Demonstrating Next-Generation Coil Forming Technologies within FEMM Hub

Research into bar wound coil forming within FEMM Hub Grand Challenge 2 has advanced to an exciting demonstration phase. A prototype coil winding system has been successfully integrated with a commercial winding machine at the Advanced Manufacturing Research Centre (AMRC).

Researchers Dr Steve Forrest and Dr Dave Hewitt, from the University of Sheffield School of Electrical and Electronic Engineering have developed techniques and experimental hardware to produce coils with competitive slot fill densities, in larger profile square conductors. The prototype coil forming demonstrator hardware adapts a Winding Technology WT500 winding machine, to achieve coil forming capability, in both solid and hollow bar type conductors. 

Earlier laboratory trials of the coil forming techniques have been successful and evaluated the individual elements of the forming process. The integration of the coil winding machine will allow further automation and forming at a more consistent winding tension, for a given coil, through constant winding speed and torque. Moreover, this will facilitate an investigation of winding tension, speed and torque and the effect on the net coil geometry.