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This behavior can be observed especially in the needle winding technology. For orthocyclic wound coils, the winding step areas is always located at the area of wire entering the winding space and is being continued in helical form against the winding direction. The wire places itself into a prefabricated groove geometry of the coil body and the wire guide does not need to follow it exactly but only approximately. In certain circumstances it can be completely performed without a relocating movement, if the distance from the nozzle to the coil is that long that the force component against the guiding behavior of the wire itself has no longer an effect. Also known as jumble winding , with this type of winding structure only poor fill factors can be achieved. In general, it can be stated that the requirements that need to be fulfilled for orthocyclic windings are very high. The design or interpretation of the required space of an orthocyclic winding is usually realized by applying an iterative approach. Owing to physical reasons, it is unavoidable that the wire leaves the wire guiding nozzle at an angle of approx. In the linear winding method, a winding is produced by winding the wire onto a rotating coil body, component or coil carrying or coil forming device. The coils should be rather small, in order to avoid a contact with the neighboring coil or the sheet metal package. The rotary motion as well as the laying movement is achieved by using computer controlled motors. 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. In relation to one rotation of the rotation axis and depending on the wire diameter, the traversing axis of the wire guiding tube is moved accordingly traverse pitch. Despite its disadvantages, it is common in mass production. Owing to the self-guiding behavior of the wire, it is therefore possible that also during orthocyclic winding the wire guide can run continually and does not need to follow gradually. The best volume use is found when the winding is parallel to the coil flange for most of its circumference. The wire is fed through a guiding tube. This movement is called winding step. Square coils are seen as orthocyclically wound when the winding and layer jump occur only on one of the sides of the winding cross-section. As a result, orthocyclic wound coils with a round coil ground are never circular in the cross over section, but the radial moving winding and layer step creates a hump shape. For the reasons described above, it is therefore in practice impossible for the wire guide to determine a precise gradient according to the wire diameter. Therefore, mechanical tensions remain inside the wire that are visible in the form of a bent winding on the winding basis. The ratio of the area of electrical conductors, to the provided winding space is called "fill factor". For orthocyclic round coils three winding geometries can be defined:. Parameters such as inductance , Q factor , insulation strength, and strength of the desired magnetic field greatly influence the design of coil windings. By the linear laying movement of the wire guiding tube, the component to be wound is turned in a way that the wire is distributed throughout the winding space of the coil body. Coils are used as components of circuits, and to provide the magnetic field of motors, transformers, and generators, and in the manufacture of loudspeakers and microphones. Starting from the second layer, the relocation is facilitated, since the wire is guided through the inter-spaces of the preceding layer. Owing to the fact that wires are crossing within the crossover section the resulting winding height is increased. The winding height of an orthocyclic coil winding results from the following equation:. 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. 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. These unevennesses and bends resulting from the winding of the wire on delivery rolls have the effect that the wires are never completely close together according to their actual diameter but at a distance according to their unevenness. The sum of all partial spaces of the not insulated turns equals. Coil winding can be structured into several groups regarding the type and geometry of the wound coil. It means for the wire guiding movement that the smaller the distance of the wire guiding nozzle towards the coil, the more precise the tracking must be. In practice, this is hardly possible at high winding speeds since, e. This winding method reaches the highest fill factor and is the best way to fill the available winding cross-section with round wires. Effects of bends and tolerances of the wire and the coil body as well as changing surface qualities can be avoided that way. This increases the efficiency of the electrical device and an improved heat conductivity of the winding. This behavior repeats itself with every layer which leads to a spiral shaped crossover section at the side of the winding. Experience has shown that, depending on the winding width, coil and wire diameter, the crossover section is about 5 to 10 percent higher than the regular winding height. For this purpose, it is necessary to take the required space for the rotation diameter of the coil in the "cross over section" into consideration. This gap formation is additionally influenced during the winding-up of the wire by the surface quality of its coating, e. An orthocyclic winding design for a round coil with windings, a wire diameter of 0. The components to be wound are mounted on so-called winding devices. The created offset leads to a different position of the layer step, from the first to the second layer, in comparison to the wire entry. The summation of all tolerances has to be kept at a very low value.

In electrical engineeringcoil winding is the manufacture of electromagnetic coils. These unpredictable circumstances may be prevented or counteracted at the beginning of the winding by forcing the wire, meaning, every single winding of the first layer on the inner coil diameter, into a predefined position.

