Perfect Layer/ Orthocyclic Winding

Working closely with our customers, coil- winders and associated machinery manufacturers has given us an unrivalled knowledge of the techniques to achieve ‘perfect layer’ or 'orthocyclic' windings.  With experience built on 50 years of precision injection moulding of bobbins, we are able to incorporate features into the bobbin that allow coil winders to repeatedly and reliably produce perfect layer coils.  We help designers looking to achieve more performance from their coils whilst production departments enjoy higher yield, less scrap and superior build quality.

The perfect layer winding technique allows a 90% fill factor of the winding window compared to a traditionally random wound coil which might only achieve 65-70% fill factor at best.  Using perfect layer/ orthocyclic winding techniques fill factors of 90% have been achieved by customers giving more turns in the same physical area without a significant compromise on spindle speed during production.  The foundation to the coil is a precision bobbin which ensures the first layer is applied in a uniform fashion allowing subsequent layers to fall into the groove below whilst the bobbin flanges remain perpendicular to the tube to prevent the wire spilling out and becoming randomly wound.

In addition, customers using perfect layering also report that they have significantly lower failure rates of wound coils from the field due to the reduction in 'hot spots' within the winding due to the uniform coil structure.