How Coils Work

A basic introduction into Coil Apparatus.

 What is a Coil ?
A coil is a wire wound in a spiral.
When a wire is wound, it takes on various characteristics
that are different from straight wire. The characteristics
are used for various electronic / electric devices and
equipment.

Coil: A component of an electronic

A Coil is an indispensable component for an
device
electronic device They play an important
A coil is called the L element, capacitor C,
role to maximize the performance of
and resistance R.
electronic devices and may greatly affect
the performance of products. L, C and R are passive components and
play an important role in helping the
A coil has 5 major functions and is applied
working of IC and transistor circuits.
to various electronic devices.

L, C and R are passive components

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 A Coil has 5 major functions and is applied to various electronic devices.
The 5 Functions of a Coil
When a magnet When current flows
moves through a in the coil, the coil
coil, voltage resists the flow. This
appears on both characteristic is
ends of the coil. Electro- called the self
This is known as Magnetic Self Induction induction effect.
the Induction Effect
electromagnetic Effect
induction effect.
Electric power or
signal can be
Electro- Mutual transferred
When current Magnet Induction between two
flows through a Effect Effect separate coils.
coil, a magnetic This is known as
field is generated the mutual
and attracts induction effect.
magnetic materials
Resonance
(iron & nickel). Effect
This is known as
Combination of a coil (L) and a
the
capacitor (C) generates a resonance
electromagnetic
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 The Self Induction Effect
Application of the Self Induction Effect
When current flows in the coil, the coil resists
the flow. This becomes strongly apparent at
higher frequencies. This characteristic is used in
the power supply circuit to change alternating
Electro- Self current (AC) to direct current (DC). If a rectifier,
Magnetic Induction instead of a coils is used, the output of the
Induction Effect rectifier contains a ripple current and is not a
Effect complete DC.

Electro- Mutual
Magnet Induction
Effect Effect input rectifier output

The output of a rectifier contains ripple current, and is not a

Resonance complete DC.
Effect

input coil capacitor output

Combination of a coil and a capacitor works against AC, and

produces stable DC.
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 The Mutual Induction Effect
Application of the Mutual Induction Effect
The Transformer utilizes this effect. The
output voltage is determined by the ratio
of turns between the primary and
Electro- secondary coils.
Self Inductance is the measure of the value of a
Magnetic Induction
Induction coil. More turns makes larger inductance.
Effect
Effect
Electro- Mutual
Magnet Induction
Effect Effect input output
Electric power can be transferred between two coils around a
core.
Resonance
Effect

voltage
voltage

input output

The output voltage is determined by the ratio of turns

between the primary and secondary coils.
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 The Resonance Effect
Application of the Resonance Effect
A certain frequency of signal is tuned by a
resonance effect. The tuning circuit that
selects a particular radio station utilizes this
Electro- effect.
Self
Magnetic Induction
Induction Effect current
Effect
Electro- Mutual
Magnet Induction Resonance Frequency (frequency)
Effect Effect Combination of a coil (L) and a capacitor (C) generates a
resonance effect.

Resonance
Effect current

Resonance Frequency (frequency)

A certain frequency of signal is tuned by a resonance effect.
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 The Electromagnet Effect
Application of the Electromagnet Effect
An electromagnet is applied to various
equipment: ABS coils in a car, motors,
electromagnetic brakes, buzzers, doorbells,
Electro- clocks, watches, speakers, earphones, etc…
Self
Magnetic Induction
Induction Effect
Effect
Electro- Mutual
Magnet Induction
Effect Effect When current flows through a coil, the iron core of a coil
becomes an electromagnet.

Resonance
Effect

When no current flows through a coil, an electromagnet

effect is not generated.

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The Electro-Magnetic Induction Effect
Application of the Electro-Magnetic
Induction Effect
When a magnet moves through a coil,
voltage appears on both ends of the coil.
Electro- Microphones and generators utilize this
Magnetic Self effect.
Induction Induction
Effect Effect

Electro- Mutual
Magnet Induction
Effect Effect
When a magnet moves through a coil, induced current flows.

Resonance
Effect

When a magnet does not move through a coil, current

does not flow.

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 1 Repair of Electrical Apparatus
coil(Contactor)
What is Contactor? is an electrically controlled switch used for switching a power circuit, similar to
a relay except with higher current ratings.
A contactor has three components.
 The contacts are the current carrying part of the contactor.
o This includes power contacts, auxiliary contacts, and contact springs.
 The electromagnet part includes the core and coil. This part provides the driving force to close
the contacts.
 The enclosure is a frame housing the contact and the electromagnet.

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 Contactors

Basic units with

three-phase Coils for different
main contacts voltages

Auxiliary contacts
side-mounting
Auxiliary contacts
top-mounting

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 Continued

Main contacts

Type of contact Symbol Function digit

Normally Open (NO)

Make contact 3 and 4

Auxiliary contacts Normally Closed (NC)

Break contact 1 and 2
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 Contactor Maintenance

 Identify the problem by performing different test, like continuity test.

