Producing wound components

This page provides practical guidance for students, staff and researchers at this University who need to wind their own inductors, transformers or solenoids. The types of wound components available, and their applications, are so varied that only general guidelines can be provided. A more complete appreciation of their capabilities (and limitations) is only gained through experience and experimentation.

Before deciding to produce a custom inductor consider whether you have an alternative. If you are designing a filter circuit, for example, then below about 100kHz it becomes attractive to use either op-amp circuits or switched capacitor ICs instead. If an inductor has to be used then look to see if it can be obtained as an 'off the shelf' part from one of the usual distributors.

Here is a procedure that you can follow to design an inductor. It may not be the most scientific way (it's somewhat 'trial and error') but it's easy to follow and understand -

  1. Decide what type of core is best.
  2. Calculate how many turns to put on.
  3. Check that saturation will not occur.
  4. Decide what wire to use.
  5. Check that there is enough space to hold the wire.
  6. Obtain the parts.
  7. Construct the coil.
  8. Test the coil.

If you find at step 5 that the core size selected in step 1 cannot accommodate the number of turns of the wire chosen then select a larger one and start again at 2.

About your browser: if this character '×' does not look like a multiplication sign, or you see lots of question marks '?' or symbols like 'Rectangular box symbol' or sequences like '&cannot;' then please accept my apologies.

See also ...
[ TSU Advisor index] [Using the TSU coil winder] [ Air coils] [A guide to the terminology used in the science of magnetism] [A guide to unit systems in electromagnetism] [ Power loss in wound components] [The force produced by a magnetic field] [ Faraday's law] [ Permanent magnets] [Bibliography] [Acknowledgements]










Choosing a Core

The most important considerations in core selection are usually -

A very approximate guide might be -

Appropriate core types
Min L Max L Type of Core Adjus-
table?
High
current?
Frequency
limit
20 nano henry 1 micro henry Air cored, self supporting Y Y 1GHz
20 nano henry 100 micro henry Air cored, on former N Y 500MHz
100 nano henry 1 milli henry 'Slug' tuned open winding YN500MHz
10 micro henry 20 milli henry Ferrite ring NN500MHz
20 micro henry 0.3 henry RM Ferrite Core YN1MHz
50 micro henry 1 henry EC or ETD Ferrite Core N Y1MHz
1 henry 50 henry Iron N Y 10kHz

Ring cores

Ring cores (AKA 'toroids') are widely available in every grade of ferrite, compact, inexpensive and useful when relatively few turns are needed. They have the most efficient shape from the viewpoint of core utilisation. The core factor is directly calculable. However, their disadvantages are significant. Without special apparatus they are harder to wind than you might think. Lacking a coil former, as the wire is threaded on, what keeps it away from the abrasive ferrite surface? What prevents the ferrite (some grades of which have relative permittivities approaching 106) from raising winding capacitance? What supports the core during winding? Instead of coil former pins how will you anchor the ends of the winding? How do you mount it on a PCB?

Rings are sometimes available with a coating of polyamide, polyurethane or other insulation. This protects the wire and helps to reduce self-capacitance by keeping the turns away from the ferrite. Current handling is limited because no air gap is possible. For these reasons toroids are mainly used above 100 kHz.

Rings made from iron dust are also available. These can have saturation points of 1T or more but permeabilities of 30 or less are common for dust cores. Some grades will perform well into the VHF region. Magnetic field leakage is low.

RM cores

RM cores are a popular choice at frequencies up to 1MHz and currents up to 1A. The formers are supplied with up to 8 pins which bring connections to or from the coil(s) and which may easily be incorporated into a layout. The bobbin material is brittle and care must be taken not to bend the pins. The clips holding the core at the sides are rather crude and it's easy to chip the ferrite when removing them. For these reasons they are not ideal for prototype work.

Two basic types of RM cores are available: gapped and ungapped. Ungapped cores suitable for power applications are available with a different grade of ferrite which has a lower permeability but a higher value of saturation flux.

The size designations, RM6, RM7, RM10 etc. indicate that adjacent cores require a minimum spacing of 0.6, 0.7 or 1.0 inches on the PCB.

