Robotic Technologies at Benatav

Electromagnetic coils are produced by winding a conducting wire in the shape of a coil, spiral, or helix. The shape and dimensions of a coil are designed to fulfill a particular purpose. Parameters such as inductance, resistance, and strength of the desired magnetic field greatly influence the design of coil windings.

Modern equipment is becoming more miniaturized which leads to a demand for micro coils. However, several challenges face the designer of modern equipment which use micro coils:

  • Economic mass production—producing large quantities of coils at the lowest feasible cost
  • Size—one of the major challenges facing the mechanical designer of modern devices is the ever-increasing need for miniaturization.

These size constraints pose multiple challenges, both in the manufacturing and in the connecting of these components to each other and their support systems.

The Challenges

Winding and Handling Micro Coils

Equipment used to wind and handle regular-sized coils can’t be used to mass-produce micro coils, which require the development of specialized equipment. To manufacture a micro coil with as many as 2000 turns, you need to greatly reduce the thickness of the wire. The thinnest insulated copper wire diameter currently available is 8.8 microns (0.00034 inches). Benatav is one of the few companies in the world working with such fine wires, and to our knowledge, the only one working with 8.8 microns. In addition, we are working on producing insulated wires even smaller than 8.8 microns.

Another problem encountered when producing miniature coils is keeping the insulation layer that covers the conducting wire undamaged, which can be caused by ultra-fine tooling sets.

Connecting Ultra Fine Wires

To connect such fine wires, traditional, solder tin-based connections are not up to the task. Solder-based connecting creates undesired side effects, such as oxidization of the connection and the region, inferior conductivity, low durability, high production cost and high rates of failures.

To overcome these problems, Benatav has developed a proven, cutting-edge, thermo-pressure technology to produce precise soldering with tight tolerances at very high temperatures. Our thermo-pressure bonding technology allows us to connect ultrafine wires with none of the previously mentioned drawbacks.

The molecular connections formed by this thermo-pressure bonding technology provide highly reliable, corrosion-free, and strain-free connectivity without any soldering, thus simplifying and lowering manufacturing costs. Thorough testing of the technology in a wide variety of customer environments, coupled with its implementation in several production processes,  this technology has been integrated successfully into mass serial production processes while meeting the standards required by demanding applications such as in medical devices.

The Solution – Industrial Robots

Benatav’s Custom Robotic Technologies

Manufacturing micro coils and connecting their extremely fine wires can’t be done using traditional technologies and still meet goals such as:

  • Economic mass production
  • Safer production process. No risk of damaging sensitive components
  • Highly reliable connections—no oxidization
  • Very tight tolerances
  • High quality to ensure the long life of each component
  • Repeatable physical and electrical characteristics
  • Robust, automated manufacturing process—eliminates human error caused by various skill levels and worker experience

Using in-house engineering, Benatav has developed state-of-the-art methods and robots which allow the winding of micro coils and  filling them with ferro-magnetic material acting as a core to an extent that was not possible before. These robotic technologies are not subject to the vagaries of manual production and therefore we can manufacture and connect micro coils on a scale and to standards not previously possible.

Speak to us regarding your micro coil requirements

Whatever your micro coil requirements, due to our extensive specialist experience in micro coil technology, chances are that we have already solved any issues that may prevent us from producing your coils at highly competitive rates.