enameled wire

According to the characteristics and uses of insulation, winding wires can be divided into four categories: enameled wires, wrapped wires, special winding wires, and inorganic composite winding wires.

The temperature resistance of composite enameled wire can reach above 520 degrees.
Composite enameled wire is an ideal wrapping wire for large-scale low-voltage and high-current electrical appliances such as power oil-immersed, dry-type, special transformers, electric welding machines, reactor rectifiers, electromagnetic separators, etc., with excellent electrical performance and stability.

Resistance:
Take 1m of the enameled wire to be inspected, scrape off the paint film at both ends, measure the resistance of the enameled wire, the resistance measurement value should be within the resistance range of GB/T6109; the standard temperature is 20 degrees, the conversion formula: 20 degrees resistance/234.5+standard Temperature = actual measured resistance/234.5 + measured temperature;

Pay-off (link pull) ¡ú annealing ¡ú painting ¡ú baking ¡ú cooling ¡ú lubrication ¡ú take-up

The 130L thin paint film polyester enameled round copper wire (QZ-1/130) belongs to the enameled wire under the winding wire classification.

Model and name
QZ-1/130, 130L thin paint film polyester enamelled round copper wire.

The electromagnetic coil is built by using the magnetic field around the wire, winding it into a spiral to strengthen the magnetic field, that is, using the smallest space to achieve the highest magnetic field strength, and replacing the ordinary wire with a wire covered with a layer of insulating paint is also to save space .

Enameled wire is a kind of cable. The specifications of the enameled wire are expressed in terms of the diameter of the bare copper wire (in mm). The measurement of the enameled wire specification is actually the measurement of the diameter of the bare copper wire. It is generally used for micrometer measurement. The accuracy of the micrometer can reach 0.01mm. There are direct measurement methods and indirect measurement methods for the measurement of enameled wire specifications (wire diameter).

Aluminum core magnet wire can be classified according to its basic composition, conductive core and electrical insulation layer. Usually according to the insulating material and manufacturing method used in the electrical insulation layer, it is divided into aluminum core enameled wire, aluminum core wound wire, aluminum core enameled wire and inorganic insulated wire.

7 step of manufacturing of magnet wire: Material preparation, Drawing, Wash with water, Annealing, Impregnation, dry, Take-up and Packing and storage

Precautions for storage should be well packaged, should not be placed in a high-humidity warehouse, should not be exposed to direct sunlight, and should not be placed near acids, alkalis and organic solvents.

Although the quality of enameled wire depends to a large extent on the quality of raw materials such as paint and wires and the objective conditions of machinery and equipment, if the operation does not take a series of problems such as baking, annealing, speed, etc. seriously and understand their interrelationships , Without mastering the operating technology, not doing the touring work and parking finishing work seriously, and not doing well in the process and hygiene, even if the objective conditions are good, it will not be able to produce high-quality enameled wire. Therefore, the decisive factor for a good enameled wire is people, and people’s sense of responsibility for work.

Aromatic polyimide enameled wire has good heat resistance, softening breakdown resistance, radiation resistance, severe cold resistance and chemical resistance. Among them, many test indicators such as unidirectional scratching, breakdown voltage, and thermal softening are far Far better than ordinary enameled wire.

Enameled wire is widely used in winding wires of motors, transformers, inductors, generators, electromagnets, and coils.
In the past, the diameter range of enameled wire usually required was 0.2-2.0mm [AWG12-32], but nowadays, thinner (diameter less than 0.18mm, AWG33) and thicker (diameter greater than 3.0mm, AWG9) are required on the market Enameled wire.

At present, almost all winding wire insulating paints in the world are solvent paints, which not only use organic solvents needlessly, but also seriously pollute the environment during manufacture and use, causing harm to organisms (human beings, animals and plants). For a long time, people have devoted themselves to the efforts to eliminate this kind of harm, especially in recent years, the proposal of ISO14000 will greatly promote this kind of efforts. The following is a general summary of the experimental research and trial production in this area. As an industrial promotion, it will take some time. It is expected that in the next five to ten years, certain varieties may be introduced to the market.

