Custom Wire Winding & Coil Winding
Coil winding and wire winding are methods of producing electromagnetic coils and assemblies. Custom wire winding assemblies are used as circuit components and create the magnetic fields required to operate motors and generators. Other electrical applications include solenoids, circuits, actuators, and other electronic components and assemblies.
The wire or conductor which constitutes the coil is called the winding. Each loop of wire is called a turn. In windings in which the turns touch, the wire must be insulated with a coating of nonconductive insulation such as plastic or enamel to prevent the current from passing between the wire turns.
Copper coiling and coil bending services are well-suited for RF applications. Copper coiling can also transmit liquids, air, or other media to cool equipment of all types. When properly applied, copper coil winding (water coiling) can function conductively and simultaneously as a cooling coil.
Custom Coil Winding and Wire Winding Capabilities
At HBR Industries, Inc. we can create custom coils with smaller dimensions than traditional coils. Our proven techniques make tight tolerances, non-standard winds, tight radii, short overall lengths, and precise pitches and diameters achievable. Whether your custom coil requires just a few turns or a few thousand, we have the expertise to deliver.
Our coil winding capabilities include odd, non-standard shapes and a wide variety of other unique characteristics. We work with wire gauges from 2 to 42, so we can produce your next project no matter how intricate your design may be, or how tight the tolerances required.
Coil Winding Material Options
Current Frequency Options for Coil Bending & Winding
Coils used for coil winding and bending applications are classified by the frequency of the current they are designed to operate with, these frequencies include:
- Direct current or DC coils or electromagnets operate with a steady direct current in their windings
- Audio-frequency or AF coils, inductors or transformers operate with alternating currents in the audio frequency range, less than 20 kHz
- Radio-frequency or RF coils, inductors or transformers operate with alternating currents in the radio frequency range, above 20 kHz
Our manufacturing expertise enables us to provide custom coil winding that exceeds the standard industry callouts of the materials used. With our in-house fixturing capabilities and strategic partnerships with area machine shops, we can produce the tooling and fixturing needed to manufacture high precision, custom coil winding based on your specifications.
Custom Electromagnetic Coils
An electromagnetic coil consists of two distinct elements, a conductor and a core. The conductor is usually made from copper wire that wraps around the core. One cycle around the core is called a turn. When the wire is turned multiple times, it’s considered to be a coil. The role of the coil is to provide inductance to an electric circuit. Inductance is an electrical property characteristic to electromagnetic coils opposing the flow of current through the circuit.
What Is American Wire Gauge (AWG)?
HBR Industries values the need for an in-depth understanding of wire gauges, and what those differences mean regarding your requirement needs. That is why we utilize the American Wire Gauge (AWG) chart as the guideline for all wire related projects.
AWG, also known as the Brown & Sharpe wire gauge, is a standardized winding wire gauge chart system used for the diameters of round, solid, nonferrous, electrically conducting wire. The diameter of each gauge is a principal factor for determining its current-carrying capacity.
Some essential aspects of the AWG coil gauge chart, include:
- Increasing gauge numbers denote decreasing wire diameters
- The AWG tables are for a single, solid, or round conductor.
- When the cross-sectional area of a wire is doubled, the AWG will decrease by 3. This doubles the ampacity.
- When the diameter of a wire doubles, the AWG will decrease by 6. This quadruples the cross-sectional area and the ampacity.
- A decrease of ten-gauge number reduces the electrical resistance and increases the conductance by a factor of approximately 10.
- For the same cross-section, aluminum wire has a conductivity of approximately 61% of copper, so an aluminum wire has nearly the same resistance as a copper wire 2 AWG sizes smaller, which has 62.9% of the area.
Wire Gauge Chart ( AWG Gauge) Diameter in Inches and MM)
Custom Wire Winding Prototypes, Design Assistance & More
At HBR Industries, Inc., we do more than just standard production runs. We can also create prototype parts and components to test fit, form, and function, along with one-off pieces for your specialized application.
Our team will work with you to enhance your part designs for improved performance or better manufacturability. We also assist with material selection and offer design assistance through our close network of vendors.