E Cores

EC and ETD cores are intended for high power applications such as switch mode power supplies and DC to DC converters. For experimental work I recommend the ETD29 core in preference to the RM core because it has more space and the pins are more numerous and robust. Transfer your design to the RM if you decide that a smaller 'footprint' is needed.

If using an ungapped EC core you can place thin pieces of plastic between each half to obtain a gap which can be made precisely the right width.

Slug Tuned Coils

There are currently three types of slug tuned coil assemblies in use in the School. These have 6 PCB pins and are suitable for low power IF transformers, filters and tuned circuits. They are most suitable when the inductance required must be adjustable. See separate description of these cores.

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Iron Cores

Iron is the oldest magnetic core material. Its advantages include a high saturation flux (2.1T) and a high relative permeability (7000). It is no longer used for transformers in its pure form for two reasons.

Firstly, iron has high remnance (1.3 T) and coercivity (80 A m-1). This results in hysteresis power loss. The remedy is to include a small amount (about 3%) of silicon. This reduces the loss by at least a factor of 10.

Secondly, iron will conduct current. This is bad in a transformer core because eddy currents lead to further power loss. As a result transformers with iron cores are limited to audio frequencies or below. Even then, the iron is used in stacks of thin sheets (laminations).

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Calculating the number of turns

Decide the number of turns to wind on according to what you want to achieve: a known inductance, winding current or winding voltage waveform ...

Known inductance

For high permeability core inductors this is simple if you know the value of inductance required and the quoted Al value of the core.

N = (109 × L / Al)1/2
Equation WCA


Example: We need to make an inductor using the standard example toroid core. How many turns do we need for 82 μH?

N = (109 × 82×10-6 / 2200)1/2 = 6.1 turns
Equation WCB


If the coil is air cored then you will need to re-arrange one of the traditional formulae for calculating the inductance of such coils from the dimensions and the number of turns.

Known winding current

A common strategy is to work the core at close to its saturation flux level.

N = Bsat le / (μ I)   turns
Equation WCC


Example: We need to make an inductor capable of carrying 1.3 amps using the standard example toroid. How many turns can be used?

N = 0.36 × 27.6×10-3 / (1.257×10-6 × 2490 × 1.3) = 2.4   turns
Equation WCD


In other words, we cannot put on more than two turns without hitting saturation! This gives us just 8.8 μH.

Known winding voltage waveform

The maximum total core flux is given by:

Φ = Bsat×Ae
Equation WCE


Where Bsat is the maximum flux density which can be supported by the particular material used for the core. By re-arranging Faraday's law,

N = ( Time integralE.dt ) / Φ   turns
Equation WCF


where E is the externally applied voltage.

Example: We need to make a transformer for a switching supply using the standard example toroid. The supply to the primary is 12 volts and the maximum 'on time' for the switch is 10 micro seconds. How many turns must we use?

Φ = 0.36×19.4×10-6 = 6.98×10-6 webers
Equation WCG


N = (12×10-5)/(6.98×10-6) = 17.2   turns
Equation WCH


Here we must round up to 18 turns. With the current driven winding the flux increased with the number of turns but with a voltage driven winding the flux goes down with the number of turns. Honest. Please address any complaints on this issue to m.faraday@rigb.org.

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Choosing the type of wire

In almost all cases this will be single strand 'enamel' insulated, also known as magnet wire. The coating is usually of poly vinyl acetal, polyester or polyurethane. The last of these is self-fluxing during soldering. It is manufactured to tightly controlled specifications laid down in standards such as BS 4520 and NEMA MW*. It can stand temperatures up to 120 centigrade or more for long periods.

There are some possible exceptions to this choice -

Coils carrying currents above about 3A. If you are using a small diameter core (RM series) it can be difficult to manipulate thick enamel wires. A better idea is to divide the winding up into two or more thinner wires which are wound on simultaneously and joined at the ends. An additional advantage of this approach is that losses due to skin effect are reduced.
Low loss coils with a Q-factor higher than about 200 and 'wave wound' coils having a high self resonant frequency. For these coils it may be necessary to employ multi-strand 'Litz' wire. Wave wound coils cannot be produced using wire with standard enamel insulation on the outside because the turns slide over each other too easily (a product called Gripeze does have a non-skid surface). Cotton covered wires are sometimes used.

