Abstract:

To address the engineering problem of inaccurate predictions of winding thickness and enameled wire length caused by large empirical deviations in the winding factor K_d during electromagnetic coil design, coil samples with different wire diameters are prepared under controlled process parameters. The weight method is used to measure and inversely calculate K_d values, and a quantitative model between K_d and the nominal diameter d of the enameled wire is established via regression analysis. The model is then applied to the design verification of DC contactor coils. The results show that a K_d dataset for enameled wires with diameters ranging from 0.265 to 0.450 mm is established, and the derived empirical formula K_d=0.83-0.23d exhibits high goodness of fit (R²=0.995). After applying the model, the prediction errors of winding thickness and enameled wire length are reduced from over ±10% (with the traditional method) to within ±2%, and the deviation in material cost estimation is also lowered from approximately 8% to about 1%. It is demonstrated that the proposed model significantly improves coil design accuracy and cost-control capability, which holds important engineering value for realizing digital coil design and shortening the development cycle.

Key words: winding factor, electromagnetic coil, quantitative relationship model, experimental verification, DC contactor, structural parameters