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Induction Coils

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An induction coil electrical transformer converts a low-voltage direct current (DC) supply into high-voltage pulses. An induction coil converts energy from an electric current into a magnetic field or the other way around by storing it as a magnetic field in the core. By continuously interrupting the direct current in the primary coil with a vibrating mechanical contact known as an interrupter, the direct current can modify the flux to induce the voltage in the secondary coil. Read More…

Induction Coils An induction coil is a type of disruptive-discharge electric coil. It is used to transform low voltages of direct current flow into high-voltage pulses or a high-voltage alternating current flow.
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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 LLC $$$

North Fort Myers, FL  |  239-997-3860

Check out what’s new online at Precision Econowind, manufacturer of the highest quality custom coils at reasonable prices, with on time delivery. Serving the coil industry for over 30 years, we’re experienced with producing loudspeaker & medical industry coils, coils wound on customers’ bobbins/tooling; freestanding, flat wire, edge wound, square, rectangle & shaped coils. Submit your specs today!

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Precision Econowind, Inc. $$$

Perris, CA  |  951-277-0757

Triad Magnetics has been in the electric coils industry for over 75 years. Giving us the knowledge and expertise to be one of the best in the industry. We have a wide range of electric coils and inductors as well as the ability to custom engineer and manufacture electric coils to our customer’s needs. Having served the needs of many industries for more than half a century, Triad believes its experience makes the difference.

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Triad Magnetics $$$

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 LLC Precision Econowind, Inc. Triad Magnetics Johnson Electric Coil Company

An electromotive force is produced in the opposite direction to balance off the change by applying an alternating current to the windings. Induction coils are frequently utilized when low voltage needs to be converted to high voltage in televisions and other electronic devices. For example, a car’s ignition system converts power from the battery by an induction coil. Induction coils are simple devices. A core and insulated wires are twisted around the core to form the device.

An air core or a core consisting of magnetic materials can serve as the core. Insulated wires are winded around the core, and coils are either made using insulated wire or uninsulated wire (such as the so-called silver steel) but with an air gap to ensure the required distance between each wire turn. Turn-by-turn winding of uninsulated wire will result in a short circuit; even with some inductance, it won't provide the necessary inductance.

Electromagnetic Induction

How an Induction Coil Works

Two coils of insulated wire twisted around a common iron core make up an induction coil (M). The main winding (P), is a single coil with just a few coarse wire turns (tens or hundreds). The secondary winding (S), the other coil, is often made up of up to one million turns of thin wire (up to 40 gauge).

The DC supply current from the battery (B) must be frequently connected and disengaged to continuously operate the coil and produce the variations in the magnetic field required for induction. Induction coils use an interrupter or break (A), a magnetically actuated vibrating arm, to quickly link and break the current flowing into the primary coil. The primary circuit's pair of contacts (K) open and disconnect the primary current when the armature has moved far enough. The magnetic field collapses when the current is cut off, resulting in the spark.

On break, an arc occurs at the interrupter contacts, which has unfavorable consequences: the arc consumes magnetic field energy, lowers output voltage, and wears out the contacts. A quenching capacitor (C) of 0.5 to 15 F is connected across the primary coil to reduce the voltage rise after a break to avoid sparks.

The primary magnetic field is produced when an electric current flows through. Most of the magnetic field from the primary winding couples with the secondary winding because of the shared core. The primary winding acts like an inductor, storing energy in the magnetic field it produces. The magnetic field quickly collapses when the main current is abruptly cut off.

Electromagnetic induction induces a high-voltage pulse across the secondary terminals. The secondary voltage pulse is generally hundreds of volts due to the secondary coil's enormous number of spins. An electric spark can frequently be produced by this voltage when it jumps across the air gap (G) separating the secondary winding’s output terminals. Induction coils were originally known as spark coils for this reason.

Working Principle

Power Losses in Induction Coils

Three main categories of power loss are taken into account while using coils. The first is the power loss experienced in a winding wire's serial resistance. When the current running through the coil has a high amperage and causes power losses, this is the most typical source of power loss in power supply circuits. The coil overheats, and as a result, overheats the gadget.

The second power loss is due to overheating of the coil, which overheats the gadget. In addition to being the most frequent source of damage, high temperatures can also short-circuit the coils and ruin the insulation. The third kind of power loss is caused by a loss of magnetic flux, which might be spread out by mechanical mounting components, air gaps in the coil's core, or careless fabrication during coil production.

Applications of Induction Coils

Wireless charging

The electromagnetic induction theory underlies wireless charging. When an electric current is transmitted through an induction coil, a magnetic field is created; this magnetic field's action causes a second, farther away coil to produce an electric current.

Short-circuit the direct current (voltage)

Since there is no change in DC, the inductor has no effect. However, the inductor opposes changes in the current. Since the voltage across the inductor in a DC system is zero, the di/it is zero, and a short circuit results.

Building filters for frequencies

Line filters, which enhance the power quality of an electrical power system, use induction coils to filter frequencies.

Decreasing or increasing voltage

Transformers employ induction coils to raise or lower the voltage in an electrical power system.

Induction heaters

Eddy current occurs on the rebar surface when a high-frequency electric current is applied to an induction coil, creating an alternating field around the coil. Inducing heat in the rebar is this current.

Amplifier coupling

Many electronic devices require numerous amplifiers and stages of amplification. More amplification stages are added when a single stage cannot deliver the necessary amplification. Impedance coupling employs inductive coils.

Impedance Coupling

Advantages of Induction Coils

  • Energy savings
  • Localized, constant, and precise heating
  • Temperature control
  • Improved process efficiency
  • Pollution-free, fast, and secure technology
  • Possibility of integration into production lines
  • Improved working environment
  • Best quality and yield/performance

Disadvantages of Inductions Coils

  • Both the equipment's cost and the process's cost are very high.
  • Wireless charging provides very slow charging.
  • Induction heating coil efficiency is typically less than 50%, which is low.

Induction Coils Informational Video

 

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