Bending and Punching Forming Coil

Introduction to Bent and Punched Formed Coils: Bent and Punched formed coils are made by first punching holes in wires or copper sheets and then shaping them into specific forms through a bending process. The core lies in the combination of "punching positioning" and "bending shaping", which not only ensures installation accuracy but also meets complex space requirements. They are widely used in precision electronic components and motor windings. I. Basic Structure and Processing Logic

Basic base materials: Enameled flat copper wires, copper sheets or round copper wires are mostly used. Some motor coils will choose insulated flat wires, taking into account both electrical conductivity and insulation performance.

The core processing steps: First, through the stamping equipment, through holes, clamps and other positioning structures are punched at the end or middle part of the wire or copper sheet - these holes can be used for coil fixation, pin connection or adaptation to the equipment slot. After punching, the base material is bent with the help of a special die and a pressure head module, which can be bent into "H" shape, "S" shape or spiral superposition and other forms. Some are also assisted in bending by hot air heating, and the pressure is held during cooling to prevent rebound, ensuring the forming accuracy.

Post-forming treatment: After bending, the integrity of the insulation layer needs to be checked. Some coils will be supplemented with insulation coatings to ensure that there is no short circuit between the windings. At the same time, the edges of the punched holes should be trimmed to avoid scratching the installed components.

Ii. Core Features

Precise positioning and installation: The holes or clamps formed by punching can precisely fit with the protrusions and pins of the equipment. Compared with coils without punching, they are less likely to shift during installation and are especially suitable for automated assembly scenarios.

Strong shape adaptability: The bending process can achieve complex planar or three-dimensional shapes, such as the "H" -shaped bending of the hairpin winding of the motor and the helical overlapping bending of the inductor coil, which can fully utilize the internal space of the equipment.

Good structural stability: The integrated structure formed by punching and bending, combined with the pressure-holding cooling process, makes it less likely to deform due to vibration and temperature changes after forming, and the current conduction and magnetic field performance of the winding are more stable.

Iii. Main Uses

In the field of motor windings: This process is commonly used for hairpin (hairpin type) windings in new energy vehicles and industrial motors. First, holes are punched at the end of the flat wire, then it is bent into a hairpin shape, embedded in the stator slots, and positioned through the holes to increase the slot fullness rate and motor power density.

Precision electronic components: The winding coils of inductors and transformers are punched to achieve solderless embedded installation, eliminating the need for frame design and directly plugging them into the PCB board to optimize circuit layout.

Power and energy storage equipment: Copper bar coils for switch cabinets and connection bars for energy storage batteries, after punching positioning and bending shaping, are adapted to different cabinet types and battery pack layouts to ensure the efficiency of current transmission.

Iv. Differences from Ordinary Formed Coils

The processing techniques are different: Ordinary formed coils are only shaped by bending and their installation relies on external fasteners. The bending and punching forming coil adds a punching process and comes with a built-in positioning structure, making installation more convenient.

The applicable scenarios are different: Ordinary coils are suitable for general equipment, while bent and punched coils are specially designed for high-end scenarios that require precise positioning and complex shapes, such as new energy motors and precision inductors.

The assembly efficiency varies: The punched structure can be directly matched with equipment clips or pins without the need for additional drilling or fixation, which can enhance the efficiency of automated assembly and reduce manual adjustment steps.