How Coil Winders Have Taken Over a Once Simple Industry

About Coil Winders

These days, it seems as if everything is getting less mechanical and more electronic. What was once the simple process of the combustion engine is coil winding mutating into forms such as hybrid cars and Tesla cars. While the mechanical alarm clock of so many cartoons and comedies, once a desperately needed aspect of American life, is now a quaint antique, replaced by digital clocks that can show the time in any time zone and play any sound we desire. Of course, these electronic components are not harvested from orchards, they must be built.

The manufacturing of electronic parts is a vast yet still growing industry, ranging from the salvaging of gold from discarded electronics to industrial firms with assets in the billions of dollars. And each part is, not to put too fine a point on it, its own world. One particular aspect of electronic machinery of note is the electromagnetic coil, an essential piece of technology for the modern age. Consisting of an electrical conductor, these days almost always a wire, the coil is wound up in a circular shape, such as a spiral, and are used in an electronic device where electrical currents interact with the world's magnetic fields. And again, these devices do not emerge from nothingness, and must be manufactured to very detailed specifications before they can be incorporated into a device. Coiling the wire usually falls as the task of coil winders, specialized machines that take a wire and transform it into the coil shape the device in question needs.

While there are other types of winders, the winders used for manufacturing electromagnetic coils are somewhat more complex than the ones used in fields such as textile manufacturing or material manufacturing. Most of these devices have a center roll on which the wire is wound up. Different winders come in different duty weights, such as light weight coil winters used in small shops for precise work to heavy duty coil winders used for large scale industry where precision must give way to power. Some are even small and compact enough for bench top use, though most are too large to be anything but free standing machines that require a human operator. Luckily, options are available to make the task easier on the operator. Many of these devices are programmable by an operator who knows the device, allowing for a greater level of consistent, repeatable quality in the resulting electromagnetic coils.

While this programming can take some training and practice, most winders are not incredibly complex programs and many are specifically coil winding built to be as user-friendly as possible. Some particularly high-end models can even memorize “recipes”, specific types of medical grade programmed functions for making a particular type of coil, and in most cases offer several different memory slots for programmed recipes for making coils, more than enough for all but the most unpredictable shop or factory. Control over the acceleration and deceleration of the winding process is also an essential aspect of the coil winding process, and many types of winder take this into account. Foot pedals that can hasten or slow down a coil winder are standard features these devices and can be essential for precision work in the production of electromagnetic coils.

Larger versions of these machines provide a more constant torque, sometimes requiring a permanent magnet direct current motor to power a gear reducer. Generally, these devices are larger than simple bench mounted models. Naturally, different coil winders handle various types of wire, with larger, thicker wires requiring a larger machine, whereas bench mounted models can usually only handle the lighter, finer types of wire.

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