The winding method of thermoplastic solenoid coils is a key process step that directly affects the performance and reliability of the coils. The following are some detailed descriptions of the ways thermoplastic solenoid coils are wound:
I. Preparation before winding
- Selection of appropriate insulating materials: Thermoplastic insulating materials typically include polyimide, polyketone, PTFE, etc. Different materials have different thermal stability, electrical insulation properties and chemical stability, so it is necessary to select the appropriate material according to the requirements of the application.
- Prepare winding tools: To ensure stable winding tension, it is recommended to use an automatic winding machine. At the same time, it also needs to be carefully adjusted according to the features of the material and the requirements of the coil.
II. Precautions in the winding process
- Control the winding tension: too high a tension may cause deformation or rupture of the insulation material, while too low a tension may result in a non-compact winding and affect the performance of the coil. Therefore, the winding tension needs to be strictly controlled.
- Ensure the uniformity of the insulation layer: Uneven insulation layers may cause local overheating, damage the insulation material, and even impair the performance of the thermoplastic solenoid coil. Therefore, proper winding technology needs to be used to ensure the uniformity of the insulation layer.
- Consider thermal insulation properties: Thermoplastic insulation materials generally have high electrical insulation properties, but may soften or degrade in high temperature environments. Therefore, it is necessary to ensure that thermal insulation measures are taken into account in the coil design to prevent the influence of high temperature on the coil.
- Control coil temperature: During the winding process, the temperature of the coil should always be within a controllable range. High temperatures may cause the insulation to melt or soften, and low temperatures may make the windings brittle. Therefore, appropriate heating and cooling equipment is required to ensure that the temperature of the coil is controlled.
III. Common winding methods
- Circular winding method: When the barrel is tubular or cylindrical, circular winding method is generally used. By estimating the thickness of the insulation cotton and the length of the coil, the clean barrel is first wrapped with the insulation cotton and then wound with the coil.
- Coil method: For horizontal cylindrical heating or drying equipment, the coil method can be used to prevent the top barrel from drying out. By customizing a specific wire reel, winding it, and fixing it on a customized bracket, it is possible to save some energy and prevent dry burning of the barrel.
- Multi-strand winding: Split one winding into multiple strands, and connect each winding in parallel. This winding method can improve the heat resistance of the heater, thereby increasing the operating temperature and capacity of the heater. There are many forms of multi-strand winding, such as paper tape winding, semicircular winding, armor winding, conical winding, rectangular winding, etc.
IV. Quality control and testing after winding
After winding is completed, quality control and testing must be performed to ensure that the coil’s performance meets the requirements. This includes resistance measurements, inductance measurements, insulation resistance tests, etc. Any potential problems should be addressed before the coil is put into service.
In short, the winding method of thermoplastic solenoid coils needs to take into account multiple factors, including the selection of insulating materials, control of winding tension, uniformity of the insulation layer, thermal insulation performance, and specific winding methods. Through scientific winding methods, it can be ensured that the coil can show good performance and reliability in various applications.
