Customer Product Specifications:

Magnetic ring (toroidal core) with an outer diameter of 18 mm and an inner diameter of 10 mm.

Copper wire diameter: 1.45 mm (pure copper).

Winding: 58 turns on each side.

Unwound length of copper wire per side: up to 1800 mm.

Winding method: butterfly cross winding.

Technical Challenges:

Small wire diameter, high number of turns, and complex winding pattern.

Wire damage must be strictly avoided during the process.

Gaps must be reserved on the magnetic ring for inserting spacers in later stages, leaving very limited working space.

The customer's factory machines operate up to 22 hours per day, demanding high output and yield rates.

This places considerable pressure on equipment stability and reliability.

Proposed Solution:

Use a butterfly common‑mode winding machine (fine‑wire version).

Applicable wire diameter range: 0.5 – 1.5 mm.

Suitable for products with a maximum wire length ≤ 2500 mm.

Fine-Wire Butterfly Winding Machine

Each machine achieves a production output of 35 pieces per hour, with a yield rate of 98.5%. The machines are required to operate for no less than 22 hours per day.

On-site actual photos and product images