In practice, however, the value cannot be reached because there exists a winding jump and layer jump area and the wire insulation is not taken click account.

The problem is amplified by the fact that in practice the ideal wire is never absolutely straight. For best packing of round wires on a multi-layer winding, the wires in the upper layer are in the grooves of the lower layer for at least degrees of the coil circumference.

That way an unnecessary bending motor winding data book the wire is being avoided and the needs space for the second winding step is minimized. It should be recognized that the wire needs to enter in a possibly flat angle into the winding space. Applying grooves to the winding basis supports the layer-accurate position of the wire during the winding process.

A wire guiding of the lower layer is not existent. The wires are placed helically in every layer.

It is characterized by low demands for machinery and operator and can be wound with very high speeds. 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 winding step can occupy an area of up to 60 degree of the coil circumference for round coil bobbins and takes one side of rectangular coil bobbins.

The choice of the winding structure to be used basically depends on the design of the coil or the coil body. Dense packing of wires reduces air space, and is said to have a high fill factor. The shape and dimensions of a winding are designed to fulfill the particular purpose.

Especially wire bends that develop due to wire deflections caused by, e. In theory, a geometric fill factor of 0. The fill factor measures the ratio between the volume of a winding package and the volume needed to house the winding pack.

Owing to the fact that the winding should be mostly positioned parallel to the winding flange, meeting an orthogonality condition, it is necessary to adjust the winding width to the number of turns per layer of the winding.

Since bringing the wire into the winding area should be done as evenly as possible, the rotational axis and the traversing axis operate synchronically during the winding process. In case of deflections that are not too excessive as far as the process is concerned, the wire leads itself and with a constant number of windings per 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. Summary of results: The calculation showed that the space needed for the purely orthocyclic winding with enameled wire fills a rectangular area that measures 1.

The area of the winding step is dependent on the wire gauge and coil bobbin geometry. This behavior is particularly beneficial for the winding processes where a plastic deformation of the wire is unavoidable immediately before the depositing of the wire onto the winding basis.

This corresponds to about half the wire tolerance according to the specification of the German standard DIN Even if the demands for low tolerances of the wire and the winding space had to be observed with correspondingly high technical effort, there would still remain the problem that the wire guiding on the machine side has to follow the previously described winding design also at high winding speeds.

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.

Mass production of electromagnetic coils relies on automated machinery. Consequently, the following values can be named as indicatory values: a Tolerance of the winding space width.

Moreover, it is possible to influence the location and the end of the last winding by selecting a clever winding pattern.

At first, the specified parameters of the required number of windings, the required wire cross section and the maximum space available for an insulated coil are used for the calculation basis. As a consequence a bigger motor winding data book width of the coil, leads to a bigger motor winding data book step area along the circumference of the coil.

This is motor winding data book to the fact, that non-circular coils are being mounted on a sheet metal package or in a circular arrangement. The sum of all partial spaces of the insulated turns equals. If the number of layers exceeds a certain limit the structured cannot be maintained and motor winding data book wild winding is created.

In order to be able to control the positions of the wire motor winding data book nozzle in relation to the component to be wound, even with different component geometries, normally three CNC axes are used for billy killer blackjack cowboy method with a wire guiding nozzle.

In particular for non-circular shaped coil cross-sectional areas, it is desired to locate the crossover area to the small side of the coil body, also called winding head. Overall, the first intruding wire mainly determines the location and quality of the winding step. 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. Among others, the available space conditions for winding width and winding height must be considered. To achieve higher fill factors, rectangular or flat wire can be used. The winding devices are coupled to driven spindles that generate the turning motion. As a result, the following windings, or also the following layers, can change in their desired position. Practice has shown that an orthocyclic winding can only be manufactured in an acceptable way when choosing a very high wire elongation level stretching leads to a straight or even wire at the beginning. Before starting the actual winding process, the wire is mounted to a post or a clamping device of the coil body or winding device. This type of winding structure creates an optimal fill factor The windings of the upper layer need to be placed into the grooves provided by the lower layer. Since the wire always loses in cross-sectional area due to the wire drawing to be used and the necessary deflections mechanical stresses under tensile load during winding, the distance between the grooves is designed only for the max. Efficient coils minimize the materials and volume required for a given purpose.