Products
1. Annealing Process
During the drawing process the bare wire’s grain structure has been changed through cold deformation. Annealing will re-crystalize the copper and make it soft again. This thermal stress relief process is carried out under protective atmosphere in order to avoid oxidizing the wire surface, which would interfere with good adherence of the initial coating of insulation later in the process. Softness of the enamelled wire is an important criteria for good windability, in particular significantly reducing the number of wire breaks.
2. Enamel Application
There are 2 main application systems for enamelling of winding enamelled wires, i.e felt application and die application, whereas felt application is mainly used in fine Enamelled wire production, while die application is mainly used in heavy enamelled wire production. The enamel coating should always be applied in as many single layers as possible rather than fewer and thicker layers to achieve better mechanical and electrical properties of the enamelled wire.
3. Curing Oven
Solvents contained in the liquid enamel are driven out in the curing oven at high Temperature and then are burnt catalytically by using the thermal energy in an environmentally friendly way. Temperature control is very important: if the temperature is too low, too many solvent residues will be left in the enamel layer, leading to poor adhesion and reduced mechanical and electrical properties of the enamelled wire. If the temperature is too high, the enamel coating will be hard and brittle, leading to cracks in the insulation coating of the Enamelled wire resulting from mechanical stress.
4. Lubrication
A defined amount of lubricant is precisely applied to the insulated enamelled wires surface. Lubrication is necessary to achieve consistent winding properties and failure-free winding of the wire even at high winding speeds.
5. Diameter Control
ELEKTRISOLA continuously monitors the Outer Diameter of all enamelled wires after the final pass by laser.
6. Tension Control
A continuous wire tension control during the enamelling process results in a consistently uniform spooling onto the spool. With effective tension control, elongation of the enamelled wire is avoided and thus a change in resistance. Furthermore, good de-reeling properties of enamelled wire for customer can be guaranteed.
7. Spooling
The wire pitch and the spool’s rotational speed are spooling process variables closely to be controlled. This results in consistently good enamelled wire de-reeling performance and minimizes other problems like trapped and tangled wires.
8. Monitor
The monitor informs the operator about all important parameters of the process.
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Industry Focused Products!
Polyester Enamelled Copper Round Wire (PEW)
Polyester Enamelled Copper Round Wire (PEW) is manufactured with high-quality electrical copper conductors and coated with polyester enamel insulation. It features excellent thermal resistance, mechanical strength, and insulation performance, and is widely used in motors, transformers, electrical coils, and industrial equipment.
Polyurethane Enamelled Copper Round Wire (UEW)
Polyurethane Enamelled Copper Round Wire (UEW) is manufactured with high-quality electrical copper conductors and coated with polyurethane enamel insulation. It features excellent abrasion resistance, flexibility, solderability, and high-frequency performance. The wire can be directly soldered without removing the enamel coating, improving production efficiency. It is widely used in precision electronic components, high-frequency coils, relays, inductors, micro motors, and communication equipment.
Polyesterimide Enamelled Copper Round Wire (EIW)
Polyesterimide Enamelled Copper Round Wire (EIW) is manufactured with high-quality electrical copper conductors and coated with polyesterimide enamel insulation. It offers excellent heat resistance, chemical resistance, mechanical strength, and reliable insulation performance. It is widely used in motors, compressors, transformers, new energy equipment, and industrial electrical applications where high-temperature and heavy-duty operation are required.
Enamelled Rectangular Copper Wire
Enamelled Rectangular Copper Wire is manufactured with high-purity electrical copper conductors, precisely formed into a rectangular shape and coated with high-performance enamel insulation.
Compared with traditional round enamelled wire, it provides higher slot fill factor, improved space utilization, better heat dissipation, and enhanced power density for electrical machines.