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Electromagnetic coils are the core components of motors, transformers, new energy electric drives, high-frequency electronic devices, servo electric controls, precision sensors to complete the electromagnetic energy conversion, power transmission and signal regulation, and they are also the indispensable basic core components of all kinds of electrical, electric power, and new energy equipment.
From the principle of energy conversion, electromagnetic coil relying on the winding wire energized to produce alternating magnetic field, to complete the two-way conversion of electrical energy and mechanical energy, magnetic field energy, the overall operating efficiency of the equipment, operational stability, service life, adaptability to working conditions, more than 90% depends on the comprehensive quality of the electromagnetic coil.
Electromagnetic Coil Winding Wire (Electromagnetic Coil Winding Wire), as the core coil substrate, directly determines the reliability of coil insulation, copper loss and iron loss, long-term heat resistance, alternating vibration durability, resistance to dielectric corrosion and the entire life cycle of the service life of the machine.
At the current stage of solenoid coil mass production processing, machine assembly, long-term operation and maintenance of the whole process, the industry upstream and downstream common five common pain points, but also the core basis for the development and optimization of the wire solution, close to the front-line production and end-use of the real working conditions.
First, the frequency PWM pulse voltage induced turn-to-turn partial discharge. At this stage, the vast majority of industrial, new energy equipment equipped with IGBT, SiC silicon carbide inverter, the voltage rise along the steepness is extremely high, conventional coil winding line insulation paint film inorganic corona-resistant filler, high-frequency pulse repeated impacts of the insulation layer rapid aging pulverization, turn leakage in a short time, short-circuit coil failure.
Secondly, the high-end electromagnetic coil generally adopts high-density dense winding arrangement design, motor, transformer cavity closed without convection heat dissipation space, winding loss continues to accumulate heat, coil hot spot temperature exceeds 180 ℃, far more than the ordinary 155 ℃ heat-resistant wire tolerance limit, accelerating the organic varnish film cracking, delamination, fall off;
Third, the power class motor electromagnetic coil long-term electromagnetic alternating vibration, rotor high-speed centrifugal double load conditions, wire surface paint film continuous friction and extrusion, very prone to paint film damage, exposed copper, coil offset, core scraping short-circuit, directly shorten the service life of the motor machine;
Fourth, high-frequency electronic control, high-speed motor coil operating frequency continues to increase, the conductor internal skin effect and neighborhood effect doubly aggravated, the coil reactive copper loss soared, the equipment operating energy efficiency dropped significantly, while the coil temperature rise further out of control, the formation of loss – heat – aging vicious cycle;
Fifth, the downstream terminal equipment scenarios are extremely differentiated, general-purpose single wire can not simultaneously take into account the production cost, high-end performance indicators, IATF16949 automotive/ISO industrial double standards, automatic high-speed winding, hairpin bending mass production process, resulting in the selection of customer dilemma.
According to the differentiated electric field strength of 400V conventional platform, 800V high voltage vehicle platform and high frequency inverter platform, we customize and match the three major paint film systems of ordinary insulation, thickened insulation and nano corona resistant modified insulation, so as to control the value of partial discharge of the coil.
According to the steady state temperature rise of the coil, the instantaneous peak temperature, and the heat dissipation conditions of the cavity, the wire is classified into five levels of temperature resistance: 130℃, 155℃, 180℃, 200℃, and 220℃, so as to prevent high-temperature thermal aging failure.
Combining the different processes of bulk winding, Hairpin bending, micro winding, and boneless self-adhesive molding, we customize the conductor hardness, paint flexibility, and wire size tolerance to fit the fully automated mass production line.
Relying on copper, aluminum, and copper-clad aluminum gradient conductor materials, we have divided into three tiers of products, namely high-end automotive, mid-range industrial, and low-end civil, to balance the electrical performance, mechanical durability, and raw material procurement costs, and ultimately achieve the optimal optimization of electrical performance, mechanical vibration resistance, mass production process suitability, and commercial procurement cost integration.
All products are manufactured in accordance with the IEC international electrical standards, GB/T standards for solenoid wires, and the IATF16949 quality control system for the automotive industry, with strong consistency in batch performance, and complete testing of electrical, mechanical, chemical, and thermal aging at the factory, which can be directly connected to the supply chain access standards of domestic and overseas coil manufacturers and equipment assembly plants.
Round Magnet Wire: The basic winding wire with the longest history of mass production, the highest degree of process maturity and the strongest market versatility. Conductor cross-section is standard round, wire diameter specifications from ultra-fine 0.03mm precision models to 5.0mm industrial large cross-section models full coverage, the wire body has excellent flexibility, bending without stress residue, suitable for all common automatic winding machines, precision wiring equipment.
