World of Induction

Flexibility and readiness

Selecting conductor materials for axial and radial flux motors

Conductor material choice significantly influences efficiency, cost, and thermal performance in both axial and radial flux motors, with options like copper, aluminum, or alloys needing to align with flux paths and power density requirements. Axial flux designs often prioritize lightweight materials to leverage their compact form, while radial flux benefits from high-conductivity options for ...

Automation

Needle winding techniques for precision in radial flux motors

Needle winding stands out as a versatile technique for radial flux motor stators, enabling high-precision coil placement in complex geometries while supporting both concentrated and distributed configurations. It excels in achieving consistent fill factors and reducing manufacturing defects, making it suitable for automated production lines. This article introduces the method, its advantages over ...

Technological leadership

Optimizing windings for losses and space in radial flux motors

Balancing wire cross-section, fill factor, and losses poses a core challenge in radial flux motor design, where AC/DC effects like eddy currents and skin effect impact efficiency and thermal performance. The optimal choice - whether single-layer edgewise for loss minimization or multi-layer Litz/orthocyclic for space utilization - depends on an overall assessment of frequency, current, and ...

Supplier as global Partner

Supply chain options for defence coil winding

In the face of evolving global strategic demands, the defence sector is experiencing a shortage in coil winding capacity. Learn how partnering with established contract manufacturers can bridge this gap and ensure mission-critical reliability. Opting for partners with established Western supply chains and production sites provides defence contractors with confidence in the reliability, ...

Flexibility and readiness

Coil winding at a glance

Coil winding encompasses a variety of techniques used in the creation of electrical components, such as transformers, motors, and inductors. These methods include different winding styles, coil types, and wire materials, each providing unique advantages suited to particular applications.

Technological leadership

Myths and facts on edgewise windings

While edgewise coils are gaining popularity among engineers for their optimal properties in specific applications, they are not necessarily the top choice compared to traditional round wire coils. Engineers can maximize the benefits of edgewise coils by carefully considering factors like wire availability, manufacturing complexity, and performance advantages, allowing them to effectively navigate ...

Technological leadership

Helmholtz coils: overcoming manufacturing challenges

Explore the essential manufacturing hurdles encountered when seeking Helmholtz coils and the critical factors to consider throughout different project stages. This blog provides engineers with a comprehensive guide to ensure they are well-equipped for their Helmholtz coils endeavors.

Technological leadership

Micro coils: An overview on design, manufacturing and applications

Discover the world of micro coils and their manufacturing process in this comprehensive guide. Explore the various types of micro coils, the materials used, and their applications in the medical and sensor industries.

Flexibility and readiness

How to select a strategic coil manufacturer for automotive Tier 1 or 2 suppliers

The automotive industry is undergoing a profound transformation driven by the rise of e-mobility and evolving customer expectations for comfort and entertainment. As automakers strive to deliver innovative and high-performance vehicles, contract manufacturers play a pivotal role in supporting their supply chains.

Technological leadership

Which factors determine the choice of core material for micro coils?

When it comes to choosing the core material for your micro coil, it's essential to carefully evaluate the advantages and disadvantages while considering the specific requirements. So, what factors should you take into account when selecting the core material for your micro coils?

Flexibility and readiness

Micro coil core materials: from amorphous to neodymium

Today, we're going to delve into the captivating world of micro coil core materials. Gaining an understanding of the various options available can truly enhance your coil-building journey. So, come along as we embark on an exploration of the realms of amorphous, nano-crystalline, and neodymium core materials, unveiling their distinctive characteristics in the process.

Technological leadership

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.

Flexibility and readiness

Metric vs. imperial: A look at AWG and mm in coil engineering

Both the AWG and metric system (mm) are used in coil design. The choice between them depends on the application, regional and personal preferences of the engineer. Both scales have advantages and disadvantages, and it's important to be familiar with both and convert between them as needed.

Technological leadership

What is important when choosing an electric coil manufacturer?

Selecting the right coil manufacturer is a crucial factor for the success of your project. A professional coil manufacturer should have the necessary experience and expertise to meet your specific requirements. Additionally, you should look for technological advancements and flexibility in production. A good coil manufacturer adapts to changes and ensures that the coils meet high-quality ...

