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ADVANCED RFID COIL FOR A NEW GENERATION OF SENSORS

Customer-specific bobbin coil manufactured by KUK Group: At Elesta GmbH, it serves as an antenna in an RFID sensor.
Customer-specific bobbin coil manufactured by KUK Group: At Elesta GmbH, it serves as an antenna in an RFID sensor.

In a larger project, KUK Group supported the Swiss technology company Elesta GmbH in the development of a new generation of functional safety sensors. In addition to the quality of the RFID coil, the optimal support throughout various project phases was convincing.

Elesta took the development of a new generation of RFID sensors as an opportunity to re-qualify suppliers for winding goods. The sensor in question is designed, among other things, for the magnetic monitoring of protective door devices, such as those used for packaging machines. The customer-specific bobbin coil serves as an antenna in this RFID sensor.

The requirements for these safety sensors are very high; for example, their functional safety must be checked every 100 ms under the conditions of machine safety. Compared to the current product, the design has been revised; in addition to technical improvements, the size has also been minimised, making a new RFID coil necessary.

Short response time for prototypes

«For ELESTA GmbH, the most important selection criteria for qualifying suppliers of customer-specific components and engineered parts are technical know-how and support, production of samples, series production and value for money,» says Martin Grimm, system architect at ELESTA GmbH.
KUK Group was outstanding in this project in an early development phase with good support and prototypes.

Modified requirements for bobbin coil implemented

Not only the bobbin coil is customer-specific, but also the packaging. Thanks to the specifically developed tape and reel packaging, the coils at Elesta go directly from incoming goods to SMD production.As often happens in demanding technology projects, the client had a number of requirements that changed during the various development phases. "With KUK, we were able to solve all challenges together and at eye level. In addition to the purely technical aspects, the way we worked together was a decisive factor for me," says the experienced developer.
Not only the bobbin coil is customer-specific, but also the packaging. Thanks to the specifically developed tape and reel packaging, the coils at Elesta go directly from incoming goods to SMD production.

Rapid scaling of coil production

The planned series volume is a few 10,000 pieces per year. With its global capacities, KUK is prepared for this. For the time being, the bobbin coil will be manufactured at the production site in Slovakia. From there, they are shipped in batch sizes that are tailored to Elesta's needs.

 

About Elesta

Elesta GmbH in Bad Ragaz (Switzerland) is part of the Pilz Group, a technology leader in automation engineering. Elesta develops and produces relays with forcibly guided contacts and sensors for functional safety applications. The products are used in a wide range of industries and applications and serve to protect people, processes and the environment.

Elesta GmbH in Bad Ragaz (Switzerland) is part of the Pilz Group, a technology leader in automation engineering. Elesta develops and produces relays with forcibly guided contacts and sensors for functional safety applications. The products are used in a wide range of industries and applications and serve to protect people, processes and the environment.

COIL MANUFACTURING AND EMS SERVICES FROM KUK GROUP IN THIS PROJECT

Windings on customer-specific bobbins

KUK offers windings on customer-specific coil formers with all common bobbin shapes and geometries. All conceivable shapes of electric coils are customer-specific manufactured.

NEWS FROM THE PRODUCTION OF COILS AND ELECTRONICS

What is the advantage of orthocyclic windings?

Orthocyclic coils are characterised by a high copper fill factor (often approx. 70%), so that a comparatively high magnetic field is realised in the smallest possible space.

What makes a successful development project for coils production?

Engineers are aware of the challenges that await them in the feasibility phase. Especially with customised inductive components, it often takes several attempts until the optimal solution is found. This is a case for the development team of the KUK Group, the leading manufacturer of customised coils and electronics.

What is the purpose of edgewise winding?

Edgewise winding is one of the modern trends in coil manufacturing. The principle of this winding technology is that the rectangular section wire is wound not on the flat part of the wire but on the short side of the wire. That’s where the terms edgewise winding or side-winding stands for.

How to prepare a complete specification for a solenoid coil

The basis for the successful production of solenoid coils is a CAD drawing as well as a proper layout of the most important parameters. In order to make rapid progress in product development, it is important that the essential requirements for a customer-specific coil are specified.

The 1x1 of coil manufacturing

In electrical engineering, coils are important electrical components that are used in transformers, electric motors or relays, among other things. Many different influences flow into coil production, making it difficult to keep track of them all.

What material can coils be wound from?

In coil production, the wire used plays a central role. While copper is undoubtedly the most commonly used conductor material, especially for customer-specific coil projects, it is also worthwhile to test alternative coil wire, depending on the application.