Prototype Coil Performance Evaluation & Verification Services | Electrical Property Measurement & Manufacturability Checks at the Design Stage

PRONEC provides contract services for the performance evaluation and verification of prototype coils in Thailand. We propose optimal manufacturing processes geared toward mass production through simulations from the design stage, characteristic inspections, resistance tests, and withstanding voltage tests. By providing seamless, integrated support from prototyping to mass production, we help identify challenges early in development, stabilize quality during mass production transition, and optimize manufacturing costs.

Table of Contents

• Preventing Yield Drops During Mass Production: Simulation & Verification from the Design Stage
• Prototype Coil Specifications & Scope of Support
• Automation of Characteristic Inspection/Testing Systems & Data Management
• Integrated Support & System at our Thailand Base
• Frequently Asked Questions (FAQ)

Preventing Yield Drops During Mass Production: Simulation & Verification from the Design Stage

Even if there are no issues during the prototyping stage, companies often face deteriorating yields or increased manufacturing costs when transitioning to mass production. PRONEC involves itself in projects from the initial development and design stages, conducting simulations that anticipate dimensional variations unique to coils. Rather than judging solely based on drawing dimensions, we verify in advance whether stable manufacturing is possible during mass production, taking into account actual wire characteristics and winding behavior. By proposing and establishing optimal manufacturing processes based on manufacturing know-how tailored for mass production, we achieve quality stability and cost optimization during the mass production transition.

Prototype Coil Specifications & Scope of Support

Prototype coil manufacturing requires compatibility with a wide variety of wire materials and shapes depending on the application. PRONEC uses various wire materials such as ultra-fine wire, litz wire, and rectangular wire to support the prototyping of both air-core coils and bobbin coils. For ultra-fine wire, we can handle sizes starting from φ0.02mm. Furthermore, we support the establishment of an integrated production system that consolidates a series of processes such as molding, winding, assembly, and overmolding into a single line. This minimizes work-in-progress (WIP) inventory between processes while establishing a stable production flow.

Automation of Characteristic Inspection/Testing Systems & Data Management

In coil performance evaluation, it is crucial to record measurement results accurately and streamline the inspection process. In PRONEC’s in-house characteristic inspection process, we standardize test probes and systematize resistance testing, withstanding voltage testing, insulation resistance testing, and impulse testing. Furthermore, by introducing the automatic measurement software "QC Pro", we minimize variations in measurement conditions while automatically analyzing and recording data. This prevents manual errors and provides highly accurate inspection reports with ensured traceability.

Integrated Support & System at our Thailand Base

When proceeding with development within Thailand, having a partner with whom you can directly discuss technical details is essential. PRONEC’s Thailand factory is equipped with various machinery, including our proprietary winding machines. Japanese staff serve as the primary contact window to directly confirm technical requirements. Since consultations regarding manufacturing feasibility and finished dimensions based on drawings can be conducted locally, you can reduce the time and transportation costs of sending items back to Japan. We make it possible to quickly create prototypes within Thailand and seamlessly transition to subsequent mass production.

Frequently Asked Questions (FAQ)

Q: Is it possible to consult with you based on drawings or specification sheets?
A: Yes, it is possible. We provide technical consultations regarding manufacturing feasibility and finished dimensions based on the drawings or specification sheets you provide.

Q: Can you handle everything from prototyping to the mass production transition?
A: Yes, we can. After performing evaluations and verifications at the prototype stage, we can establish an integrated in-house production line optimized for future mass production.

Q: Is it possible to issue inspection reports?
A: Yes, it is possible. We issue accurate inspection reports based on measurement data recorded and calculated by our automatic measurement software.

※For more details, please download the materials or contact us via the inquiry form below.