Flat / Rectangular Enameled Wire: for high-power, high-density, miniaturization of high-end electromagnetic coil special R & D upgrade wire, the two structures are highly similar to the subtle differences in the process to distinguish between the different processes suitable for different coils. Among them, rectangular electromagnetic wire has regular cross-section and balanced edge hardness, suitable for industrial high-power motor fixed dense winding coil.
Flat magnet wire optimizes the curvature of rounded corners and the toughness of lacquer film bending, which is specially designed for new energy motor Hairpin hairpin coil molding process. The two types of wires completely optimize the round wire stacking gap defects, stator slot inside the wire closely fit row, the overall slot fullness of the coil from 45% to 65% -70%, the same core volume under the effective conductive area to enhance the more than 22%, the overall structure of the coil is compact and rigid, the cavity heat transfer and cooling efficiency increased by 35%.
Enameled copper winding wire (Enameled Copper Magnet Wire): the main high-end core wire of the whole set of programs, 99.95% high-purity oxygen-free copper electrolytic as the core conductor, grain uniformity and denseness, impurity content is extremely low, with a low electrical resistivity, low loss at room temperature and high frequency conditions, conductive current-carrying capacity, resistance to high-temperature creep, and excellent fatigue performance of long-term alternating vibration multiple advantages. Advantages. Copper wire conductor welding performance is stable, joint resistance without drift, the surface of the composite insulating varnish film adhesion is excellent, long-term high temperature, vibration, oil immersion conditions do not delamination, no cracking.
Enameled aluminum winding wire (Enameled Aluminum Magnet Wire): lightweight, the ultimate cost-oriented supporting wire, using high-purity industrial electrolytic aluminum extrusion molding conductor, coated with conventional polyester insulating varnish curing molding, insulation structure, winding process and enameled copper wire is fully compatible with the same specifications can be achieved directly interchangeable products. The core advantage of the product is the low price of raw materials, the self-weight of the wire is 38% lower than that of copper wire, which significantly reduces the cost of raw materials for coils and the pressure on the counterweight of the whole machine.
Copper-Clad Aluminum Magnet Wire (Copper-Clad Aluminum Magnet Wire): The cost-effective composite conductor wire in the mid-range market adopts the metallurgical composite process, with the outer layer of highly conductive copper and the inner layer filled with a lightweight aluminum conductor, combining the dual advantages of pure copper wire and pure aluminum wire. The outer copper layer protects the conductivity of the wire surface, oxidation corrosion resistance and coil welding stability, completely solving the problem of pure aluminum wire welding welding and oxidation of the surface; the inner layer of aluminum core significantly compressed raw material purchasing costs, reducing the overall weight of the coil. Compared with pure copper wire of the same specification, the procurement cost is reduced by about 20%. The product is accurately adapted to medium-sized industrial frequency industrial control motor coils, conventional power transformer coils, and mid-range civil drive coils, which perfectly fills the gap between the price and performance of high-end copper wires and low-end aluminum wires, and improves the price gradient of the whole product.
High-temperature resistant coil winding wire: equipped with 180℃-220℃ PEI+PAI double-layer composite insulation system, abandoning the traditional single-layer polyester insulation structure, the bottom layer improves the conductor adhesion, the surface layer strengthens the heat-resistant and anti-aging performance, special solution to the closed electromagnetic coil cavity air circulation, heat buildup, hot spot temperature exceeds the standard, high temperature cracking and aging of organic varnish aging industry pain, suitable for oil-cooled motor closed coil, high-temperature industrial motor coil, indoor closed coil, high temperature industrial motor coil, high temperature industrial motor coil, high temperature industrial motor coil, high temperature industrial motor coil, high temperature industrial motor coil, and high temperature industrial motor coil. It is suitable for oil-cooled motor closed coil, high-temperature industrial motor coil and indoor closed transformer winding, with no degradation of insulation performance in long-term high-temperature continuous operation.
High Frequency Magnet Wire: High-end power electronics special functionally modified wire, using low dielectric constant environmentally friendly insulating coatings, with multi-strand ultra-fine transposition of the conductor structure, from the insulation material, conductor structure of the dual-dimensional weakening of the coil of high-frequency eddy currents, skin effect and proximity effect, and significantly reduce the frequency converter, inverter, automotive electronic control, photovoltaic inverter, high-frequency electromagnetic coil reactive power loss. High-frequency electromagnetic coil reactive power loss, inhibit coil high-frequency abnormal temperature rise, suitable for SiC silicon carbide frequency conversion supporting high-frequency electromagnetic coil, enhance the energy efficiency of high-frequency equipment operation.
