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Automatic Wire Coiling Machine
A UK client contacted us regarding maintenance / servicing on a custom built automatic wire coiling machine. This machine is a high-end piece of equipment, costing over £500,000 at the time of purchase. It had undergone over 250,000 cycles without maintenance; whilst still operational, it was flagging errors during cycles, forcing the operator to manually clear them, more than doubling cycle time. The client requested that we resolve the errors and perform a service on the machine.
With such an expensive and unique piece of machinery, it is critical to work extra carefully. Our engineers started by learning to operate the machine, understanding the working principles and reproducing the error in real time.
Using the service panel, individual actuators were tested and confirmed to be functional.
Automatic coil winding machine. A custom piece of high-end machinery
Pneumatic system at the rear of the machine
Cable + pressure lines underneath the machine
The faulty linear actuator (bottom) with pressure lines removed for testing.
The problem: a pneumatic linear actuator, with two hall sensors confirming the retracted and extended positions. One of the sensors had slipped slightly after the high number of cycles, failing to provide a positive reading for the extended position. This was adjusted to be placed in the correct position, and tested to ensure it was working as intended.
During the process of searching for the faulty sensor, a loose ground connection was discovered which was causing a breaker to occasionally trip, forcing the machine to shut down. This was correctly connected in accordance with the wiring diagram. The machine was cleaned of debris, re-lubricated and remaining sensors of actuators were readjusted to avoid the same problem in the future.
Once more, the machine was tested and confirmed to be working without error. Cycle time was reduced to less than half its previous value, fully restoring automated operation. The client was provided with a detailed service report outlining the faults found, corrective actions taken, and preventive measures recommended.
Whilst the machine was still operational, the high number of cycles without attention meant it was only a matter of time before a critical failure occurred — potentially leading to costly unplanned downtime, expensive part replacements, or even permanent damage to the machine. Proactive maintenance not only restores performance and reliability but also protects your investment, maximises uptime, and ensures long-term operational continuity.
If you have a piece of machinery, no matter the complexity, our engineers will take time to understand it and work carefully, protecting your asset. Get in contact to discuss your particular needs, we are always happy to talk.