New inductor winding technology.

[Sceadwian]

https://www.electro-tech-online.com/custompdfs/2009/03/508PET22.pdf
3 pages of babble to say "Power inductors wind better if you crimp the inner ring of the toroid to increase density."
I love electronics publications =)

 

[Roff]

I would like to see a toroid winder in action that has this crimping capability. The standard, garden-variety toroid winder is already a minor miracle, in my humble estimation.

 

[crutschow]

Looks like a significant advance in the ability to wind toroids efficiently without winding gaps. Bet that winder would make Rube Goldberg proud.

 

[Sceadwian]

It looks like it's designed primarily around a single layer coil. With a static coil diameter all you'd need is a press tool spaced properly with the incoming feed wire. It's probably really simple.

 

[Roff]

It looks like it's designed primarily around a single layer coil. With a static coil diameter all you'd need is a press tool spaced properly with the incoming feed wire. It's probably really simple.

Well, yeah, but have you ever seen a running toroid winder? Maybe for single-layer coils, they don't use the winders with shuttles. The ones that have a human in the loop appear to be a lot simpler.
I searched for toroid winder on Youtube to see some current examples. The last one I saw running was about 50 years ago.

 

[Nigel Goodwin]

I would like to see a toroid winder in action that has this crimping capability. The standard, garden-variety toroid winder is already a minor miracle, in my humble estimation.

Years ago, Elektor did an article showing how they wind toroidal transformers, I never did understand how it worked!

 

[Ubergeek63]

https://www.electro-tech-online.com/custompdfs/2009/03/508PET22-1.pdf
3 pages of babble to say "Power inductors wind better if you crimp the inner ring of the toroid to increase density."
I love electronics publications =)

I was going to ask how is this new since they have been purchasable for years, but since I opened the link to check the date I will instead ask didn't you?

 

[ericgibbs]

https://www.electro-tech-online.com/custompdfs/2009/03/508PET22-2.pdf
3 pages of babble to say "Power inductors wind better if you crimp the inner ring of the toroid to increase density."
I love electronics publications =)

hi SC,
The pdf I mentioned is attached:

I couldnt add it to my temp blog file, for some reason, now cant edit my blogs.?

 

[MrAl]

Hi,

Very interesting. I see this as a positive step in the right direction for inductors,
however it pretty much leaves out hand winding unless we can come up with
a way to accurately squeeze the wire as needed. The shape would have to be
variable so that would make it even more difficult.

The interwinding capacitance would certainly INCREASE though, due to the
smaller gaps between winding turns.

 

[Sceadwian]

The crimped parts of the wire are effectively plates as well.

 

[crutschow]

Hi,

Very interesting. I see this as a positive step in the right direction for inductors,
however it pretty much leaves out hand winding unless we can come up with
a way to accurately squeeze the wire as needed. The shape would have to be
variable so that would make it even more difficult.

The interwinding capacitance would certainly INCREASE though, due to the
smaller gaps between winding turns.

It's usually the capacitance from one set of windings to another that's of interest (for isolation concerns), not the capacitance between two turns on the same winding.