Coil

A coil usually refers to a wire winding in a ring shape. Common applications of coils include: motors, inductors, transformers and ring antennas, etc.

The coil in a circuit refers to an inductor. It refers to the winding of wires one by one, with the wires insulated from each other. The insulating tube can be hollow or contain an iron core or a magnetic powder core, which is simply called an inductor.

An inductance coil is a device that operates based on the principle of electromagnetic induction. When current flows through a wire, a certain electromagnetic field will be generated around the wire, and the wire itself within this electromagnetic field will induce other wires within its range.

The effect on the wire itself that generates an electromagnetic field is called "self-induction", that is, the changing current produced by the wire itself generates a changing magnetic field, and this magnetic field further affects the current in the wire. The effect exerted on other wires within this electromagnetic field range is called "mutual inductance".

Inductors can be further classified into fixed inductors and variable inductors. A fixed inductor coil is simply called an inductor or coil. Denoted by L, the units are Henry (H), millihenry (mH), and microhenry (uH). 1H=10^3mH=10^6uH.

Coils can be classified into single-layer coils and honeycomb coils.

The wire excitation coil is a coil through which the current changes. There are magnetic field lines passing through the center of the coil. The greater the current, the more magnetic field lines there are. Until saturation, when the current is cut off, the magnetic field lines disappear.

The current-carrying coil used to excite the magnetic flux in the magnetic circuit is called the excitation coil (or excitation winding), and the current in the excitation coil is called the excitation current (or excitation current). If the excitation current is direct current, the magnetic flux in the magnetic circuit is constant and does not change over time. Such a magnetic circuit is called a direct current magnetic circuit. The magnetic circuit of a DC motor falls into this category. If the excitation current is alternating current, the magnetic flux in the magnetic circuit changes alternately over time. Such a magnetic circuit is called an alternating current magnetic circuit. The magnetic circuits of AC core coils, transformers and induction motors all fall into this category.

In today's highly competitive manufacturing market, cost control is one of the key factors for enterprises to maintain their competitiveness. For enterprises involved in coil winding, the cost loss during the coil winding process directly affects the profit margin of the enterprise. As an enterprise that has been deeply engaged in the field of automation equipment for many years, Yeyi Automation Technology (Suzhou) Co., Ltd. has launched a series of automation equipment, providing an effective way to reduce the cost of coil winding. Next, we will delve into how to reduce cost losses during the coil winding process by leveraging Yeyi automation equipment.

Yeyi Automation Technology (Suzhou) Co., Ltd. was established on July 21, 2015. It is a high-tech enterprise integrating R&D, production, sales and after-sales service. The company adheres to the business philosophy of "people-oriented, technological innovation, and promoting industrial progress", and has a professional technical team with independent design and research and development capabilities. The technicians with various professional backgrounds in power equipment in the team have all worked in the industry for more than seven years and are highly experienced. The company mainly produces a variety of industrial automation equipment, including foil winding machines, winding machines, tension wire laying frames, etc., and enjoys a good reputation in the industry.

In the traditional coil winding process, there are many factors that lead to cost loss. First of all, manual winding is inefficient and consumes a large amount of labor costs. Take a medium-sized motor manufacturing enterprise as an example. If manual winding is adopted, it may take dozens of workers several days to complete a medium number of coil winding tasks, resulting in a huge expenditure on labor costs. Moreover, manual operation is greatly influenced by human factors, making it difficult to ensure that the winding quality of each coil is exactly the same, and the defective rate of products is relatively high. According to relevant data statistics, the defect rate of manual winding may be as high as 10% to 15%, which means that for every 100 coils produced, 10 to 15 May need to be reworked or even scrapped due to quality issues, resulting in a huge waste of raw materials. In addition, during the manual winding process, due to the instability of the operation, it may also lead to inconsistent tightness of the coil winding, affecting the electrical performance of the coil and further impacting the performance and service life of the entire product.

