In loose-lay winding, the winding is shaped during the winding process, and the ends are shaped only after the winding is fully inserted into the core. In contrast, shaped coils do not have a shaping process during winding; even if they do, it's only a minor adjustment. Therefore, coil shaping is crucial to ensure the coil meets requirements after being inserted into the core. To improve coil processing efficiency and quality, motor manufacturers with the resources use automated forming processes, resulting in excellent coil consistency. Simply inputting the coil parameters is all that's needed.
Gel curing is a special process for adhesive-insulated electromagnetic wires. The gel curing process involves heating to melt the adhesive in the insulation, which then bonds the turns together, curing the wire harness and enhancing the motor's vibration resistance.
Description of the gelation process
At a certain temperature, solvent-free paint transforms from a viscous liquid into an elastic gel, undergoing a sudden change in properties. This phenomenon is called gelation, or simply gelation. Initially, the gel consists of two parts of molecules with different structures. One part is a high-molecular-weight network structure, which is insoluble, hence the name gel. The other part is a smaller sol, encased within the gel's network structure. Under the influence of temperature, the gel continues to react, the sol portion gradually decreases, the gel portion gradually increases, the elasticity and toughness of the mixture increase, and finally, a solidified product is obtained.
If the insulated magnet wire is left for too long, it may fail. The most direct impact is that the gelling process cannot achieve proper bonding. Therefore, the purchase of magnet wire must be limited during the production and processing of high-voltage motors to prevent unnecessary waste.