It is often seen in the electronics industry that when returning goods, the quality reason is “multi-threaded”. This is really wrong to the enameled wire factory. Because the current production machines of enameled wire are single-end pay-off and single-end take-up, there is no multi-end.

The wrapped wire is made of natural silk, polyester fiber, glass fiber, insulating paper or synthetic resin film, etc., tightly wrapped on the conductive wire core to form an insulating layer. There are also insulating layers wrapped around the enameled wire. In addition to thin-film insulation, others such as glass filaments need to be dipped in adhesive insulating varnish to improve their electrical, mechanical and moisture-proof properties. In fact, they are combined insulation.

The purpose of collecting and arranging the wire is to continuously, tightly and evenly wind the enameled wire onto the spool. The wire take-up mechanism is required to drive smoothly, with low noise, proper tension and regular wire arrangement. In the quality problems of enameled wire, the proportion of returns due to poor wire collection and arranging is very large, which is mainly manifested in the large wire tension, the wire diameter is thinned or the wire reel burst; the wire tension is small, and the wire reel is broken. Loose lines cause chaotic lines, and uneven lines cause chaotic lines. Although most of these problems are caused by improper operation, it is necessary to take necessary measures in the process to bring convenience to the operators.

Enameled wire
The insulation of enameled wire is varnish film, which is formed by coating insulating varnish on the conductive wire core and drying it.

Product features and uses
The paint film of the enameled wire is uniform and smooth, which is conducive to the automatic winding of the coil; the paint film is also thin, which is conducive to improving the space factor, and is widely used in small and medium-sized or micro electrical products

As one of the core three-electric systems of new energy vehicles, electric motors account for 5-10% of the value of the entire vehicle. Among the top 15 new energy vehicle sales in the first half of 2021, the penetration rate of flat wire motors has increased significantly to 27%. The industry predicts that in 2025, the proportion of flat wires in the drive motors of new energy vehicles will exceed 80%.

The key to pay off is to control the tension. When the tension is high, it will not only draw the conductor thin, make the surface of the wire lose its brightness, but also affect many properties of the enameled wire. From the appearance point of view, the enameled wire that is drawn thinner has poor gloss; from the performance point of view, the elongation, resilience, flexibility, and thermal shock of the enameled wire are all affected. If the pay-off tension is too small, the line will easily jump and cause the line to be merged and the line to touch the furnace mouth. When paying off, the most fear is that the half-turn tension is high and the half-turn tension is small. This will not only cause the wires to loosen, break, and be thinned one by one, but also cause large jumps of the wires in the oven, resulting in failures of merging and touching the wires. Pay-off tension should be even and appropriate.

The temperature distribution of the oven has a great relationship with the baking of the enameled wire. The distribution of oven temperature has two requirements: longitudinal temperature and transverse temperature. The longitudinal temperature requirements are curved, that is, from low to high, and then from high to low. The lateral temperature requires a linear shape. The uniformity of the lateral temperature depends on factors such as equipment heating, heat preservation, and hot air convection.

Application
? Oil-immersed transformer windings, Dry-type transformer, High temperature transformer,
? Motor, transformer, generator, welding machine; Sealed motor, Power tools motor, Auto alternators motor, Magnet coil, High power motor, household electro motors and micro-motors;
? Medium and large electrical motor and transformer windings;
? Power substations, rectifiers, f urnace transformer oil-immersed transformer coil winding;
? Lifting electromagnet, reactors and other low-voltage and high current electromagnetic winding;
? Used in aerospace, submersible motor and high voltage coil, wind turbines, micro-electronics and so on.
Windings with light weight, high conductivity, good heat resistance; Winding used for high frequency signal transmission
Magnetic wire used in High Frequency transformer, common transformer, inductance coils, electrometers.

