For full-automatic winding processing of 3416 circular coils, the following key points need to be focused on:

1. Equipment and process preparation

Material matching‌: The magnet wire needs to be selected according to the application scenario for its heat resistance grade (such as B gradeF grade) and insulation thickness, and the storage environment should maintain a temperature of 15-25℃ and a humidity of ≤60%.

The installation the skeleton and fixture should be in place, and the mandrel should be tightened to avoid looseness during winding, which could lead to eccentricity or deformation.

Equ adjustment‌: Before starting the winding machine, it is necessary to check the main shaft lubrication, bolt fastening, and the stability of the power supply voltage, and to run empty to confirm the precision of the wire arrangement and the parking position.

Set the parameters for the direction of wire arrangement and the direction of winding to ensure that the direction of the arrangement axis matches the direction of the main shaft rotation, to avoid equipment alarms.

2. Process control during winding

Key parameter setting‌: The winding speed needs to be according to the diameter of the wire: the initial acceleration of the thin wire should be small, and the thick wire needs to reduce the speed but ensure sufficient torque.

The tension to be evenly controlled (usually 30-50% of the material's yield strength), with a fluctuation range ≤10%, to avoid stretching the thin or breaking it.

: Number of turns and shape precision‌: Use a turn counter or an automatic winding machine to ensure precise number of turns, and calibrate sample data for multi-turn coils.

The angle error of coil forming needs to be ≤2°, and the tolerance of the length of the straight side is within ±1mm to avoid difficulties in embedding.

Special wire treatment‌: The tension of the aluminum wire needs to be smaller than that of the copper wire, and the diameter setting value should increased appropriately to prevent stretching deformation or cracking of the enamel coating.

For non-smooth wires such as self-adhesive wire and enameled cotton wire, increase the between wire arrangements to reduce the inertial effect of winding.

3. Quality and safety control

Insulation and curing‌: For multi-turn coils, add inter-turn paper ≥0.1mm, and set the curing temperature according to the material specification (such as epoxy resin glue 120-150℃) and keep it warm for ≥30 minutes.

After curing, check for no "hollow" sound by knocking, to ensure that there is no void in the layer.

Detection standard‌: The inter-turn withstand voltage test needs to apply 2 times the rated voltage continuously for 1 minute, with no breakdown or partial.

The inductance error ≤5%, the direct current resistance error ≤10%, and the precise measurement is made with an LCR meter.

 the above comprehensive control, it can ensure the electrical performance, mechanical strength, and batch consistency of the 3416 circular coil