Aerospace transformers and coil winding

Transformers are electrical components, electrical components used to change the voltage and current in an alternating current circuit.

The core of a transformer is made of a stack of soft iron laminations, and the windings, which consist of several coils of insulated wire, are wound around the core. The winding connected to the power source is called the primary winding, and the windings connected to the electrical loads are called secondary windings.

The voltage difference between that across the primary winding and that across any one of the secondary windings is directly proportional to the ratio of the nuymber of turns in the secondary winding to the number of turns in the primary winding. The higher the ratio, the higher the secondary voltage.

The current difference between that in the primary winding and that in the secondary winding is inversely proportional to the ratio of the number of turns in the secondary winding to the number of turns in the primary winding. The higher the ratio, the lower the secondary current.

The majority of custom coil wound components are produced using copper wire but when called for special purpose coils, use specialist wires such as Nichrome wire, Aluminium wire and super-conducting wire.

Wound components coil winding, sometimes called toroid winding, mostly produces electric motors for Aerospace.

Perfect layer coils employ the orthocyclic winding method and reducing the size of certain coils produces transformers which eliminate burn out problems in high voltage situations due to the build of the orthocyclic coil.

Using automation can also guarantee high quality, consistent throughput and competitive pricing.

Where volumes are sufficient, operations such as coil winding, wire stripping, soldering, application of epoxy glue, vision checking, testing, printing and packing of coils are incorporated into an automated production cell.

Typically this means that a coil former or bobbin is fed into the start of the automated system by a bowl feeder and processed sequentially until the coil winding and assembly is complete.

Aerospace Synchros

Synchros are used to transmit angular data electrically from one location to another, where a high degree of accuracy is required. They are essentially variable transformers in which the coupling between windings varies with the rotor position relative to the stator.

Several different types are produced to suit particular applications and whilst their external appearance is similar, the internal construction varies to optimise the unit’s functional requirements.

Typical applications include remote positioning of low torque mechanisms, remote control by servo motor driven mechanism, remote digital measurement of angle via a suitable signal converter, remote pointer indication of angular position.