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Coil Winding

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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 More…

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.
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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. $$$

Bristol, CT  |  800-825-4319

Established in 1973, Classic Coil Company is a Contract Manufacturer of electronic coils. We manufacture coils for a variety of industries; winding wire gauges from 4-58 AWG. We are ISO 9001-2015 certified, ITAR registered and DFARS Compliant. Our Engineering services allow us to assist with design, reduce cost, and increase efficiency in production. Call or visit our website to learn more about our capabilities.

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Classic 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. $$$

Alpha, NJ  |  800-867-3526

Since 1962, Torelco has been a supplier of electric coils and transformers of superior quality. We offer custom coils, solenoid coils, ferrite core coils & toroid wound coils to serve a range of industries. Markets served include medical, military, electronics, and industrial. When you work with us, our promise is to build to the exact specifications and meet the custom needs of our customers.

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Torelco $$$

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 $$$
placeholder image Sag Harbor Industries, Inc. Classic Coil Company Quality Coils, Inc. Torelco Johnson Electric Coil Company

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.