That way an unnecessary bending of the wire is being avoided and the needs space for the second winding step is minimized.įor Orthocyclic wound coils, the winding step areas is always located at the area of wire entering the winding space and is continued in helical form against the winding direction. It should be recognized that the wire needs to enter in a possibly flat angle into the winding space. Overall, the first intruding wire mainly determines the location and quality of the winding step. If the winding step cannot be executed properly then the self-guiding ability of the wire is lost, and a wild winding is produced. The area of the winding step is dependent on the wire gauge and coil bobbin geometry. The winding step can occupy an area of up to 60 degrees of the coil circumference for round coil bobbins and takes one side of rectangular coil bobbins. When the winding has been placed around the coil body it will meet with the previous positioned wire and needs to make a step with the size of the wire gauge. The best volume use is found when the winding is parallel to the coil flange for most of its circumference.

To speak with a sales representative, contact us regarding your requirements. MWS skilled technicians produce the highest-quality magnet wire used in custom windings. To achieve higher fill factors, rectangular, square or flat wire can be used. Since round wires will always have some gap, and wires also have some space required for insulation between turns and between layers, the fill factor is always smaller than one. The ratio of the area of electrical conductors, to the provided winding space is called “fill factor”. Parameters such as inductance, energy loss ( Q factor), insulation strength, and strength of the desired magnetic field greatly influence the design of coil windings.Įfficient coils minimize the materials and volume required for a given purpose. The shape and dimension of the wire used in a coil winding are designed to fulfill a specific purpose.

Coils provide the magnetic field of motors, transformers, and generators, and are used in the manufacturing of loudspeakers and microphones.

Flat wire helical power inductors