Secure Bifilar Windings through Color-Coded HF Litz Wires
PACK LitzWire supported an industrial customer in optimizing the manufacturing of its bifilar wound transformers and chokes. In this application, two parallel wound HF litz wires were used to achieve a particularly tight magnetic coupling or defined parasitic capacitances.
The Challenge
In production, bifilar windings regularly led to errors and high effort:
- Risk of misidentification: With braided litz wires, it was almost impossible to clearly distinguish the beginning and end of the two winding strands, as both appeared visually identical.
- Increased error rate: Incorrectly connected windings caused failures in final testing or later in the field.
- Complex logistics: The parallel handling of two separate litz wire packages complicated the manufacturing process.
The customer was therefore looking for a solution that would make both assembly safer and intralogistics more efficient.
Bifilar windings of HF litz wires in various designs, used in industrial electronic assemblies to specifically influence electrical properties such as coupling and symmetry.
Schematic representation of relevant coil dimensions as a basis for the precise design of bifilar windings. The defined geometry parameters allow for exact coordination of litz wire routing, number of turns, and space utilization.
Support from PACK LitzWire
As part of a joint Design-for-Manufacturing project, PACK LitzWire combined its HF litz wire expertise with supply chain services:
- Customizing: Delivery of HF litz wires with color-coded covering – e.g., one litz wire white, the second clearly color-marked – so that the beginning and end of each winding were clearly identifiable at all times.
- Optimized delivery forms: Provision of prefabricated lengths or customer-specific packages that could be directly inserted into winding machines and manual processes without additional steps.
- Manufacturing Consulting: Recommendation of suitable insulation materials whose electrical and thermal properties remained unchanged despite color coding and met all standard requirements.
Result
The introduction of color-coded HF litz wires completely eliminated mix-ups in assembly. The scrap rate significantly decreased, and both manual and automated winding processes were noticeably accelerated. At the same time, the optimized delivery forms simplified the customer's internal handling and reduced manufacturing time and costs.
RUPALIT® Plus
RUPALIT® Plus offers reinforced electrical protection for demanding high-voltage applications while optimizing HF losses. The integrated multi-layer insulation allows for space-saving designs without compromising safety.
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