Coil Winding

A reliable source for Electric Coil information and leading Electric Coil Companies & Manufacturers.

Coil winding is a method for producing electromagnetic energy by winding a conducting wire as a coil, spiral, or helix. The key to coil winding is the method used to wind the coil, which can be pancake, jumble or wild, toroidal, helical, or orthocyclic. Each of these methods produces a different strength of electromagnetic energy. Read Moreā€¦

Coil Winding Coil winding is a method for producing electromagnetic energy by winding a conducting wire as a coil, spiral, or helix. The key to coil winding is the method used to wind the coil, which can be pancake, jumble or wild, toroidal, helical, or orthocyclic. Each of these methods produces a different strength of electromagnetic energy.

Leading Manufacturers

Sag Harbor, NY  |  800-724-5952

We are proud of the craftsmanship of our engineers. All of our products are made right here in the United States and we promise that these items are created from high quality resources. Our electrical coils are unique and efficient.

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Sag Harbor Industries, Inc. $$$

Antigo, WI  |  800-826-9741

Johnson Electric Coil Company is a family owned manufacturer that specializes in custom transformers, coils and inductors. From three phase isolation transformers to single phase inductors and chokes, we carefully design our products to meet your exact specifications.

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Johnson Electric Coil Company $$$

Bristol, CT  |  860-584-0927

We are an ISO 9001:2015 certified company which is internationally known for manufacturing high quality electromagnetic-coils. It is our goal to provide quality products, a commitment to speedy delivery, and competitive pricing. We understand that every application is unique, so we encourage you to contact us to discuss your specific requirements. Call us at 1-860-584-0927 and find out what our 50+ years of experience can do for you.

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Quality Coils, Inc. $$$

North Manchester, IN  |  260-982-8508

At Custom Magnetics, we manufacture transformers and coils, custom designed, for electrical and electronics industries. Our products often serve applications such as audio amplifiers, intercoms, power supplies, transducers, transportation, power generation, etc. Many types of transformers are produced including laminated, toroidal, ferrite cores of all shapes and sizes, and R-Core. Call today!

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Custom Magnetics, Inc. $$$

McAllen, TX  |  888-664-9495

Industrial Coils, LLC is a leading manufacturer that specializes in high quality custom solenoid coils wound to customer's specifications From three phase isolation transformers to single phase inductors and chokes, we carefully design our products to meet your exact specifications. Our experienced engineers are available to assist during every step of the process. Let us make great parts for you!

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Industrial Coils, LLC. $$$

Marlton, NJ  |  800-822-9190

Repco Inc. was founded in 1976. Our name stands for Replacement Electrical Parts Co. The products currently sold by Repco are electrical contacts and coils for industrial control and carbon brushes for industrial motors. The business is located approximately 12 miles east of the city of Philadelphia in Marlton, NJ.

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Repco Inc. $$$
placeholder image Sag Harbor Industries, Inc. Johnson Electric Coil Company Quality Coils, Inc. Custom Magnetics, Inc. Industrial Coils, LLC. Repco Inc.

The efficiency and reliability of a coil depends on how tightly wound the conductor is. Ones that are densely packed with no air space have increased efficiency and excellent heat conductivity. The differing methods of winding account for the density and conductivity of the coil.

The most used, but least efficient, method of coil winding is jumble or wild, a process that can be done quickly. In the jumble method, wires are placed randomly, which causes a wider distribution of wire lengths and ranges of coil resistances. Jumble winding is mainly used for high volume production and for the manufacturing of small transformers, ignition coils, and small electric motors with small gauged wires of less than 0.05 mm.

Toroid coil windings are used in low frequency applications to boost the frequency of the electrical coil. As the toroid coil turns, the frequency increases. They are produced by winding copper wire around the circumference of a circular ring, which evenly distributes the wire. A toroid winding has low core loss with increased power density.

Orthocyclic coil winding has an excellent fill factor. Each layer of conductors is placed in the grooves of the previous layer. Wires are wound parallel to the coil flange for the greatest amount of volume. A step is created when the winding goes around the coil body to meet the previous wire, which is called a winding step. The area of each step is determined by the wire gauge and coil bobbin geometry.

Helical winding is cylindrical. The winding process leaves a gap between each adjacent turn. Flat rectangular parallel conductors are placed close to each other in the radial direction of the winding. Transpositioning of the conductors creates uniform distribution of the current.

In pancake winding, conductors are aligned like discs. Pancake winding normally refers to a type of coil used for shell form transformers. In the winding process, wires are wound in a rectangular pattern with their wide face horizontal or vertical. This form of winding is used for interleave arrangements.