Winding
High Voltage Potting & Coating (HVPC) has several possibilities to carry out your winding work. You have the choice to wind coils and transformers manually or mechanically. We also have various coil-winding techniques and winding machines available. The winding can be part of an entire production process, but we are also at your service for single winding work. The winding work that HVPC does is customer-specific and tailor-made. The required winding moulds are often designed by HVPC.
Mechanical winding of coils and transformers
Mechanical winding is preferred over manual winding because of its reproducibility. It is also possible to wind more tightly with thinner wire and it is also easier to scale up to several windings. In addition to cyclic coils/transformers, there are also cores available for machine use where the wire has to be wound through, the so-called toroidal core winding. Cross-winding, which is particularly important for high-voltage products, is also possible. HVPC has at least 1 machine operational for each type.
Wire winding techniques
HVPC has several cyclic winding machines, a toroidal core machine and a cross-winding machine. We can provide cyclic winding, toroidal winding and cross winding with various wire thicknesses, winding widths and outer diameters. Partly,these can also be wound manually. However, mechanical winding is a better option because of its reproducibility, and it is cheaper for the customer. In case of difficult geometries, we opt for manual winding, as this requires extra complexity. When winding coils, winding moulds are usually made, as the coils have to remain within certain dimensions.
The following table shows the most common winding specifications. Should you require other specifications for your product, this is certainly possible.
|
|
Cyclic winding |
Toroidal winding |
Cross winding |
|
Wire thickness |
0.05 - 6 mm |
0.05 - 1 mm |
0.05 - 1 mm |
|
Winding width (max) |
460 mm |
25 mm |
12 mm |
|
Outer diameter |
3 - 400 mm |
3 - 51 mm |
3 - 120 mm |
|
Inner diameter |
|
from 1 mm |
|
Manual winding of coils and transformers
In addition to mechanical winding, HVPC also offers the possibility of manual winding. Customers choose manual winding if mechanical winding is not possible. This may be due to the high voltage, a large diameter wire through a small toroidal core or a deviating geometry. When winding manually, it is important that it is carried out as accurately as possible. An advantage of manual winding compared to mechanical winding is that very small series (starting from 1 piece) can be made with a fast turnaround time.
Choose the right wire for your product
If you don’t know which wire is best for your product, HVPC will be happy to advise you. You can choose from various types of wire such as insulated hook-up wire, flexible and solid Litz wire, profile wire and adhesive wire. Do these types of wire not meet the specifications of your product? Then it is also possible to wind with copper foil in various thicknesses and widths. Copper foil has an additional function in addition to volume density: it can act as a static shield for the operation of the transformer from primary to secondary.
Winding under cleanroom conditions
Both mechanical and manual winding is carried out under cleanroom conditions. However, to wind high-frequency or unique pulse transformers in combination with external high voltage in a reliable product requires more than just clean production conditions. Special materials and geometries will be used to keep possible field strengths within limits. HVPC can help you design your coil and/or transformer and choose the right material for your product. This will eventually result in a very high MTBF (Mean Time Between Failure) of the high-voltage transformers and/or pulse transformers. Transformers and other inductive components are subject to increasingly high demands, together with the required core or ferrites.
HVPC also has experience in the custom grinding of ferrites, so that they can be applied in customer-specific products.