Abstract: To reduce the two-operator dependence and inconsistent manual tension in winding connecting wires longer than 1 m, an automatic long-wire winding machine was designed and retrofitted. The system uses an FX5U-32MT/DS PLC. Pulse and direction signals from Y0/Y1 control the stepper drive, while an adjustable receiving table, pneumatic straightening, clamping transfer, and rotary unloading mechanisms complete the process. Turn commands are converted at 1600 pulses per revolution, and high-speed count verification and sequential control provide interlocking. Field application reduced direct staffing for one machine from two operators to one and improved operational continuity and consistency.