Spaced Orthocyclic Winding Pattern for Improved Die Compressed Coils

Abstract

Winding fill, coil fill, or packing factor, is critical to the performance of many types of electromagnetic devices from electric machines to actuators, transformers, inductors, etc. One technique to increase the packing of conductors in the winding area is to compress round magnet wire conductors in a die, so that they deform and air voids between coil turns are removed. The winding layout of the coil turns on a bobbin before compression has a direct impact on the achievable coil fill and the damage to the coil insulation or conductors after compression. It is thought that winding the turns in an orthocyclic pattern on the bobbin before compression would minimize damage to the turns. This however causes turns to displace during the winding compression process. A new pre-compression winding pattern is proposed, a spaced orthocyclic winding, to minimize turn displacement and damage. A design of experiments study has been carried out to optimize this winding method and to compare it to the traditional orthocyclic winding.