Innovation in winding technology

BLOCK’s new in-house developed Future Winding technology is taking performance optimization of inductive winding products into a new dimension. The extraordinary variability in the design of the winding structure comes with a number of benefits for winding products: Optimal cooling by maximizing the heat-emitting conductor surface while also creating cooling ducts via the winding structure and minimal proximity losses with rising switching frequencies are just some of the strengths of this state-of-the-art technology.


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Future Winding - your practical advantages

Get valuable input for your practical applications. In our new tutorial, our General Manager Research & Innovation Dr. Dennis Kampen briefly and concisely explains the advantages of using winding goods with Future Winding technology. In addition to savings in effort and time during installation, a very clear advantage is the cost savings.

Long life

Thanks to the new Future Winding technology high inductivity can be realized with a single-layer winding structure. The benefit is that additional layer insulation, and possibly even basic insulation to the core, is not needed. Aging effects in the insulation materials – as are typical with the conventional structure of inductive winding products – no longer occur, which maximizes service life.

Cooling

The combination of increased conductor surface, spread of the winding, and cooling ducts created via the winding structure enables optimal cooling of the entire product. The new Future Winding technology shows off its strengths with forced air cooling in particular, taking the performance optimization of inductive winding products into a new dimension.

Low losses

Varying the conductor spacing in the winding structure effectively reduces proximity losses in the conductor that are generated by ripple currents from switching frequencies, particularly as frequency increases. This effect is significant, especially for future applications of SiC- and GaN-based semiconductor technologies. It also represents a potentially cost-effective alternative to the use of expensive high-frequency litz wires in conventional winding technologies.

Potential control

The specific winding structure results in more or fewer parasitic capacitances and, therefore, in the case of transient overvoltages, differences in potential between the individual windings. This can damage the conductor insulation, potentially leading to a winding short. Future Winding variably controls such parasitic capacitance – and, thus, the potential across the winding – through the partial spreading of individual winding sections. This prevents damage to the conductor insulation and accordingly any winding shorts.

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Due to the variable configurability of its winding structure, the new Future Winding technology from BLOCK can adapt accurately to the core geometry and prevailing flow conditions of the air cooling system.

High current density

Due to the flexible design of the winding structure a maximum of the conductor’s heat-emitting surface is exposed to the prevailing cool air flow. The result is a high current density and efficient use of the conductive material (CU or AL), reducing structural volume, weight and costs.

Reduced costs through Future Winding

In addition to its purely technical advantages, the new Future Winding technology has a lot of potential for reducing the costs of inductive winding products. Due to the optimized cooling effect on the conductor, significantly affordable and lighter aluminum can be used instead of copper as the conductive material. This also does away with costly insulation materials and the corresponding production steps to install this insulation. Windings are produced in a fully automated process on in-house designed winding machines – in line with Industry 4.0. Combined with the new innovative connection concept, the result is a self-supporting winding structure. All these strengths deliver inductive winding products that are best-in-class for technical performance and price.

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