Nomex covering corresponds to class H insulation is mainly used in the construction of condensers and capacitors. Main application of it is in shielding of cables in high temp. environments (200¡ãC) such as dry type transformers, military and aerospace cables. Nomex covered conductors are more effective in condition where temperature resistance and dielectric strength requirements are high.
Application of Nomex Paper Covered Aluminum wire :
Mobile Transformer,Traction Transfomers,Pole-mounted distribution transformers,Power substantions,rectifiers,oil-immersed transfomer coil winding.

An electrical motor is one kind of machine which is used to change the energy from electrical to mechanical. Most of the motors work on the principle of interaction among the electric current as well as the magnetic field within a wire winding. This can generate force in the form of shaft rotation. These motors can be powered with DC or AC sources. The DC sources are batteries whereas the AC sources are inverters, power grids, generators. A generator is mechanically similar to the motor but works in the reverse direction by converting the energy from mechanical to electrical. An electric motor can be built with the rotor, stator, air gap, windings, bearings, & commutator. The classification of motors can be done with considerations like the type of power source, construction, motion output type, and applications. This article discusses what is a motor winding, types, and its calculation.

3M paper covered aluminium wire feature :
* High dielectric strength/Excellent therm alstability/Wrapped tightly;
* Paper covered Aluminum wire is a special kind of magnet wires. Its conductors is electrical round aluminum rods which squeeze
and draw by the certain size of mold. And its insulations is special material;
* Our 3M paper covered aluminum wire uses two layers or several layers as the insulation layer;
* The wrapping direction of paper is same. And every layer paper twines conductors continually and compactly without wrinkles;
* Uses for oil-immersed transformers, reactors and other windings;

List 5 type of enameled wire characteristics
Acetal enameled wire
Polyurethane enameled wire
Polyester and modified polyester enameled wire
Polyesterimide/polyamide imide composite enameled wire
Polyesterimide/polyamide composite enameled wire

Enameled wire is a type of electromagnetic wire, usually refers to the insulation wire used to make coil or winding in electrical products. It is also called the winding wire.
The electromagnetic wire must meet the requirements of various applications and manufacturing processes. The former includes its shape, specification, working at high temperature in short and long time, as well as the strong vibration and centrifugal force under high speed on certain occasions, resistance to corona and breakdown under high voltage, and chemical corrosion resistance in special atmospheres, and the requirements for tensile, bending and wear, as well as the requirements of drawing, bending and wear during winding and inlaying. Swelling and erosion during immersion and drying.

Correspondence table of enameled wire diameter and resistance value
The resistivity of the copper wire ρ= 0.0172, the aluminum wire ρ = 0.0283, the wire resistance calculation formula:
R=ρ×L/S
(L = wire length, unit: meter, S = wire cross section, unit: mm^2)

The current mainly passes along the copper-clad aluminum wire on the surface of the wire, which is called the skin effect. The higher the frequency, the more obvious it is. The copper-clad aluminum wire uses this feature to save material. But its resistivity is slightly higher than that of pure copper wire, and the resistivity is also different with the thickness of the copper clad.

Aluminum is not only cheaper than copper, but also as an excellent conductor, it has better flexibility than copper, its density is only 1/3 of copper, and the same weight of aluminum conducts electricity twice as much as copper; therefore, aluminum Wire requires a larger wire gauge than copper wire to conduct the same current.
Compared with copper, another advantage of enameled round aluminum wire is that the NEMA standard recognizes aluminum wire as a higher thermal enameled wire. For example, replacing copper wires with aluminum wires, using high-temperature polyester TeresterR@ C966, and composite polyamide-imide topcoat, the thermal level can be increased from 200 to .220. The reason is that during the aging experiment of the enameled copper wire, the catalysis of copper ions promotes the aging of the paint film.

The wire drawing metal processing technology can form fine lines on the surface of the metal material, which makes the metal more textured, and is used as a decoration by users and is well-loved. In the production process, the drawing lubricating fluid is indispensable in the drawing metal processing technology. It is widely used in the lubrication of the middle drawing, small drawing and micro drawing of enameled copper wire. So how to choose this kind of drawing fluid?