Instruction manual

Coil Design & Manufacture
How to design and manufacture an X-TERRA coil
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Coil Design
Coil design is a long and complex task that requires many steps to ensure the coil
will continue to work correctly for many years. These steps are generally divided
into two main teams that initially work independently and then combine their
skills to nalize the product. The teams are the electronics designers and the
mechanical designers.
56Understanding your X-TERRA - Coils
Electronic design process includes:
• Calculating and modeling electromagnetic elds
• Designing specications for wire size, type and number of turns
• Manufacturing prototype templates for windings
• Manufacturing prototype windings and soldering to cable
• Constructing a prototype search coil by attaching windings to
the template
• Testing, calibrating and programming the microcontroller with
initial software parameters
• Measuring and rening the software parameters for the
microcontroller
Mechanical design process includes:
• Designing mechanical CAD (Computer Aided Design) model
• Constructing mould ow and analyzing the structure using
specialized mechanical engineering software tools
• Building rapid prototype models of coil housing parts
• Building prototype cables and strain relief
• Building prototype coil using draft electronic specications
• Field testing the prototype coil