Corona Resistant High Voltage Winding Wire: The insulating varnish is internally doped with nano alumina and silica inorganic modified fillers, which reconstructs the microscopic dense structure of the varnish film, greatly improves the onset voltage of PDIV partial discharge of the coil, and buffers the impact of high-voltage pulsed electric field, which is specially adapted to the new energy 800V high-voltage platform solenoid coils and the high-voltage power transformer windings.
Self-Bonding Magnet Wire: special functional wire with integrated process, coated with an extra layer of thermoplastic self-adhesive layer on the outer layer of conventional insulating varnish film, no need for shop dipping and curing, end taping, skeleton fixing and support, and low-temperature heating, power heating to realize the coil layer-to-layer and turn-to-turn self-adhesive shaping.
Aiming at the pain points of stator and rotor solenoid coils of industrial frequency conventional asynchronous motors, frequency control industrial motors, and heavy-duty continuous operation motors. This program focuses on industrial-grade polyesterimide enameled copper wire as the main supporting wire, standard H-class 180 ℃ temperature grade, high crosslinking density of the paint film, interface adhesion is very strong, can withstand long-term electromagnetic alternating vibration coil, equipment frequent start and stop temperature shock, day and night temperature difference between hot and cold alternating loads, long-term operation without paint film shedding, no leakage faults between the turns.
Layers of products to accurately adapt to customer needs: ordinary small and medium-sized frequency industrial motors, the use of standard round polyesterimide copper wire, compressed raw material procurement costs, to adapt to large-scale mass production; high-power heavy-duty frequency conversion industrial motors, high-temperature workshop motors, upgraded double-layer composite thickened insulated wires, strengthen the coil anti-impulse impact, anti-heat aging ability, and effectively adapted to the long-lasting warranty for industrial motor coils for more than 8 years, Continuous uninterrupted operation requirements, suitable for fans, pumps, machine tool spindles, general industrial solenoid coils.
Transformer solenoid coils have a dense array of layers, turn-to-turn electric field concentration, cavity closed constant temperature, no severe mechanical vibration, 24-hour uninterrupted voltage operation of the exclusive conditions, the wire selection does not need to focus on vibration resistance, the core of the strict control of the paint film uniformity, pinhole defects, insulation voltage three major indicators. This program focuses on high density ultra-thin varnish special winding wire, the production stage adopts multiple filtration paint, dust-free workshop coating process, completely eliminating varnish pinholes, bubbles, uneven thickness production defects, balanced coil turns, interlayer electric field distribution, significantly reducing the risk of high-voltage state of interlayer breakdown, short circuit to ground. Layered adaptation: industrial frequency power grid transformers, civil power transformers, selecting standard heat-resistant uniform enameled round copper wire, cost-effective and stable operation; high-frequency switching power transformers, new energy vehicle isolation transformers, matching low-loss high-frequency special winding line, optimizing high-frequency eddy current loss, suppressing local overheating of coils, ensuring that transformer coils are stable year-round, low-loss and long-term work, adapted to the power grid, Industrial control power supply all kinds of transformer coils.
New energy vehicle drive motor solenoid coil is the industry’s toughest working conditions, the highest quality threshold solenoid coil category, the coil at the same time superimposed on the 800V high-voltage platform, SiC high-frequency frequency pulse, shell oil-cooled immersion, 20,000rpm + rotor high-speed centrifugal, -40 ℃ ~ 180 ℃ wide temperature range of hot and cold alternating loads, the ordinary direct application of industrial wires in 3-6 months, that is, the insulation failure. This special solution mainly promotes nano electric resistance. This special solution is mainly promoted nano corona resistant Rectangular enameled copper wire composite flat wire winding line, 220 ℃ ultra-high temperature temperature grade, the surface layer of PAI polyamideimide insulating layer of refrigerant resistance, resistance to hydrolysis corrosion of cooling oil, internal nano-fillers to resist the high-frequency corona continuous bombardment; wire rounding precision optimization, paint bending-resistant performance of the pull full, a perfect match! Automotive Hairpin integrated hairpin coil bending, twisting, embedded wire full automation process; the entire line follows the IATF16949 automotive supply chain production certification, raw material traceability, batch stability standards, suitable for passenger cars, commercial new energy vehicles, the main and auxiliary drive motor coils, to meet the vehicle 10 years / 200,000 kilometers of vehicle-class durability standards.
