Enameled wire's flat winding and vertical winding

Flat Winding and Vertical Winding

Flat winding and vertical winding will produce different stress areas on enameled copper wire.

The copper wire is parallel to the coil surface, forming a planar coil; the force-bearing area is small and the mechanical strength of the coil is low; high space utilization, suitable for small and lightweight products.

Vertical winding

The copper wire is perpendicular to the coil surface to form a three-dimensional coil; the force-bearing area is larger and the mechanical strength of the coil is higher; the space utilization rate is low, but it can withstand large external forces; suitable for products requiring higher mechanical strength, such as transformers, motors, etc;

When choosing a winding method, how to evaluate the specific application requirements of the product?

When selecting the winding method of enameled copper wire, it is necessary to evaluate and select based on the specific application requirements of the product. Here are some key factors to consider:

1. Working environment and mechanical load:

If the product needs to withstand large external force or vibration, you need to choose the vertical winding method to provide higher mechanical strength.

If the product’s working environment is relatively stable, the flat winding method may be more suitable.

2. Volume and weight requirements:

If the product has strict requirements on volume and weight, the flat-wound method can provide higher space utilization.

If the product volume and weight requirements are relatively loose, the vertical winding method is also optional.

3. Thermal and electromagnetic properties:

The flat winding method can provide better heat dissipation effect because the coil surface area id larger.

The vertical winding method may produce a more complex electromagnetic field distribution, which requires further electromagnetic performance evaluation.

4. Manufacturing cost and complexity:

Flat winding is usually simpler and less expensive to manufacture.

The vertical winding method requires a more complex manufacturing process, but can achieve higher mechanical strength.

How to evaluate the electromagnetic performance of different winding methods?

1. Magnetic field distribution

The magnetic field distribution of flat-wound coils is more uniform and easy to control.

The magnetic field distribution of vertically wound coil is relatively complex and requires careful design and analysis.

2. Magnetic flux

The magnetic flux of a flat-wound coil is relatively small, but the distribution is more even.

The magnetic flux of vertically wound coils is larger, but the distribution may not be uniform.

3. Electromagnetic induction

The electromagnetic induction effect of flat-wound coil is relatively simple and easy to calculate and design.

The electromagnetic induction effect of vertically wound coils is more complex and requires more sophisticated modeling and analysis.

4. Self-inductance and mutual inductance

The self-inductance and mutual inductance parameters of flat-wound coils are relatively stable and predictable.

The self-inductance and mutual inductance parameters of vertically wound coils may vary greatly due to the influences of the shape of the coils.

5. Current distribution

The current distribution the flat-wound coil is relatively uniform, which can better utilize the conductor cross-sectional area.

The current distribution of vertically wound coil may be less uniform due to skin effects.

All in all, in order to comprehensively evaluate the electromagnetic performance of different winding method, it is necessary to combine theoretical analysis, numerical simulation and experimental testing.