Quoted from twenty84:Dual wound coils can use a smaller coil for holding the flipper up after the limit switch is activated. This is a separate issue from using PWM to change flipper power which is what is used in any modern game where flipper power is adjustable in software including JJP and Stern. I haven't had an AP game or Rick and Morty so I can't speak to those.
Any piece of metal you put current through will heat up, so that issue isn't limited to Stern, and is well documented for JJP flipper coils and others. It has become fashionable to monitor flipper coil temperature during games and document that the flippers do in fact get warmer. That said I feel the effect on game play caused by heating has been overstated recently. Looking at the timing until the limit switch was activated on Stern games I was not able to find any effect of heating at least to near 1 ms or less. I have yet to see anyone measure a decrease in coil power or change in timing with heating.
PWM is mostly used on single wound flipper coils to my knowledge. On the dual wound flipper coils they don't need to PWM because they have two driving transistors, one for hold and one for power. On these, the time in MS from changing from power to hold is what is being modified. For example, trigger power coil for 35ms then simultaneously switch off and turn on hold.
Single wound coils use a single transistor and PWM to do the power and the hold. I'm not exactly sure how Stern implements their PWM, but it's generally really good. It is something like 50% PWM for 30ms, then 15% PWM while flipper is held. (Just example numbers)
Yes coils get hot. It's not just a Stern issue. But single wound coils are more difficult to manage the heat profile and takes more fine tuning than a dual wound coil designed for this problem. If the hold PWM is too low, the flipper bat is easily knocked down and if it's too high then the coil quickly overheats
I'd love to know why JJP flippers are so different in execution than everyone else. They do heat up quickly and generally have a very unique feel to them.
Heat changes the resistance of the coil, which lowers the power of the electromagnet. I would also theorize the heat also likely causes the nylon sleeve to slightly expand in size which adds additional friction to the plunger, and makes the flipper feel weaker.
And this is all about flipper coils. Regular coils, like pops and slings, are modifying the timing pulse of the one coil fire to activate the device. This is not done through PWM