Yeyi Automation equipment has significant advantages in enhancing production efficiency. Take its fully automatic winding machine as an example. This equipment can automatically complete the winding operation, greatly shortening the production cycle. Compared with the traditional manual winding method, using a fully automatic winding machine can save at least 30% of the time. In the practical application of a certain transformer manufacturing enterprise, after the introduction of the Yeyi fully automatic winding machine, a batch of transformer coil winding tasks that originally took a week can now be completed in just three days. The production efficiency has been significantly improved, enabling the enterprise to take on more orders within the same period of time and increase its profits. Meanwhile, the efficient operation of Yeyi Automation equipment reduces the idle time of the equipment and lowers the unit usage cost of the equipment. The increase in equipment operating time leads to a corresponding decrease in equipment depreciation costs and other expenses allocated to each product.

Through advanced technical means, Yeyi Automation equipment can precisely control various parameters of coil winding, thereby significantly improving product quality. For instance, its winding machine adopts an accurate control system, which can ensure the precision and stability of coil winding, effectively avoiding problems such as coil loosening and deformation due to friction that are prone to occur during manual winding. According to the actual production data, after using the Yeyi winding equipment, the defective rate of products can be reduced to below 5%, significantly reducing the rework and scrapping costs caused by product quality issues. In some electronic equipment manufacturing fields with extremely high requirements for coil quality, such as the production of wireless charging coils for mobile phones, Yeyi Equipment can ensure that all performance parameters of the coils meet strict standards, improve the yield rate of products, enhance the competitiveness of enterprise products in the market, and indirectly reduce the marketing costs and other costs of enterprises.

The cost of raw materials accounts for a large proportion of the total cost of coil winding. Yeyi automation equipment plays a significant role in reducing the loss of raw materials. Take the foil winding machine of Yeyi as an example. This equipment adopts PLC automatic control variable frequency stepless speed regulation system, photoelectric hydraulic deviation correction system, automatic welding mechanism and other automatic control functions, which ensures the welding quality of the transformer foil winding and significantly reduces the loss of the transformer. In the traditional foil winding process, due to unstable welding quality and other issues, some foil materials may be wasted. However, the Yeyi foil winding machine, through precise control, reduces the occurrence of such waste. In addition, Yeyi's technological innovation in molds also helps to reduce the loss of raw materials. On January 20, 2025, the company successfully applied for and obtained a patent named "A Multi-Form Vertical Winding Coil Combination Mold" (with the authorization announcement number CN222354933U). This multi-form mold not only includes the elliptical vertical winding coil forming mold but also the square vertical winding coil forming mold. By innovatively using the wire die and the lower support rotating die, it can effectively achieve precise winding of the wire, avoiding the waste of wire caused by unsuitable molds. After the enterprise adopted this mold, the average raw material loss in the production of coils of different shapes was reduced by 15% to 20%.

In addition to the advantages of the equipment itself, Yeyi Automation Technology (Suzhou) Co., Ltd. also provides customers with all-round after-sales service, which to a certain extent also helps to reduce the comprehensive costs of enterprises. The company has a professional after-sales team that can promptly respond to any problems customers encounter during the use of the equipment. When equipment malfunctions, the after-sales team can promptly arrive at the scene for repair, reducing equipment downtime and lowering the production halt costs caused by equipment failure. Moreover, Yeyi will provide customers with equipment operation training and maintenance guidance to help enterprise employees operate the equipment correctly, extend the service life of the equipment, and reduce the cost of equipment replacement. After the equipment has been in use for a period of time, Yeyi will also conduct follow-up visits and inspections to identify potential problems in advance and solve them, avoiding high losses caused by sudden equipment failures.

Today, with the increasingly fierce competition in the manufacturing industry, enterprises can effectively reduce costs in multiple aspects such as production efficiency, product quality, raw material loss and after-sales service by leveraging the advanced equipment of Yeyi Automation Technology (Suzhou) Co., LTD. In the long run, this not only helps enterprises enhance their economic benefits and strengthen their market competitiveness, but also promotes the entire coil winding related industry to develop in a more efficient, energy-saving and environmentally friendly direction. For enterprises that are intent on reducing the cost loss of coil winding, choosing Yeyi automation equipment is undoubtedly a wise move, laying a solid foundation for the sustainable development of the enterprise.