Flexibility and readiness

Benefits of 3D printing in electric coil prototyping

Coil prototyping has come a long way since its inception, and 3D printing technology has played a significant role in its evolution. The benefits of using 3D printing in coil prototyping are numerous, from faster prototyping to increased design flexibility. This technology has also paved the way for the development of new materials and applications in various industries, such as automotive and ...

Flexibility and readiness

Solenoid coil: Key factors to consider when designing

Solenoid coils are versatile components that are used in a wide range of applications across many different fields, from automotive to medical and beyond. Depending on the application, there are several important influencing parameters to consider in the development and design process of a solenoid coil.

Flexibility and readiness

Coil development for and with the customer

Coil development is an important process that requires careful planning to achieve the desired performance and reliability. During the feasibility phase, experienced coil manufacturers understand the challenges that may arise. The cooperation with a customer-specific coil manufacturer during the feasibility phase and for sampling is of great importance.

Technological leadership

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, ...

Automation

As an automation engineer I have found my dream job

Gabriel Scheifele is one of the KUK engineers who has moved his workplace to the new Technology Centre in Appenzell (Switzerland). What the automation engineer appreciates about his work - designing machines - is the great variety, the high level of responsibility and the short decision-making processes.

Technological leadership

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.

Integrated services

How high-tech companies thrive by relying on custom contract manufacturing

KUK Coils has established a reputation in the coil manufacturing industry as well as in the assembly of complete modules, including motors. Its global network is valued by companies in the automotive, medical technology, and industrial sectors, who use KUK as a subcontractor to fulfill their needs.

Technological leadership

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.

Technological leadership

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.

Integrated services

Different supply chain concepts at a glance

In the ever-changing landscape of modern markets, the procurement of goods and primary products for in-house production has become vital to business success. Developing the right sourcing strategy based on existing concepts is a crucial task for management, and only customized procurement can ensure future success.

Technological leadership

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.

Integrated services

Challenges and reasons for supply chain disruption

A well-functioning supply chain is one of the most important prerequisites for your successful business. If there are problems with your suppliers, this can, in the worst case, lead to a standstill in your own production. This must always be prevented by taking preventive measures!

Flexibility and readiness

Why Lean methods are beneficial in coil and electronics production

Anyone who knows Lean as a production method is probably familiar with the benefits of Lean. But what is Lean actually? How can you use Lean to speed up business processes? Learn more about Lean management methods that KUK Group, as a leading manufacturer of coils and electronics, applies itself.

Integrated services

This is why modular sourcing with your coil manufacturer makes sense

When purchasing electronic components, you can purchase individual parts from separate suppliers. Another variant is so-called Modular Sourcing, in which you hand over the assembly of complete modules to a customer-specific coil manufacturer. This reduces the complexity in your supply chain.

Technological leadership

The 1x1 of coil winding

Coils play a crucial role in electrical engineering, finding various applications in transformers, relays, and electric motors. However, coil winding involves several factors that make it challenging to manage.

Automation

No series production without tools

In today's tumultuous supply chain landscape, companies are struggling to maintain their footing. Yet, the ability to quickly establish a series production for customised coil manufacturing can be a game-changer. Of course, the key to successful series production lies in having the right tools. At KUK Group, we understand this better than anyone, which is why we predominantly manufacture our ...

Flexibility and readiness

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.

Integrated services

Much more than winding goods - these technologies KUK masters as well

Just winding coils is usually not enough, further production steps are necessary until an equipment manufacturer obtains a functional component. KUK Coils offers the entire package from coil production to the assembly of a complete motor from a single source. High flexibility and fast turnaround times are the biggest advantages for the customer.

Technological leadership

These are the areas in which micro coils are generating major innovations

Coil manufacturing in the medical field has revolutionized the way we approach healthcare. The micro coils or sensors required for many medical technology applications are becoming increasingly powerful, while at the same time requiring less space. The applications of miniature coils in the medical field are vast, ranging from diagnostic and therapeutic uses to navigation and orientation ...

Technological leadership

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.

Automation

Tailor-made automation for customer-specific coil production

At KUK Coils, customer-specific coils and electronic assemblies are largely produced on automated plants developed in-house. This means that we can offer you a very attractive coil production process in terms of quality and commerce, tailored to your volume and technical specifications.

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