The enameled wire is tightly wound turn by turn across a small bobbin in a single layer.
This winding method is suitable for low-power signal relays. It requires no overlap between adjacent turns and stable winding tension to maintain tight control of DC resistance.
Different numbers of turns or wire diameters are used across different layers to create a stepped winding structure.
This method helps optimize pull-in voltage and power consumption and is commonly used in energy-efficient relays for battery-powered applications.
An intermediate tap is brought out during the winding process for applications such as dual-voltage or latching relays.
The production line must support automatic tap extraction and accurately record the tap position to ensure consistent electrical performance.
The relay's operating voltage is closely related to the coil's DC resistance.
Automated production lines provide precise turn counting and stable tension control, keeping resistance variation within a tightly controlled range across the same production batch and helping prevent relay pull-in failures.
Eternal's automated production lines can integrate automatic bobbin loading, winding, insulation/adhesive application, tap extraction, and wire cutting.
The winding line can also be connected to an automatic soldering system, minimizing manual handling, improving production efficiency, and increasing overall yield.
Relay coil bobbins are available in round, square, and irregular/custom shapes.
Eternal provides modular tooling and fixtures for rapid product changeover, making the equipment suitable for high-mix, low-volume production as well as mass production.
With more than 20 years of experience in coil winding technology, Zhongshan Eternal Automation Co., Ltd has provided automated production solutions for numerous relay manufacturers.
Our fine-wire winding equipment is capable of reliably winding ultra-fine wire, and is equipped with high-sensitivity wire-break detection and winding-tension memory functions to ensure stable and repeatable production.
For the high-volume requirements of automotive relay manufacturing, Eternal offers multi-station winding machines with high daily production capacity to support large-scale manufacturing.
We also work with customers to optimize key coil parameters, including number of turns, wire diameter, and number of layers, helping achieve the required electromagnetic force with minimum power consumption.
From process commissioning and operator training to after-sales technical support, Eternal provides comprehensive service to help customers achieve efficient, stable, and reliable relay coil production.