The electromagnetic coils of industrial high-speed spindles, high-speed centrifugal fans, and high-speed air compressor motors above 15,000rpm operate at ultra-high speeds for a long period of time, with high-frequency eddy current loss, high-frequency resonance in the winding, and fatigue pulverization of the insulating layer as the three major core failures. This special solution in accordance with the speed gradient layered matching wire: 15000-25000rpm medium and high speed motor coil, the use of modified low-loss composite insulation flat wire, thickening the surface wear-resistant varnish film, to enhance the coil’s ability to resist centrifugal stretching, anti-resonance wear; 25,000rpm or more ultra-high-speed special motor coils, the exclusive matching of high-frequency transposed Leeds winding line, multi-stranded ultra-fine conductors transposed stranded from the root cause of the conductor structure to weaken the skin effect. Conductor structure from the root to weaken the skin effect and neighborhood effect, coil AC loss reduced by more than 32%, while strengthening the conductor annealing process, release the internal stress of the wire, suitable for high-speed coils limit centrifugal load, to eliminate coil deformation, film fatigue cracking.
Industrial precision sensors, miniature servo motors, audio devices, medical microelectronic control small electromagnetic coils, with tiny size, high winding density, no skeleton support, low NVH noise reduction requirements of the machine, conventional wire winding loose, need to be fixed by the skeleton, cumbersome processing procedures. This program is exclusively matched with Self-Bonding wire, the wire surface layer of environmentally friendly self-adhesive adhesive layer can be cured and bonded quickly at high temperature, the coil does not need to be insulated and dipped in paint, no plastic skeleton support, no artificial tape binding, and it can be shaped directly after the automatic winding is completed. The volume of formed coils is more compact, the layout precision is higher, the vibration noise of the whole machine is greatly reduced, which is suitable for the current trend of miniaturization, lightweight and low-noise production of electronic devices, and at the same time, it reduces the three back-end processing procedures, reduces the cost of labor and equipment production in the coil workshop, and is suitable for the mass production of large quantities of precision miniature electromagnetic coils.
| Coil Application | Recommended Winding Wire | Core Solution Advantage |
| General Motor Electromagnetic Coil | Polyesterimide Enameled Copper Wire | Cost-effective, strong vibration resistance, mass production stable |
| Transformer Coil | Uniform Film Round Enameled Wire | Low partial discharge, high insulation consistency |
| EV Motor Drive Coil | Corona-resistant Rectangular Enameled Wire | High slot filling rate, oil-proof, automotive standard |
| High-speed Motor Coil | Low-loss High Frequency Magnet Wire | Reduce AC loss, anti-centrifugal stress |
| Mini Precision Coil | Self-bonding Magnet Wire | Integrated shaping, simplified coil process |
| Cost-sensitive Ordinary Coil | Enameled Aluminum / CCA Wire | Light weight, lower raw material cost |
Wire + production process integration supporting empowerment, improve the electromagnetic coil overall landing closed-loop solutions, close to the downstream coil factory mass production practical needs, from the process end to improve the coil yield rate, reduce costs and increase efficiency.
First, for high-speed automatic precision winding, dense winding line, supplying micron-level size tolerance winding line, wire surface clean and burr-free, uniform film thickness, to avoid high-speed winding line jamming, film scratches, line offset process defects, coil mass production yield increased to more than 98%;
Second, high-power high-voltage energy storage solenoid coils, industrial heavy-duty motor coils, supporting the exclusive VPI vacuum pressure dipping paint process guidance program, so that the winding wire, insulating varnish film, the core structure of the trinity curing molding, improve the overall coil vibration, deformation, heat and humidity resistance;
Third, the new energy Hairpin flat wire hairpin coils, supporting bending crack-resistant proprietary modified wire, optimize the toughness of the paint film and the conductor softness, to solve the right-angle bending, twisting angle molding process of the paint film cracking, exposed copper high-frequency bad problems; Fourth, open customized supporting services to support the customer’s proprietary fine-tuning of the wire diameter, insulation thickness thickness thickening/thinning, temperature level modification, surface lubrication adjustments, and to provide free sample testing, process debugging, technical docking services. We also provide free sample testing, process debugging, and technical docking services to meet customers’ exclusive solenoid coil development and mass production needs in an all-round way.
Precise selection and matching using standardized general wire scale cost reduction, high-end special modified wire to attack high-end working conditions two-way product layout. Not only to meet the needs of general industrial frequency solenoid coils for high-volume and low-cost mass production, but also to match the needs of new energy EV motors, ultra-high-speed motors, high-voltage transformers and high-end solenoid coils for high-reliability, automotive-grade and stringent requirements.
The whole package covers the whole chain of product production, sample debugging, process docking, batch delivery, and after-sales technical Q&A, providing one-stop closed-loop solenoid coil and wire supporting solutions for global coil processors, motor assemblers, new energy Tier1 supply chain, and power equipment manufacturers, and assisting downstream customers to improve coil yields, optimize product performance, compress comprehensive production costs, and strengthen the end-product market. Core Competitiveness
