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Engineer's Design aids

 

Here we are going to build up a list of helpful futures, tools and design aids, used in the Coil Winding Industry.

Use the links below to jump to your required section

 

Wire size conversion AWG & SWG

Optimum Wire tension calculations

 Correction factor of coil resistance measurements

 Cycle time Vs volume output 

Wire specifications-definition

Toroid winding calculator

 

 

 

 

 

*Disclaimer

IWM does not warrant or assume any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed below.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AWG // SWG // mm Wire Size conversion

When looking at drawings, technical documents and specifications wire size can be shown in a variety of forms, however, when programming the winding machine most often you require mm.... make sense of it all here.

 

Use the Yellow cells to input your wire size, the Blue cell will show the conversion.

CSA = Cross sectional area.

   AWG - Bare Wire Diameter of Copper excluding insulation (AWG 1 - AWG 56)

 This wire can be expressed as: 

 Ømm  Øinches

With the following CSA:

 mm^2 inches^2 .

   SWG - Bare Wire Diameter of Copper excluding insulation (SWG 1 - SWG 50)
 This wire can be expressed as: Ømm Øinches
 With the following CSA: mm^2 inches^2
 

 

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Optimum Wire tension calculations

When winding it is vital that wire tension is optimised to achieve a good winding.
Use the Yellow cells to input your wire size, the Blue cell will recommend the optimum tension.
 

(mm)- Bare Wire Diameter of Copper excluding insulation

 Optimum tension for this wire is: Grams //   KG //   Lbs //   Ounces.

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 Correction factor of coil resistance measurements

When making winding resistance measurements, a given tolerance band from coil drawing will be set at a nominal ambient temperature
Use the Yellow cells below to adjust your reading from room temp. The Blue cell will show corrected actual reading.
Please bear in mind for air coils the measurement will require 8-12 hours to settle.

25 Deg Nominal

  Room temperature

Resistance in Ohms

 The corrected resistance for this reading to 25 deg nominal is   Ohms  

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20 Deg Nominal

Room temperature

Resistance in Ohms

 The corrected resistance for this reading to 20 deg nominal is   Ohms  

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 Cycle time Vs volume output

When making winding volume calculations, it is often important to know monthly and yearly production rates.

Use the boxes below to generate your figures.

 

Cycle time of product (Seconds)

Number of Machines

Efficiency (%) (1-99)

Yearly Operating Time (hr) / SHIFT  (Typical 2000Hrs)

Number of Shifts (1-4)

Production OUTPUT

@

Efficiency (100 %)   

Hourly Rates (coils per hour)

Monthly Rates (coils per month)  

Assumes each shift is 8 Hrs and there are 21.5 working days per month  

 

Yearly Rates (coils per year)

 

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 Wire specifications-definition

When investigating the various wire types available on the market today, it can become a mine field of specification numbers and complex variations thereof .                        

The list shown below aims to be a guide in simplifying this process.

Specification

 

 Part Sheet

 

 Description NEMA Previous BS

 

