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Wire-Wrapped Copper Rings

05/11/2007 1:13 PM

We've been tasked in my department with manufacturing an item (or purchasing the item) to add to one of our products. Only problem is this: I have no idea how it is made or who makes it for possible purchase.

The item is really rather simple. A carbon steel ring, about 12" in diameter, is wrapped with copper wire. The wrap twists around the ring, totally covering the stell. The wrap goes around the circumference 6 times, where the two ends are then connected via a pressed fitting. The wrap must be done after the carbon steel has been made into a ring, and must be very tight and consistent in its spacing. Because of this, wrapping by hand is not acceptable.

Help??

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#1

Re: Wire wrapped copper ring

05/11/2007 3:09 PM

You need a ("toroidal" winding machine) transformer manufactures use these to do their doughnut transformers. A split ring is placed over the ring to be wound onto and the correct length of the correct gauge is transfered on the winding ring, once this is done the wire is attached to the core and the process of transferring the wire can begin as the wire unwraps the core is rotated so as to match the wire transfer rate. Once you have seen it done it is very easy to work out how to do your own winding.

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Location: Indiana, USA
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#3
In reply to #1

Re: Wire wrapped copper ring

05/14/2007 9:59 AM

Thanks for the suggestion! I was able to find 2 US based makers of these machines and have contacted them for information and pricing. Looks like their equipment may be able to help with this! Thanks again!

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#4
In reply to #3

Re: Wire wrapped copper ring

05/14/2007 10:48 AM

Glad to be of help.

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There's them that knows and them that just thinks they know, whitch are you? Stir the pot and see what rises up. I have catalytic properties I get a reaction going.
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#2

Re: Wire-Wrapped Copper Rings

05/11/2007 4:33 PM

I have seen something like you have described used in large electrical distribution panel as part of a ground fault system. The grounds were routed thru to shut down the panel. Try look at electrical supplies. By large it was 60,000 amp main for a 35 story building.

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