / Inductive Automation
Enabled flexible HMI development and remote diagnostics tools. - AutomationDirect
Supplied key motion control components and contributed to budget-friendly procurement.
CONCLUSION & FUTURE OUTLOOK
By transforming an aging, one-off system into a fully engineered coiling solution, Cleveland Automation Systems® delivered measurable operational gains and long-term value for the client.
The completed system not only replaced obsolete components with modern, off-the-shelf hardware—it also introduced new levels of control, flexibility, and repeatability. Operators now have the ability to select product-specific recipes, adjust speed and spacing with precision, and monitor production in real time. All components are documented, easily sourced, and supported for future maintenance or upgrades.
Key Outcomes:
- 100% of components are readily available from multiple suppliers—no custom black-box parts
- Operator setup time reduced significantly with recipe-based inputs
- Consistent product quality across multiple product types
- System ready for future integration with IIoT, remote monitoring, or predictive maintenance features
Looking ahead, this project has laid the groundwork for a new generation of purpose-built equipment within the client’s operation. With standardized PLC code, scalable hardware, and a modular design approach, CAS has enabled the client to confidently scale production and simplify long-term system management.
FROM CONCEPT TO COMMISSIONING—PARTNER WITH CAS FOR TURN-KEY AUTOMATION SOLUTIONS
This case study showcases how Cleveland Automation Systems delivered a fully engineered, custom-built winding system—from initial site assessment to final installation—eliminating legacy challenges and future-proofing operations.
If your team is looking to replace aging, one-off equipment or scale up with a fully integrated solution, explore our Turn-Key Services. CAS provides complete, start-to-finish systems built around your needs—designed to increase control, enhance quality, and deliver real-world results.
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About the Author: Rylan Pyciak
Rylan Pyciak, CEO of Cleveland Automation Systems™, is a Systems and Control Engineering graduate from Case Western Reserve University. With expertise in PLCs, robotics, and industrial engineering, Rylan leads CAS in delivering innovative automation solutions. Passionate about mentoring future trades professionals, he combines technical knowledge with a commitment to fostering sustainable growth in manufacturing.