 Earlier BS
IEC 60317 0 1 General requirements - Enamelled round copper wire        
IEC 60317 0 2 General requirements - Enamelled rectangular copper wire        
IEC 60317 0 3 General requirements - Enamelled round aluminium wire        
IEC 60317 0 4 General requirements - Glass-fibre wound resin or varnish impregnated, bare or enamelled rectangular copper wire      
IEC 60317 0 5 General requirements - Glass-fibre braided resin or varnish impregnated, bare or enamelled rectangular copper wire      
IEC 60317 0 6 General requirements - Glass-fibre wound resin or varnish impregnated, bare or enamelled round copper wire        
IEC 60317 1   Polyvinyl acetal enamelled round copper wire, class 105   BS6811 3..5 BS4516
IEC 60317 2   Solderable polyurethane enamelled round copper wire, class 130, with a bonding layer MW 29-C BS6811 3..4 BS4738
IEC 60317 3   Polyester enamelled round copper wires, class 155      
IEC 60317 4   Solderable polyurethane enamelled round copper wire, class 130 MW 75-C BS6811 3..1 BS4520
IEC 60317 7   Polyimide enamelled round copper wire, class 220 MW 16-C BS6811 3..8 BS4663
IEC 60317 8   Polyesterimide enamelled round copper wire, class 180   BS6811 3..2 BS4665
IEC 60317 10   Enamelled round copper wires with a temperature index of 180 for use in refrigerant systems        
IEC 60317 11   Bunched solderable polyurethane enamelled round copper wires, class 130, with silk covering   BS6811 3..6  
IEC 60317 12   Polyvinyl acetal enamelled round copper wire, class 120   BS6811 3..7  
IEC 60317 13   Polyester or polyesterimide overcoated with polyamide-imide enamelled round copper wire, class 200 MW 35- C/A BS6811 3..3  
IEC 60317 14   Polyvinyl acetal enamelled round aluminium wire, class 105   BS6811 5..1  
IEC 60317 15   Polyesterimide enamelled round aluminium wire, class 180   BS6811 5..2  
IEC 60317 16   Polyester enamelled rectangular copper wire, class 155   BS6811 4..4  
IEC 60317 17   Polyvinyl acetal enamelled rectangular copper wire, class 105   BS6811 4..5  
IEC 60317 18   Specifications for particular types of winding wires. Part 18: Polyvinyl acetal enamelled rectangular copper wire, class 120 BS6811 4..6  
IEC 60317 19   Solderable polyurethane enamelled round copper wire, overcoated with polyamide, class 130 MW 28-C      
IEC 60317 20   Solderable polyurethane enamelled round copper wire, class 155 MW 79-C BS6811 3..9  
IEC 60317 21   Solderable polyurethane enamelled round copper wire overcoated with polyamide, class 155 MW 80-C      
IEC 60317 22   Polyester or polyesterimide enamelled round copper wire overcoated with polyamide, class 180 MW 76-C/A BS6811 3..10  
IEC 60317 23   Solderable polyesterimide enamelled round copper wire, class 180 MW 77-C BS6811 3..11  
IEC 60317 24   Polyester or polyesterimide enamelled round aluminium wire overcoated with polyamide, class 180        
IEC 60317 25   Polyester or polyesterimide overcoated with polyamide-imide enamelled round aluminium wire, class 200 MW 35-A BS6811 5..3  
IEC 60317 26   Polyamide-imide enamelled round copper wire, class 200 MW 16-C BS6811 3..12  
IEC 60317 27   Paper tape covered rectangular copper wire MW 33-C BS6811 8..1  
IEC 60317 28   Polyesterimide enamelled rectangular copper wire, class 180        
IEC 60317 29   Polyester or polyesterimide overcoated with polyamide-imide enamelled rectangular copper wire, class 200 MW 36-C      
IEC 60317 30   Polyimide enamelled rectangular copper wire, class 220 MW 20-C BS6811 4..7  
IEC 60317 31   Glass-fibre wound resin or varnish impregnated, bare or enamelled rectangular copper wire, temperature index 180 BS6811 6..1 BS4799
IEC 60317 32   Glass-fibre wound, resin or varnish impregnated, bare or enamelled rectangular copper wire, temperature index 155 BS6811 6..2  
IEC 60317 33   Glass-fibre wound resin or varnish impregnated, bare or enamelled rectangular copper wire, temperature index 200 BS6811 6..3  
IEC 60317 34   Polyester enamelled round copper wire, class 130L        
IEC 60317 35   Solderable polyurethane enamelled round copper wire, class 155, with a bonding layer   BS6811 3..13  
IEC 60317 36   Solderable polyesterimide enamelled round copper wire, class 180, with a bonding layer MW 1000 BS6811 3..14  
IEC 60317 37   Polyesterimide enamelled round copper wire, class 180, with a bonding layer   BS6811