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Development of the enameled wire industry Technology must take the lead

2020-11-30

  After decades of development, the enameled wire industry has made rapid progress. However, many problems in the industry should also be noted, such as (1) the quality of enterprises varies greatly, with a considerable number of companies having outdated processes and equipment, lacking testing methods, making it difficult to produce high-quality products. If this situation cannot be changed quickly, they will inevitably lose their space for survival; (2) many enterprises confuse and misunderstand the meaning of technology introduction and equipment import, resulting in imported equipment failing to form innovative advantages. This is also an important reason for quality homogenization and excessive competition in special wires; (3) insufficient understanding of the value of quality and brand leads to unstable product quality and poor consistency, which is still quite common; (4) poor ability for enterprises to develop independently, with product variety development relying on imitation of foreign products, etc. If these problems continue to exist, they will clearly be insurmountable obstacles to achieving the goal of expanding enterprises and strengthening the industry. To solve these problems, it is necessary to strengthen research on material applications, process optimization, and testing technologies at the technical level, and to improve the enterprises' own technological innovation capabilities through continuous accumulation.

  1. Strengthen research on material applications and accumulate application experience.

  Conductor materials are well known! The production of electromagnetic wires requires the use of copper materials, which is even more important for enameled wires. Currently, the commonly used oxygen-free copper rods and electrical ductile copper rods have differences in their drawing and annealing characteristics due to different manufacturing technologies! The conclusion of the application research is that for electromagnetic wire products with high flexibility requirements, it is recommended to use electrical ductile copper rods as conductor materials. Currently, the electrical ductile copper rods used abroad for the production of enameled flat wires and fine wires often require planing treatment in many cases, and to reduce wire breakage, fine wire production may also use copper alloys containing small amounts of other metal components as conductor materials. Although the importance of conductor quality has been recognized by more and more enterprises, the reasonable use of drawing equipment, continuous monitoring of lubricants, selection of molds, maintenance, and other aspects still do not receive the same level of attention as subsequent processes. Research abroad shows that 10% of the causes of surface quality issues and coating continuity defects in enameled wires come from the drawing process of copper wires, which is enough to illustrate the importance of research on conductor material applications.

  2. Ensure product quality and production efficiency of the wires.

  There are many varieties and brands of enameled wire coatings. Although this causes some trouble in usage, it also increases the options available. Therefore, mastering the quality characteristics and process rules of the coatings is particularly important for ensuring the product quality and production efficiency of the wires. It has been confirmed that even for the same variety, but with different brands from different origins, the coatings often need to be used under different process conditions to achieve good quality performance! The performance levels of the wires will still vary. For example, THEIC: modified polyester varnish, formaldehyde varnish, and self-adhesive varnish all have this characteristic. Through application research, these rules can be discovered and mastered, and it can also verify the applicability of others' experiences under the specific conditions of one's own enterprise.

  3. Strengthen research on process optimization and master advanced practical technology.

  The main focus is on experimental research on the relationship between equipment, materials, and process technology, revealing the laws between process and quality! Mastering the process conditions for product production to form advanced practical technology; enterprises can only maintain quality and product differentiation advantages in fierce market competition by continuously creating and possessing their own proprietary technologies.

  4. Strengthen research on testing technology to promote the development of product quality.

  China's electrical machinery and appliance industry began to introduce foreign manufacturing technology in the 1980s. The demand for the localization of raw materials has stimulated the enthusiasm for variety development and quality improvement in the electromagnetic wire industry, while also driving the improvement and development of testing technology. Currently, domestic electromagnetic wires can not only meet IEC, NEMA, JIS standards. Although the production and use of electromagnetic wires have a long history, some product characteristics are still not well understood, which also requires the application of more diverse and advanced testing methods for further exploration. For example, the issues of 'winding suitability' and 'cohesion' of enameled wires, summarizing the results of recent domestic and foreign related research, it is generally believed that this is a characteristic exhibited by the metal conductor and the coating together, and is therefore influenced by various factors such as the surface quality of the wire, flexibility, tensile strength, coating toughness, and surface lubricity. This requires further research in future work to determine relevant performance indicators and their testing methods.

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