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
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.
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
Insulation layer on magnet wires: A common stumbling block for engineers
In coil production, the insulation of the wire has an influence on a wide variety of product properties such as application range, service life, costs or coil design. Wire insulation also has an effect on various factors during coil manufacturing, such as scrap or further processing. This article summarises the essential facts about wire insulation - and its effect on coil design - for engineers.
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.
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.
Self-supported coils: Facts about coils made of selfbonding wire
Self-supported coils are coils made of wire that is coated with a thermoplastic layer - the bonding varnish. The term selfbonding enamel wire already indicates it: This wire is bonded during the winding process to give the coil the necessary stability without any other aids, especially in the case of air coils. The use of selfbonding wire can offer advantages over a bobbin coil in some cases, ...
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.
Misconceptions about the fill factor of electric coils
In the realm of electric coils, there exists a common misconception among engineers regarding the fill factor. This misconception often leads to misunderstandings about the overall efficiency and performance of these coils. It is imperative to address these misconceptions and shed light on the true implications of the fill factor.