The next step is to calculate the thickness of wire required.

For self supporting coils this is usually decided on mechanical grounds; the larger the diameter of the coil the larger the diameter of wire used. A coil of 6 millimetre internal diameter might use 0.5 millimetre wire. Increase this pro rata if the coil takes heavy current.

For normal coils the diameter is chosen so that temperature rise and efficiency are both acceptable. Modern insulation materials are able to withstand temperatures so high that designing for tmax alone is probably not sensible. See the section on copper losses for more details.

You are encouraged to bring your own supplies of wire if using the Workshop winding machines but if the quantity you require is small (<20g) then ask a member of Workshop staff.

Handling wire

Always handle reels of thin enamel wire by the ends. When such wire is used in equipment at high temperature or high voltage for long periods of time then the acids present in fingerprints can lead to insulation failure.

After using a reel please anchor the ends of the wire to the bobbin either using tape or by a hole or slot cut in the flange. Never simply tuck one turn under another; the next user won't realise what has happened and will attempt to unwind the free end - until the reel jams, usually leaving it a write-off.

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Coil formers

Coil formers, which are made of an insulating material, are bobbins onto which wire may be wound so that each turn is of the correct diameter and is held in place around whatever core material (if any) is used.

If you need many turns (>20) and wish to use one of the coil winders in the workshop then you must use a coil former.

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Self resonance

Ideal and practical models of inductors Self resonance is the term used to describe the way in which the electrical characteristics of wound inductors deviate at high frequencies from that of an ideal inductor. The reactance of an ideal inductor increases linearly with frequency.

The practical inductor model includes a capacitor in parallel with the ideal inductor in order to represent stray capacitance between each turn and the turn next to it. There will also be distributed capacitance to any core that is used, and an exact model is too difficult to derive.

The consequence of this stray capacitance is that at some point (called the self resonant frequency) the impedance of the inductor will reach a peak. At higher frequencies the stray capacitance will become dominant and the impedance will begin to drop.

If you are deliberately using the inductor as part of a resonant circuit then it is important to note that the Q factor of a self resonant circuit is generally not high. Better values of Q can be obtained by choosing a smaller value of L and adding external capacitance to tune it. This behaviour is the reverse of that predicted by the simple formula for Q.

One method of minimizing self capacitance is to use 'wave wound' coils.

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Calculating the space for the windings

Once the thickness of wire and the number of turns has been decided, a check should be made that sufficient space exists on the coil former. It is sometimes imagined that turns can be packed in thus - Naive packing scheme

This is impossible because if the first layer is wound from the left hand side of the coil former to the right hand side and has a normal 'right handed thread' (like a screw) then the second layer will have a 'left handed thread' as it moves back from the right side to the left. Since the turns on adjacent layers do not lie precisely parallel to one another, and must cross over at some point, they cannot always sit in the arrangement shown above. That said, the 'hop over' stretches may be quite short and much of the turn may still be in close contact with the turns below.

In practice you should allow for each layer to be separated by the whole thickness of the wire from the one underneath. The value of thickness used should be taken about 10% greater than the actual thickness to allow for irregularities. This applies only where the wire is fed on taking care that one turn is in close contact with the next. When thin wire (<0.2 millimetres) is used then this becomes impractical. About 15% should be added to the real diameter in the case of 'random wound' coils.

The wire sizes quoted in catalogues always refer to the diameter of the conductor. The enamel insulation increases this by about 10%.

Example -

  Core type RM7,  conductor diameter 0.56 millimetres


  From data sheet -
    Length of winding space = 7 millimetres
    Height of winding space = 3.1 millimetres

  Nominal diameter including insulation = 0.56 × 1.10 = 0.62
  Working diameter of wire = 0.62 × 1.10 = 0.68 millimetres

  Turns per layer = 7 / 0.68 = 10
  Maximum number of layers = 3.1 / 0.68 = 4

  Total = 10 × 4 = 40 turns.

This method produces conservative estimates which allow for any lead-out wires and extra insulation that may be needed.

Usually it is only possible to keep close packing going for about 4 or 5 layers without the 'cross over' effect mentioned spoiling the winding. By placing a layer of polyester or masking tape round the coil after every 2 or 3 layers to 'stabilise' the winding then close packing can be continued indefinitely.