 Cleaning contacts.
 Contactors should be checked for loose or worn contacts, weak spring pressure,
displaced or burned arc shields, defective coils, low insulation resistance to ground,
corrosion etc.
Rewinding the coil

In order to wind a coil, it is necessary to know the following data.

 Operating Voltage.
 Number of turns.
 Cross section of wire (or diameter of the wire).
 Type of operation (ac or dc).
 Operating time (short time, intermittent or continuous duty).
 What if the coil is totally burned?
Steps for determining the coil winding data.
 Determine number of turns of the coil.
1st Determine core cross section c = a∗b.
where a-core length in cm
b-core width in cm
2nd Refer graph for selecting appropriate TPV.
3rd Number Turns N = TPV * Operating Voltage.
 Cross section of the wire.
First find the area of the window or opening area of the core 𝑞0 .
𝑞0 = ℎ ∗ 𝑙(𝑚𝑚2 )
Then find the fill factor (Space factor ) from the graph.
𝑞 = 𝑞0 ∗ 𝑘𝑓 .
𝑊 = 𝑁/𝑞 where 𝑞0 Area of the window.
𝑘𝑓 Fill factor, N number of turns, 𝑞 Total cross section of the entire conductor .
W number of turns per cross section area of the core.
 Finally Refer the graph for determining the diameter of enamelled wire.

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2 TRANSFORMER
 Transformer
•A transformer is a device which transfers electrical energy (power)
from one voltage level to another voltage level.
•A transformer is a static device.
•The transfer of energy takes place through the magnetic field.

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 Transformer Construction Iron Core
• The iron core is made of thin laminated silicon
steel (2-3 % silicon)
• Pre-cut insulated sheets are cut or pressed in
form and placed on the top of each other
• The sheets are overlap each others to avoid
(reduce) air gaps.

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Transformer Construction Winding
• The winding is made of copper or aluminum
conductor, insulated with paper or synthetic
insulating material
• The windings are manufactured in several
layers, and insulation is placed between
windings.
• The primary and secondary windings are
placed on top of each others but insulated by
several layers of insulating sheets.
• The windings are dried in vacuum and
impregnated to eliminate moisture.
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 Types of Transformer
• Depending on there construction there are two
types of transformer:
1 Core form transformer
 The winding surrounds the core.
 It more economical
2 Shell form transformer
 The core surrounds the coil
 For HP application shell type is more preferable
because short circuit strength characteristics.
 It also exhibits a better power to weight ratio.
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 Transformer Construction
• The three phase transformer iron core has
three legs.
• A phase winding is placed in each leg.
• The high voltage and low voltage windings are
placed on top of each other and insulated by
layers or tubes.

A B C

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 Transformer Construction

• The dried and treated

transformer is placed in a
steel tank.
• The tank is filled, under
vacuum, with heated
transformer oil.
• The end of the windings
are connected to bushings.

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 Transformer Construction

• The transformer is equipped with

cooling radiators which are cooled
by forced ventilation.
• Cooling fans are installed under the
radiators.
• Large bushings connect the
windings to the electrical system.
• The oil is circulated by pumps and
forced through the radiators.
• The oil temperature, pressure are
monitored to predict transformer
performance.
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 Questions

 Why Transformer works only on AC?

 What is the difference between core type
and shell type transformer?
 Why a transformer core is made of IRON?
 Why a transformer core is laminated?
 What are the losses in a transformer?
 Designing
Parameters for Transformer designing :-
 Nominal power and power factor.
 Type of duty (short time, continuous, intermittent)
 Primary voltage
 Load secondary voltage
 Number of phases and type of connection
Step 1 Calculate core area of a transformer.
∅
𝐶𝐴 =
𝐵
∅ = 𝐾𝑈 𝐾𝑉𝐴/𝑓
𝐾𝑈 and B are constants and taken from table.
Step 2 Determine approximate column width of the core.
4
𝐶 = 𝑉𝐴
Using the above two calculated data select the appropriate size of the core.

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 Designing

Step 3 Determine net thickness of the iron package.

𝐶𝐴
𝐿𝑝 =
𝐶
𝐿𝑝
𝐿𝑝𝑜 = ,𝐾𝑠 Packing coefficient
𝐾𝑠
𝐿𝑝𝑜
𝑁𝑜 𝑜𝑓𝑠ℎ𝑒𝑒𝑡 =
0.5
Step 4 Determine number of turns.
1st determine VPT
𝑉
= 4.44 ∗ 𝑓 ∗ ∅
𝑇
𝑉𝑝
𝑁𝑝 =
𝑉𝑃𝑇
𝑉𝑠 +∆𝑉
𝑁𝑠 = ,Assuming a voltage drawn from no load to a load condition of 3%-4%
𝑉𝑃𝑇
Step 5 Calculate the currents in the winding.
𝑆𝑛
𝐼1 =
𝑉𝑝 ∗ 𝑒𝑓𝑓
𝑆𝑛
𝐼2 =
𝑉𝑠

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 Designing

Step 6 Determine cross sections of the conductors.

𝐼1
𝐴𝑐𝑢1 =
𝐽
𝐼2
𝐴𝑐𝑢2 =
𝐽
Then take the standard wire size.
Finally Verify the radial dimension of the winding.

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