Custom Winding - Transformers - Inductors
Services and Capabilities
Winding Transformers Inductor Services and Capabilities
Butler Winding manufactures coils, transformers, and inductors. Most of our business is from custom orders. Custom orders being orders built to customer drawings and/or to customer specifications; or orders requiring specialized handling, material and/or equipment. The coils, transformers, and inductors our customers ask us to build are not readily available as “off the shelf” parts.
What kind of services and capabilities can Butler Winding offer its customers?
Manufacturing ( Manufacturer of Inductors - Transformers - Coils)
After receiving a customer order Butler Winding will purchases the cores, bobbins, winding tubes, terminals, magnet wire, lead wire, and/or insulation needed to build the customer’s parts. Then Butler Winding winds the coils; terminates the coil windings to pins, pads, terminals, or lead wires as required (including soldering and/or crimping); assembles (or stacks) the core(s) into the coils; tests the parts; bakes the parts if required; varnishes or encapsulates the parts; labels the parts; and then ships the parts. Yes, Butler Winding also sends a bill for the parts to the customer.
Manufacturing can do any of the above processes as a “value added” process. One of our customers sends transformers to Butler Winding to encapsulate (pot) in epoxy. Manufacturing makes every reasonable effort to meet the customer’s delivery dates.
Manufacturing can vacuum impregnate varnishes and encapsulate (potting) under vacuum. Manufacturing also has the capability to temperature cycle parts if needed. Butler Winding has one coil winder capable of winding with single digit wire gauges. For toroids #12 A.W.G. is the largest single conductor wire size our machines can handle. Manufacturing equipment available for use includes:
- Tanac AX3 automated (programmable) winding machine.
- Tanac AX10 automated (programmable) winding machine.
- Bobifil ER-900 MP winding machine (can handle single digit wire
gauges).
- Seven hand winders.
- Two directional motors with a turns counter, speed controlled with
a foot pedal.
- Anacoil Meteor M10 coil winder.
- Bachi Model 115 E/C SCR coil winder
- Jovil Model 200 and Jovil Universal SMC-1 toroid winder.
- Jovil model 200 toroid winder equipped with a taping header.
- Gorman Productor B and model 920A toroid winders.
- Universal model 63 and model 6LS toroid winders.
Various size shuttles for each of the toroid winders.
- Two toroid hook winders.
- Carpenter Manufacturing Co. Model 88E mechanical wire stripper.
- Several handheld mechanical wire strippers, rotating knife edge type.
- Banding Machine, compressed air type, for banding “C” cores.
- Brady Model 3481 label maker
- Two Voltech Instruments AT3600 automated (programmable) transformer testers
- Two Baking Oven.
- Vacuum Chamber and a Vacuum Oven Chamber.
- Varnish tanks
- Small machine shop – drill press, band saw, sander, and grinder.
- Tenney Temperature Chamber
- EFD Model 1500 XL precision dispensing machine.
- Air compressor.
Transformer - Inductor Design Services
Butler Winding has an engineer on staff who is experienced in transformer and inductor design. If customer personnel need technical advice, they can telephone Butler Winding and ask to speak to engineering. Schedules permitting, our engineer may design transformers for our customer. As of present date, simple design work is usually done (not always) at no charge as a courtesy to our customers. A more extensive effort may warrant and incur a charge to the customer for the service. Schedules permitting, our engineering may be available for an hourly or daily fee contracted through Butler Winding.
Prototyping
Butler Winding will make prototypes for customers if requested. A prototype sample is recommended for parts new to Butler Winding. Small inexpensive prototypes might be supplied to the customer at no charge as a courtesy to the customer. There will be a charge for larger more expensive prototypes. Typically, our engineer will produce a parts list, a coil sheet, and perhaps an assembly drawing. These will be submitted to production (manufacturing) for quoting (if applicable) and/or production. If the necessary materials are on hand production will insert the prototype work into its schedule after receipt of the purchase order (if applicable). If materials are not on hand, then material will be procured. Butler Winding tries to produce prototypes within two weeks, but this is not always possible.
Customer Service
Butler Winding strives to provide good customer service. Butler winding recognizes that good customer service entails on time deliveries, polite friendly personnel, quick response times, monitoring of customer order status, and attention to detail. Butler winding will accommodate customer schedule changes and cancellations when practical, but Butler Winding cannot be expected to suffer monetary loss due to customer changes.
Quality Control
Quality is important to our customers therefore it is important to Butler Winding. Bad parts cost the customer money and cost the vendor money. The cost occurs in lost time troubleshooting, communicating, and shipping return and replacement parts. Tracking the quality of thousands of parts is not an easy task. To help ensure quality, Butler Winding purchased two automated programmable transformer testers. Both testers are the Voltech Insturments model AT3600. Butler Winding does nearly 100% testing of the parts it produces. Where warranted, inspection steps are added to our manufacturing process to help ensure a quality part. Also, there are procedures in place that help catch paperwork mistakes thereby reducing late deliveries.
Butler Winding personnel are willing to work with customer personnel to resolve any quality problems that may come up.
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