Stamping Metal Stamping Service Copper Coil Bobin Circle Square Shape Tolerance

Materials Available :Copper,tin

1) This coil will go to final assembly with a core, and intend to be submersed in Transformer Oil (Shell 45 or similar), so all insulators, dipping warmish, and materials used to produce coil need to be compatible with above.
2) All dimensions are in millimeters, coil wire – copper.
3) Winding is an open bobbin design or simple core wounding. A bobbin core, flanges need to be made only for winding tooling, polish surfaces where flat bar (wire) is touching. Please advise on total winding tension, and bobbin core design;
4) Please refer to Drawings document (page3) and STEP model (will supply per request) ;
5) Windings done with Rectangular Magnet Wire, copper, flat bus at a 5 x 1.5mm cross-section of 7.5mm2 in fiberglass or electro-technical silk thread insulator or paper covered. Please provide specifications for the wire, insulation;
6) Layer-to-Layer insulation shall be design for not less than 600V. Please provide wire passport or Technical specifications;
7) Total winding layers shall be kept to a minimum of not more than 12mm total thickness, each winding section consist of :
i. 7 layers without insulator;
ii. 15 windings (turns) in each layer;
iii. 105 total windings (turns) per section;
8) Entry wire (marked on drawings “B”) bended according to drawings, open length is 150mm;
9) Finish wire (marked on drawings “E”) bended according to drawings, open length is 150mm;
10) Please pay attention to the “scissor” effect during winding, at layer transitions, on the end of each layer and use appropriate anti-wearing insulator patches (suggested 15x15mm square patch). Please provide details on this with dimensions and place where and how you plan to install this patch;
11) After removing from Tooling fixtures, support winding assembly – suggested place showing by two red lines on the drawings – please advise on details and materials. This support threads will be shipped to us and need to be removed before final assembling;
12) Coils need to be impregnated with varnish by dipping, in a vacuum and processed through appropriate drying/curing complete cycle. We are deep in heated varnish coils with 5min vacuum about ~50micron level, with following decompression to atmospheric pressure and again 10min vacuum to a ~25micron level. This cycle allows the de-gazing deep internal air pockets more efficiently;
Please consult with E2, C2, and F1 standard description.
Please provide a guidelines what you are currently use for similar coils production, for us to familiarize, and comment if we need to follow them or slightly change.
13) Post Production Testing :
a. Resistivity at 20C shall be 32mOHM +/- 2.5% (0.032OHM);
b. Inductance without core 1.8uH +/-0.5uH at no current;
14) Mechanical details:
a. Approximate total copper bus length for coil – about 14.1 meters;
b. Approximate coil weight– 0.95 kg;

MOQ :It depend on your design,small quantity accept

Capacity: 100,000 pieces per month

quality control :
IPQC inspect each one during every step: 100% inspection before shipment by micrometer , height gauge ,

projector measuring machine , coordinate measuring machine etc . any disqualification should be avoid and

solve by us before shipment .

Business Type: Manufacturer (Customized CNC Machining Services),OEM CNC Machining,CNC Machinery,High precision

CNC Machining,CNC Turning,Sheet metal fabrication,Die casting,Cold forging ,Heat Forging ,Customized metal

parts

Our Advantage:

1. We are a professional OEM/ODM hardware(Aluminum,stainless steel,Copper and so on) manufacturer,professional

CNC Machining,CNC Turning,stamping,milling and other hardware processing.

2. Full production line:CNC Machining aluminum parts(Extrusion aluminum alloy or die casting A380

aluminum),CNC Turning aluminum parts,Die casting aluminum parts,Die casting zinc alloy parts,CNC

Machining&Turning stainless steel parts,CNC Machining&Turning copper parts;Consumer electronic hardware

accessories such as telecommunication aluminum cavity,LED Lighting aluminum housing,Setup box

housing...;Thermal solution heat sinks&radiator;Computer hardware accessories;Furniture hardware parts

3. We have experienced engineers and quality control team as our strong backing.

4. High quality, competitive price, quick response is our mission.

5. Professional technical support

6. High efficiency/Fasting delivery time

7. Strictly quality control processing(Two dimensional inspection instrument&Three dimensional inspection

instrument)
8. Cost-Effective

9. Full experience in CNC Machining and surface treatment
10. ISO/5S system guarantee

FAQ

1)What Payment terms do you offer for international customer?
T/T,paypal ,west union or others
For product:50% deposit before production,50% before shipment.
For mould:full amount before production

2)What is your annual production capability ?
8 Millions-10 Millions US $

3)how many CNC machines do you have?
20 Brother CNC Machines
8 Cutting CNC
8 Milling CNC Machines
1 Three Dimension Measurement Machine
Auxilary equipment:Drilling machine, tapping machine, polishing machine and etc.

4)What is normal lead time?
Sample Lead time:3-7 working days(Without mould)
Mass Production:30 days.It depend on the Qty and the structure).

5)sample pictures of diffrent materials machining
See our showroom for your reference
6)surface treatment?
Ordinary anodic oxidation, hard anodic oxidation, rodin, chromate, SurTec, Buffering,Sand Blasting,Powder

Coating,Painting,Hard Anodizing,Brushingelectrophoresis, spraying, electroplating, etching, laser, black

passivation, pickling, QPQ, heat treatment, medium frequency, high frequency, nitride, carburizing, tempering,

phosphating, magnetic force grinding, ultrasonic cleaning

7)what is your quality process
New drawings analysis - the internal production control conversion - drawing process flow chart - first

manufacturing inspection - modified with numerical optimization - normal production - QC inspection record -

surface treatment - FQC inspection report and record - packaging logistics

8)Do you measure details and attach measure protocoll with delivery?
Inspection report, material certificate, packing list and material details of label attached in the package.