Segmented Secondary Winding
The secondary winding is divided into multiple sections, separated by insulating materials between segments to reduce inter-layer voltage gradient and prevent high-voltage breakdown. The production line must feature automatic paper padding/segment switching and turn counting functions.
U-core / I-core Closed Magnetic Circuit Winding
Both primary and secondary windings are wound on U-shaped or I-shaped magnetic cores, then assembled to form a closed magnetic circuit, widely used in microwave oven high voltage transformers. The production line must support thick wire winding and automatic tape wrapping for insulation.
Fully Enclosed Epoxy Potting Winding
After winding, the coil is placed into a mold for vacuum epoxy resin potting to achieve complete sealing, suitable for outdoor or high-humidity environments (such as high-voltage igniters for instant water heaters). The equipment must reserve lead wire anti-leakage structures and can be integrated with an automatic glue dispensing line.
Self-adhesive Bobbinless Winding (Secondary)
The secondary winding uses self-bonding enameled wire to be directly wound on the mold, heated for bonding, then demolded and assembled with the primary winding. It is used for ultra-thin high voltage coils (such as high-voltage electrostatic modules for range hoods). The production line must be equipped with a heating control system.
High Insulation Reliability & Consistent Withstand Voltage Performance
Inter-turn breakdown is the most common failure mode of high voltage coils. Automated production lines, through precise wire arrangement, constant tension control and automatic paper padding, ensure no overlapping turns or enameled wire insulation damage, delivering an extremely high withstand voltage test pass rate.
Damage-free Winding for Ultra-fine Secondary Wires
The secondary winding uses extremely fine wire gauges, which are extremely prone to wire breakage or insulation scratch during manual winding. Yite's production lines adopt low-inertia tension control and ceramic wire nozzles, with minimal dynamic tension fluctuation and ultra-low wire breakage rate.
Automatic Taping & Potting for Higher Production Efficiency
An automatic tape wrapping machine can be integrated to wrap insulating tape after each layer or segment. After winding, the coil is automatically transferred to the vacuum potting line to realize integrated molding of the coil and housing, reducing manual handling and eliminating air bubble defects.
With over 20 years of experience supplying full turnkey winding and potting line solutions to numerous home appliance high voltage coil manufacturers worldwide, Eternal's production lines support winding of various wire gauges, with high secondary winding arrangement accuracy. The maximum achievable turn count fully meets all kinds of design requirements.
Standard configurations include active tension controllers, automatic paper padding/tape wrapping units, with optional vacuum glue dispensers and inter-turn withstand voltage testers. For typical products such as gas stove igniters and microwave oven transformers, we provide cost-effective multi-station models. Our after-sales services include timely technical support, on-site installation & commissioning, operation training, and dedicated assistance to help customers obtain relevant safety certifications.