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Sources of Supply

Not all companies are prepared to deal in the small quantities that an experimenter usually requires. Try to reward those that are with a sensibly sized order.

Here is a small selection of external links which may be of use to you. A few of these companies have indicated that they may be able to supply this University with sample products †.

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Constructing the coil

There are two basic types of enamel wire insulation. You will need to remove it at the ends to make electrical connection.

1) Conventional enamel. This is usually dark brown in colour. In a production environment it is removed by a special rotary stripping machine. For prototype construction thick (>0.2mm) wire is best stripped with a scalpel blade. Rest the wire on a firm, flat surface and scrape the blade along at right angles to the wire.

Thinner wire is best stripped with fine sandpaper or emery cloth, although this is very slow. The process can be speeded up by first burning the enamel using a fine gas jet. This will leave a carbonized residue but this is much easier to sand away.

2) Self-fluxing enamel. This is usually pink or straw coloured. If you have a solder pot then simply dip the end of the wire in for a few seconds. The enamel will melt readily leaving you with a ready tinned end.

You can also remove the insulation if you have a soldering iron hot enough to melt it - about 400 centigrade. Most thermostatically controlled irons can be adjusted to run at this temperature. The joint will have been made correctly after the insulation is seen to 'bubble' for a second or two. When this happens the fumes emitted contain a small quantity of toluene di-isocyanate gas which is toxic and irritant.

If bubbling does not happen then the iron is not at the right temperature. Provided the soldering temperature is adequate, 'dry' joints are very rare.

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Testing the coil

Any of the digital readout inductance bridges should give a reasonably good idea of the inductance of your coil. More precise tests can be made with the HP bridge in the final year lab. This can test over a range of frequencies, and can also determine the Q factor.

If you don't get the right inductance then remember that this is related to the square of the number of turns. If your inductance is 20% too low then you must increase the turns by just under 10%.

If you are building a power transformer then bear in mind the non-linearity of permeability.

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Dead Tree

The principles involved in designing a simple wound component have changed little in the last 100 years; so older publications may contain useful, or perhaps just more comprehensible, information. Most of these publications are out of print but are included here as sources of reference.

Few of the vast number of works covering electromagnetism are without value, but a topic described intelligibly in one may be totally opaque in another.

  1. Agilent Technologies, 'High Accuracy and Fast RF Inductor Testing', Applicaton Note 369-10.
      Do precisely what it says in the title ... if you have a HP 4285A LCR Meter.
     
  2. Balanis, Constantine A. 'Antenna Theory', 2nd. Edit., John Wiley, 1997, ISBN 0-471-59268-4
    Heavily mathematical but unavoidable if you are into loop antennas. SI units.
     
  3. Babani, Bernard B. 'Coil Design and Construction Manual', Bernard Babani (publishing) Ltd. 1960, ISBN 0 85934 050 3
    Empirical formulae, data tables and construction guidance. Highly practical. Mainly iron-core devices; no ferrites. CGS units.
     
  4. Bozorth, Richard M. 'Ferromagnetism', Van Nostrand 1951.
    A wealth of experimental techniques, results and data. There's also a (pricey) 1993 edition. CGS units.
     
  5. Chambers, Ll. G., 'An introduction to the Mathematics of Electricity and Magnetism', Chapman and Hall 1973, SBN 412 10990 5.
    The equations are hard going for non-mathematicians but the notes are copious, intelligible and often revealing. Lots of examples. SI units.
     
  6. Dugdale, D. 'Essentials of electromagnetism', Macmillan Press, 1993, ISBN 0333563026.
    Rather dry and mathematical, but useful if you already have an idea what is being described. Good appendix on units.
     
  7. Duffin, W. J. 'Electricity and magnetism', McGraw Hill, 1980 ISBN 007084111X.
    A conventional approach but written so that the maths is easy to digest.
     
  8. Flanagan, William M. 'Handbook of Transformer Design & Applications', 2nd. Edit., McGraw Hill, ISBN 0-07-021291-0.
    Written by someone with much experience of the design and specification of power transformers. Strong on materials selection and reliability criteria. Non-SI units.
     
