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In electrical engineering, coil winding is the manufacture of electromagnetic coils. Coils are used as components of circuits,and to provide the magnetic field of electrical machines such as motors and generators, and in the manufacture of loudspeakers and microphones. The shape and dimensions of a winding are designed to fulfill the particular purpose. Parameters such as inductance, Q factor, insulation strength, and strength of the desired magnetic field greatly influence the design of coil windings. Coil winding can be structured into several groups regarding the type and geometry of the wound coil. Mass production of electromagnetic coils relies on automated machinery.
Wild winding
Also known as jumble winding, with this type of winding structure only poor fill factors can be achieved. The random wire placement leads to a wider distribution of resulting wire length on the coil body and consequently a wider range of electric coil resistances. Despite its disadvantages, it is common in mass production. It is characterized by low demands for machinery and operator and can be wound with very high speeds. Wild windings are mostly applied in contactor- and relay coils, small transformers, Ignition coils, small electrical motors, and generally devices with relatively small wire gauges up to 0.05 mm. Achieved fill factors with the use of round wires are about 73% to 80% and are lower compared to orthocyclic windings with 90%.
The winding height can be estimated using the formula:
{\displaystyle h=d^{2}\cdot {\frac {n}{b}}} {\displaystyle h=d^{2}\cdot {\frac {n}{b}}}
{\displaystyle d} d - Wire gauge including the insulation
{\displaystyle n} n - Number of windings
{\displaystyle b} b - Width of winding
Wild Winding
Helical winding
Helical winding
The wires are placed helically in every layer. Owing to the direction of movement from layer to layer changing between right-hand and left-hand, the wires cross and locate themselves within the gap of the layer underneath. A wire guiding of the lower layer is not existent. If the number of layers exceeds a certain limit the structured cannot be maintained and a wild winding is created. This can be prevented with the use of a separate layer insulation, which is needed anyway when the voltage difference between the layers exceeds the voltage strength of the copper wire insulation.
Orthocyclic winding
Orthocyclic windingOrthocyclic wound coilOrthocyclic winding of a round coil
Orthocyclic winding of a rectangular motor coil
This type of winding structure creates an optimal fill factor (90.7%) for round wires. The windings of the upper layer need to be placed into the grooves provided by the lower layer.
In electrical engineering, coil winding is the manufacture of electromagnetic coils. Coils are used as components of circuits,and to provide the magnetic field of electrical machines such as motors and generators, and in the manufacture of loudspeakers and microphones. The shape and dimensions of a winding are designed to fulfill the particular purpose. Parameters such as inductance, Q factor, insulation strength, and strength of the desired magnetic field greatly influence the design of coil windings. Coil winding can be structured into several groups regarding the type and geometry of the wound coil. Mass production of electromagnetic coils relies on automated machinery.
Wild winding
Also known as jumble winding, with this type of winding structure only poor fill factors can be achieved. The random wire placement leads to a wider distribution of resulting wire length on the coil body and consequently a wider range of electric coil resistances. Despite its disadvantages, it is common in mass production. It is characterized by low demands for machinery and operator and can be wound with very high speeds. Wild windings are mostly applied in contactor- and relay coils, small transformers, Ignition coils, small electrical motors, and generally devices with relatively small wire gauges up to 0.05 mm. Achieved fill factors with the use of round wires are about 73% to 80% and are lower compared to orthocyclic windings with 90%.
The winding height can be estimated using the formula:
{\displaystyle h=d^{2}\cdot {\frac {n}{b}}} {\displaystyle h=d^{2}\cdot {\frac {n}{b}}}
{\displaystyle d} d - Wire gauge including the insulation
{\displaystyle n} n - Number of windings
{\displaystyle b} b - Width of winding
Wild Winding
Helical winding
Helical winding
The wires are placed helically in every layer. Owing to the direction of movement from layer to layer changing between right-hand and left-hand, the wires cross and locate themselves within the gap of the layer underneath. A wire guiding of the lower layer is not existent. If the number of layers exceeds a certain limit the structured cannot be maintained and a wild winding is created. This can be prevented with the use of a separate layer insulation, which is needed anyway when the voltage difference between the layers exceeds the voltage strength of the copper wire insulation.
Orthocyclic winding
Orthocyclic windingOrthocyclic wound coilOrthocyclic winding of a round coil
Orthocyclic winding of a rectangular motor coil
This type of winding structure creates an optimal fill factor (90.7%) for round wires. The windings of the upper layer need to be placed into the grooves provided by the lower layer.
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