Post-Forming Coil

Introduction to the back-end forming coil

The post-forming coil is first wound into the initial shape of the wire (such as shuttle shape, planar ring shape, etc.), and then undergoes secondary processing such as bending, twisting, and bulging through special fixtures or equipment. Finally, it is shaped into a coil with a specific structure. The core lies in the "winding and then forming" process, which precisely meets the equipment's requirements for the shape and size of the coil. It is commonly found in fields such as motors and precision electronic equipment.

I. Basic Structure and Processing Logic

The main body of the coil: Initially, it is mostly wound with enameled copper wire (round wire or flat wire), which can be single-layer or multi-layer stacked. Some parts are first completed with basic insulation wrapping (such as mica tape winding) to prepare for subsequent molding.

The core of the post-forming process: Based on the initial coil, key parts are fixed through positioning fixtures, and then processed with devices such as bending, top arc, and twisting - for instance, the planar two-dimensional coil is stretched and twisted into a three-dimensional shape, or the tail of the coil is bent into an outward eight shape. Some also precisely shape special structures like "twisted nose" to ensure that the dimensions after forming are exactly matched with the installation position of the equipment.

Post-forming treatment: After some coils are formed, insulating layers will be added (such as applying insulating glue or wrapping covering tape), or the ends will be shaped to ensure a stable structure and reliable insulation.

Ii. Core Features

Strong shape adaptability: It can break through the initial winding limitations, process complex structures such as twisted noses, irregular ends, and three-dimensional curved surfaces, precisely meet the special requirements of motor stator slots and irregular installation Spaces of equipment, and solve the problem of single shape of traditional wound coils.

High dimensional accuracy: By controlling parameters such as the bending Angle and torsion amplitude through CNC forming equipment, the pitch, span and elevation of the coil after forming can strictly comply with the design standards, with small errors, and can ensure consistency in batches.

More stable insulation and structure: During the molding process, targeted protection can be provided for the insulation layer (such as strengthening the wrapping at areas with concentrated deformation), and the coil shape is fixed after molding, making it less likely to deform due to vibration or temperature changes. The insulation compressive strength is superior to that of loosely wound coils.

Iii. Main Uses

In the field of motor windings: They are core components of large and medium-sized motors and traction motors. For instance, the stator coils of back-wound motors are formed through the subsequent process to meet the requirements for yoke insertion, thereby enhancing the slot fullness rate and motor power. The flat copper wire wave winding is formed at the tail and shaped by twisting the nose to optimize the winding performance.

Precision electronic equipment: In automotive electronics and industrial control modules, inductive coils and drive coils used to adapt to compact Spaces are precisely formed to reduce installation gaps and enhance equipment integration.

Special electromagnetic components: such as the formed coils of linear motors, after being formed by subsequent pressing, have reliable insulation and stable dimensions, which can meet the performance requirements under high-frequency drive.

Iv. Differences from Ordinary Coils

The process sequence is different: Common coils are mostly "wound into shape in one go", and their shape is restricted by the winding die. The post-forming coil is "wound first and then formed", with winding and shaping separated, making it more flexible and adaptable to complex shapes.

Performance and cost differences: The dimensional accuracy of the post-forming coil is high and the structure is stable, but it requires dedicated forming equipment, has more processing procedures, and the cost is slightly higher. Ordinary coils have a simple manufacturing process and high mass production efficiency, making them suitable for scenarios with regular shapes.

The applicable scenarios are different: Ordinary coils are suitable for small and general-purpose devices; In high-end scenarios where the post-forming coil focusing requires complex shapes and high precision, such as special motors and precision control systems.