Introduction to multi-wire layering and winding

Multi-wire laminating winding is a coil processing method that involves simultaneously or in layers laminating and winding multiple insulated wires (usually two or more) on a frame. The core lies in optimizing the current carrying capacity, heat dissipation and electromagnetic performance of the coil through the coordinated arrangement of multiple wires, making it suitable for high-current and low-loss application scenarios.

I. Basic Winding Methods and Key Points

Wire selection and pretreatment: It is advisable to choose enameled copper wires of the same diameter and material (different diameters can also be matched as required). Before winding, multiple wires should be arranged in parallel to ensure consistent tension and avoid wire misalignment or uneven tightness during winding.

Winding process: Multiple wires can be wound simultaneously on the frame through a multi-axis synchronous winding machine to form a "single-layer multi-wire parallel" structure. If the number of turns needs to be increased, "multi-layer stacking" will be adopted. Insulating paper should be placed between each layer to prevent short circuits between layers. Moreover, when winding each layer, the wires should be neatly arranged to minimize gaps.

End treatment: After winding is completed, the two ends of multiple wires are respectively aggregated. After removing the insulation layer at the ends, they are uniformly crimped or welded to ensure uniform current distribution among the multiple wires.

Ii. Core Features

Strong current-carrying capacity: Multiple wires conduct electricity in parallel, which is equivalent to increasing the cross-sectional area of the conductor. Compared with a coil wound from a single wire, it can carry a larger current, and the current is evenly distributed among multiple wires, avoiding local overheating.

High heat dissipation efficiency: There are tiny gaps between multiple wires, which can form natural heat dissipation channels. At the same time, the total surface area of the wires increases, making it easier for heat to dissipate and reducing the performance degradation of the coil caused by high temperatures.

Reduce the impact of skin effect: In high-frequency scenarios, a single wire is prone to increased resistance and loss due to the skin effect (where current is concentrated on the wire surface). Winding multiple thin wires can reduce the diameter of a single wire, weaken the skin effect and lower high-frequency losses.

Iii. Main Uses

Power equipment: For instance, the windings of large transformers and reactors need to carry high currents. Multiple wires are stacked to meet the current requirements, and at the same time, safe operation is ensured through layered insulation.

Industrial motors: Used for the stator and rotor coils of high-power motors, they enhance the motor's current-carrying capacity and heat dissipation performance, ensuring long-term high-load operation of the motor.

High-frequency electronic devices: such as the coils of RF generators and high-frequency induction heating equipment, multiple fine wires are wound together to reduce high-frequency losses and ensure the efficiency and stability of the equipment under high-frequency working conditions.

Iv. Differences from Single-wire Winding

The performance focuses are different: The single wire winding process is simple and the cost is low, making it suitable for scenarios with small current and low power. Multi-wire winding focuses more on high current and low loss, requiring dedicated equipment and insulation treatment, and the cost is slightly higher.

The winding difficulty varies: single-wire winding does not require synchronous control of the tension of multiple wires, and the operation is simple and convenient. When multiple wires are stacked and wound, it is necessary to ensure that the wires are synchronized and neatly arranged, which places higher demands on the precision of the equipment and the process.