Leading Coil Winding Manufacturers

How a Coil Winding is Made

When discussing coil windings, there are two factors that need to be considered. The first is the core that can be made of plastic, steel, iron, aluminum, or other materials. The type of core increases the inductance, its ability to store electric energy. The best type of core is ferromagnetic since it focuses the magnetic field and increases inductance.

The next factor in coil winding is how the wire is wound, a factor that controls the efficiency and conductivity of the coil. The winding is a form of current carrying conductor that is wound around the core, which must be properly insulated and supported to be able to withstand the operational parameters. The primary materials for winding wire are aluminum and copper with copper being the most used due to its excellent conductivity.

Winding of Coils for a Coil Winding

Though the concept of winding is relatively simple, there are a variety of ways that a coil can be wound. An important part of planning a coil winding is the fill factor, or winding factor, which is the of number turns, area of the wire, and the window area. How the winding is completed determines the efficiency and performance of the coil.

All coil windings have more than one coil wound around the core. How the different layers interact is another factor regarding the winding and is a measure of the fill factor. The types of coil winding are wild, helical, orthocyclic, pancake, and toroidal. The key to the winding process is that the wires fit tightly and closely to eliminate air flow or space, which increases the efficiency of the coil.

Types of Coil Windings

Wild or jumble windings are a very common type of winding for mass production of coils. The wires are randomly placed around the core, which creates wider distribution resulting in a wide range of coil resistance. This type of winding leads to poor fill factors. Wild windings are found in relay coils, small transformers, ignition coils, and small motors with a fill factor of 73% to 80%.

Toroid winding is unlike the normal winding of wire around a core. This type of winding has the wire wrapped around the outside of a donut shape where it is evenly distributed around the circumference. Toroid coils are used with low frequency electricity where the coil serves as an inductor.

Orthocyclic windings have a fill factor of 90%. When the wire is being wound, using round wire, the upper layers are carefully placed in the grooves of the lower layer, which limits the amount of air flow and space. The windings must be placed exactly at 60o of the coil circumference to achieve the proper efficiency. If the winding is not done properly, a wild winding is the result.

Helical windings have the wires placed helically on each layer where the direction of the wires change from layer to layer. At first, they are wound left to right for the first layer and then right to left for the second layer. In the process, the wires cross themselves and fill in the gap between the wires. The number of layers for this type of winding is limited to prevent it from becoming a wild winding.

Purpose of Coil Windings

Coil winding is an essential part of the production of electronic equipment and serves as the core for a wide variety of components. The more technical and complex the device, the more likely the winding is done very efficiently and precisely to ensure proper conductance.