Winding Modes of Transformer Coils

There are numerous coils inside a transformer, and each coil is made of enameled wire wound repeatedly. Transformer coils are formed by continuous winding, with varying winding directions and techniques. Accordingly, coils wound in different ways serve distinct functions, which you can master by learning the various winding methods.

The winding structure of transformer coils greatly impacts the equipment’s service performance and energy efficiency. Below is an introduction to common transformer winding methods and their differences for your reference:

Step 1

Take two strands of 0.72 mm enameled wire, fix one end to pin 6 (the start terminal of the high-voltage winding), and wind 2 layers with 35 turns. Do not cut off the other end. After wrapping the insulation layer, start winding the primary winding.

Step 2

Prepare six strands of 0.72 mm wire, arrange them neatly, bind with adhesive tape, and clamp the bundle between pins 1 and 2 of the bobbin.Prepare another six strands of 0.72 mm wire in the same way, bind with tape, and clamp between pins 3 and 4 of the bobbin.These 12 strands together form a neat single layer, wound for 3 turns.

Lead out the wire bundle from pins 1 and 2 between pins 9 and 10, reserve an appropriate length, then cut it off.Similarly, lead out the wire bundle from pins 3 and 4 between pins 12 and 13, reserve an appropriate length, then cut it off.

Repeat the identical winding procedure for terminals (2,3) to (11,12), and (4,5) to (13,14).

Step 3

Wrap the insulation layer, then continue winding the high-voltage winding for another 2 layers with 35 turns. Keep the wire tail intact for subsequent use.

Step 4

Wrap the insulation layer, then fully repeat all operations in Step 2, with wire starts and tails led out at the corresponding positions.

Step 5

Wrap the insulation layer, continue winding the high-voltage winding for a final 2 layers with 35 turns, then terminate the wire end to pin 7.

The transformer winding process is now complete. Refer to the diagram for detailed analysis:All wires connected to pins 1, 2 and 3 are bundled together as the start of one 3-turn winding group.All wires connected to pins 12, 13 and 14 are bundled together as the end of the other 3-turn winding group.Wires between pins 3, 4, 5 and wires between pins 10, 11, 12 are interconnected to form taps for the two 3-turn windings.

Though compact in size, transformer coils play an extremely critical role. Therefore, the coil winding process deserves high attention, as it directly determines the overall operating performance of the transformer.