  9. Grover, Frederick W. 'Inductance Calculations (Working Formulas and Tables)', Dover Publications; , 1982, ISBN: 0486495779.
    A very comprehensive collection: Mutual and self inductance for all geometries of air coil, the force between coils. Appeals both to the practising engineer and those seeking the underlying theory. Mixed units.
     
  10. Hammond, P. and Sykulski, J.K., 'Engineering electromagnetism: physical processes and computation', Oxford University press, 1994, ISBN 0 19 856288 8.
    The most accessible introduction to electromagnetic field theory that I have seen. Bundled with DOS software for numerical analysis. SI units.
     
  11. Jansson, L. E. 'Power-handling capability of ferrite transformers and chokes for switched-mode power supplies', Technical Note 31, Mullard Limited, 1975.
    All you need to know in order to determine the power throughput of a given core in any switching configuration.
     
  12. Jiles, David, 'Introduction to magnetism and magnetic materials', 2nd. edit., Chapman and Hall, 1998, ISBN 0 412 79860 3
    One of the few up to date texts on magnetism around. Starts with the basics and progresses up into quantum theory. Strong on technological applications. SI units.
     
  13. Kaye, G.W.C & Laby, T.H. 'Tables of Physical and Chemical Constants', 14th. Edit., Longman, 1973, ISBN 0 582 46326 2.
    A useful source of data for scientists, but only about 8 pages relate to the magnetic properties of materials. Now available online. SI units.
     
  14. Klein, H. Arthur, "The World of Measurements", 1974, George Allen Ltd., ISBN 0 04 500024 7
    A wander through the history of science and its unit systems which, although sometimes rambling, is completely intelligible.
     
  15. Kraus, John D., 'Electromagnetics', 4th. Edit., McGraw-Hill, 1991, ISBN 0-07-112661-9.
    A deservedly popular text, many illustrations, covers a lot of ground. Magnetic components are described in preparation for Maxwell's equations and finally antennas. SI units (tables included).
     
  16. Lee, Rueben 'Electronic Transformers and Circuits', John Wiley & Sons Inc, 1988, ISBN 047181976X. Another post WW2 text, but clearly written.
     
  17. Meyer, H. W., "A history of Electricity and Magnetism", 1971, The MIT Press, ISBN 0 262 13070 X
    A narative concentrating on the work of the pioneers.
     
  18. Nadkarni, M.A., S.R.Bhat 'Pulse Transformers, Design and Fabrication', McGraw-Hill 1985.
    Has a practical approach. Non-SI units.
     
  19. Sauer, H. Modern Relay Technology, 2nd. edit., 1986, Huethig, ISBN 3-7785-1251-X.
    More a data book on one company's relays than a text book, but still excellent none the less.
     
  20. Smith, Ralph J. 'Circuits Devices and Systems', 2nd. Edit., John Wiley. 1971, ISBN 0-471-80170-4
    A general electronics textbook from my day (i.e. now out of date). About 100 pages within Part III relate to the material here. Lots of helpful examples. MKS units.
     
  21. Snelling, E.C. 'Soft Ferrites Properties and Applications', 2nd. Edit., Butterworths, ISBN 0-408-02760-6.
    If you are using a ferrite core and this book doesn't have the answer then you are in trouble. Wide ranging both in theory and practice. The maths is intelligible and (bliss o' joy) uses SI units. I can't afford a copy of my own :-(
     
  22. Terman, F.E. 'Radio Engineers' Handbook', McGraw-Hill 1943.
    An influential work which, together with 'Radio Engineering', supplied the practising engineer with information previously buried in scientific papers and technical journals. Early editions are strong on air coils, skin effect, mutual-inductance, self-capacitance and Q-factor. Mixture of cgs and Imperial Units.
     
  23. Wheeler, H.A. 'Simple Inductance Formulas for Radio Coils', Proc. I.R.E., Vol 16, p.1398, Oct.1928

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Other external links

Software: mini Ring Core Calculator.

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Acknowledgements

Thanks are due to the following for their kind assistance on the subject wound components:

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E-mail:R.Clarke@surrey.ac.uk
Last modified: 2014 July 22nd.