High-Density Alignment Winding for Air-Core Coils | Precise 8,000-Turn Layering via In-House Developed Winding Machines

PRONEC CO., LTD. undertakes contract manufacturing of high-density layer-wound air core coils in Thailand. Utilizing ultra-fine wire with a diameter of Φ0.08 mm, we have successfully completed a technical verification test demonstrating precise multi-layer winding of 8,000 turns within a winding width of 20.5 mm. We also welcome technical consultations starting from the prototyping phase.

Table of Contents

• Precise Multi-Layer Winding of 8,000 Turns at a High Speed of 3,000 rpm by PRONEC
• Applicable Specifications & Range of Capability
• Control Technology and Technical Know-How
• Prototyping and Technical Testing
• Frequently Asked Questions (FAQ)

Precise Multi-Layer Winding of 8,000 Turns at a High Speed of 3,000 rpm by PRONEC

In the manufacturing of cylindrical air core coils, layer winding which minimizes gaps between layers is essential to maximize the number of turns within a limited space. However, as the number of turns increases, even a slight misalignment in the lower layers tends to expand into the upper layers, increasing the risk of the coil losing its proper shape.

PRONEC conducted a test project to push the performance limits of our in-house developed winding machines, successfully achieving a high-density accumulation of 8,000 turns on a cylindrical coil with a winding width of 20.5 mm. Furthermore, assuming mass production, this test was conducted under actual operating conditions at a high rotation speed of up to 3,000 rpm.

Our control technology completely synchronizes the traverse movement and rotation even during high-speed operation, ensuring that the ultra-fine wire is beautifully aligned into a cylindrical shape without overlapping or creating gaps. Because this guarantees that the coil satisfies its magnetic properties exactly as designed, it enables the downsizing of devices such as actuators and sensors.

Applicable Specifications & Range of Capability for Air Core Coils

• Wire Diameter: Φ0.08 mm
• Inner Diameter: Φ2 mm
• Thickness / Winding Width: 20.5 mm
• Number of Turns: 8,000 turns
• Shape: Cylindrical air core coil
• Remarks: Passed the maximum limit test using an in-house developed winding machine

Control Technology of In-House Developed Winding Machines Supporting High-Precision Winding

High-density layer winding requires delicate parameter control that conventional, off-the-shelf winding machines cannot handle. To build the optimal mechanical structure for each specific processing condition, PRONEC develops and continuously improves its winding machines in-house.

Technical Know-How to Overcome Variance Between Wire Batches

The precision of layer winding is not determined by machine performance alone. Subtle, batch-to-batch variations in insulation thickness or the smoothness of the wire surface can accumulate over thousands of turns, resulting in significant cumulative errors.

At our factory in Thailand, we always check the surface condition of the wire prior to production. To accommodate variations between batches, we finely adjust the traverse pitch every single time. Furthermore, we have accumulated proprietary in-house know-how to optimize the heater temperature relative to the winding speed, establishing a stable winding process unaffected by environmental changes.

This rigorous process control suppresses variations in outer dimensions even during mass production. Consequently, it effectively prevents negative impacts on subsequent assembly processes, thereby contributing to improved production yields.

Prototyping and Technical Testing

We welcome consultations even from the early stages, such as when you are uncertain whether the aligned winding structure can actually be maintained with the number of turns specified in your drawings. PRONEC has an independent technical testing framework using our in-house developed machines, allowing us to handle difficult air core coil prototyping.

Our local team in Thailand conducts prototyping and testing in accordance with Japanese quality control standards. Based on the results, we swiftly propose manufacturing methods geared toward mass production. We have staff members who can communicate technically in Japanese, providing a support system that covers everything from aligning specifications to launching actual mass-production lines.

Frequently Asked Questions (FAQ)

Q: Is it possible to consult on a prototype with special specifications that other companies rejected, claiming it would cause the winding to collapse?
A: Yes, absolutely. Building upon our successful track record of the 8,000-turn verification test, we will adjust parameters such as the traverse, rotation speed, and tension of our in-house developed winding machines to match your specifications, addressing the challenges of extreme boundary specifications.

Q: Can you maintain stable dimensional accuracy in high-density layer winding?
A: Yes, we can. In addition to data management utilizing the "QC Pro" automatic dimensional measurement software, we guarantee stable dimensions even in multi-layer winding through precise tuning tailored to each wire batch and precise tension management using servo systems.

Q: What are your operational standards?
A: We manage each process based on Japanese-level quality control standards. Before production begins, our technical staff will review your requests and challenges to propose the most suitable method.

※For further details, please download the attached materials or contact us using the inquiry form below.