Transformer wire winding and foil winding are two different winding methods used in the manufacture of transformers. They have some significant differences in structure and performance:

Wire Winding:

Wire winding is the more common winding method, using insulated conductive wires (usually copper or aluminum) to create windings.

The wires are wound into spiral coils, and multiple coils are placed on a magnetic core to form primary and secondary windings for current transmission and voltage transformation.

Wire winding is typically suitable for small to medium power transformers.

Foil Winding:

Foil winding is a less common winding method that employs thin metal foil strips (usually copper or aluminum foils) to create windings.

The foil strips are stacked layer by layer in a typically parallel fashion within the winding to increase the effective cross-sectional area for electrical conduction.

Foil winding is commonly used in high-power transformers as it provides a larger effective cross-sectional area, reduces current density, and minimizes losses.

In summary:

Wire winding uses wires, while foil winding uses thin metal foil strips.

Foil winding is typically used in high-power transformers, while wire winding is suitable for small to medium-power transformers.

Foil winding offers a larger effective cross-sectional area, reduced current density, and lower losses but comes with higher manufacturing costs.

Foil winding may require more insulation materials to isolate foil strips and prevent electrical short circuits.

Foil winding has a more complex structure and requires more specialized manufacturing processes and techniques.

The choice between wire winding and foil winding depends on specific transformer application requirements, power needs, and the trade-offs between manufacturing costs and performance.

LuShan, est. 1975,  is a Chinese professional manufacturer specializing in power transformers and reactors for 48 years. Leading products are single-phase transformer, three-phase transformers, DC inductors, AC reactors, filtering reactor, expoxy resin high-voltage transformer and intermediate, high-frequency products. Our transformers and reactors are widely used in 10 application areas: rapid transit, construction machinery, renewable energy, intelligent manufacturing, medical equipment, coal mine explosion prevention , excitation system, vacuum sintering, central air conditioning.

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