At an enameled wire manufacturer, we can see that the manufacturing process of enameled wire mainly includes: wire feeding → annealing → coating → baking → cooling → lubrication → wire take-up. On a normally operating enameling machine, most of the operator's energy and physical strength are consumed in the wire feeding section. Changing the wire feeding reel requires a lot of labor from the operator. When changing wires, the joints are prone to quality problems and operational failures. An effective method is to feed large-capacity wires.
The key to wire quality is tension control. Excessive tension not only thins the conductor, causing it to lose its shine, but also affects many properties of the enameled wire. Visually, a thinned conductor results in a less lustrous enameled wire; performance-wise, the elongation, resilience, flexibility, and thermal shock resistance are all affected. Insufficient tension during unwinding can cause the wire to jump, leading to tangling or contact with the furnace vent. Uneven tension in half a turn is particularly problematic during unwinding. This not only causes the conductor to become loose, break, and thin in sections, but also results in significant jumping within the furnace, causing tangling and contact issues. Therefore, the unwinding tension must be uniform and appropriate.
Enamelled wire characteristic test
● Conductor resistance. Measured using a conductor resistance testing instrument, and then compared with the value at 20℃.
● Insulation breakdown voltage. Two strands of enameled wire are twisted together, and a voltage is applied between the conductors. The breakdown voltage is used to determine the insulation breakdown voltage. This property is analyzed and judged through two tests: normal state and cold state breakdown voltage.
●Film continuity (pinholes). This involves inspecting for pinholes in the paint film using a test piece of a specified length. This test is performed using a high-pressure paint film continuity tester.
●Flexibility (bending and stretching). When winding or stretching, judge by whether the paint film cracks or pinholes appear.
● Adhesion. This is determined by a rapid tensile test; the paint film should exhibit cracking under rapid stretching.
●Abrasion resistance. The abrasion resistance is measured by the number of times the conductor is exposed or the abrasion damage value when the paint film is abraded using an abrasion tester.
●Aging resistance. Analysis is performed under specified heating conditions, based on whether pinholes or insulation breakdown voltage occur in the paint film.
● Softening resistance. Heating crossed enameled wires under specified conditions and applying current, the temperature at which a short circuit occurs is measured. Alternatively, heating two stranded enameled wires under specified conditions, and observing whether the enamel film shows any abnormalities.
● Thermal shock resistance. When stretched or wound, heat under specified conditions and observe whether the paint film cracks.
● Solvent resistance, chemical resistance, and oil resistance. When immersed in solvents, chemicals, or insulating oils, the condition of the coating film is indicated using the fingernail method or pencil method.
●Solderability. Depending on the specified temperature and solder conditions, and whether the solder adheres evenly.
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