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Transformer as power transmission, voltage conversion, electrical isolation of the core infrastructure equipment, widely used in the national power grid, industrial manufacturing, new energy industry, home appliances, electronics, communications, industrial control and other fields.
Whether it is a high-voltage power main transformer, industrial distribution transformers, or small high-frequency electronic transformers, vehicle-mounted transformers, its core working parts are electromagnetic winding coils. The core raw material to support the stable, efficient and long-term operation of the transformer is enameled winding wire.
Enameled wire with unique structural design, excellent electrical properties, stable heat resistance and mechanical properties, become the only preferred material for transformer winding. This article will be from the transformer working principle, enameled wire core characteristics, adaptability advantages, scenarios of application, selection logic, etc., in-depth analysis of enameled wire applied to the transformer of the core reasons.
Want to understand the irreplaceability of enameled wire on the transformer, first of all need to clarify the operation mechanism of the transformer. Transformer follows the principle of electromagnetic induction work, through the primary side winding, secondary side winding electromagnetic coupling, realize the AC voltage rise and fall, power transmission and electrical isolation, the whole process of the winding wire has a very high exclusive requirements, ordinary wire can not meet.
Transformer operation, the winding coil will continue to carry alternating current, alternating magnetic field, accompanied by three core conditions of pressure: First, the Joule heat generated by long-term energization, resulting in a continuous rise in the internal temperature of the coil; Second, the alternating voltage brought about by the insulation withstand voltage load, coil turns and turns, layers and layers of the existence of the potential difference between the third, electromagnetic vibration, vibration of the operation of the equipment, brought about by the mechanical tensile, friction pressure Fourth, high frequency working conditions of skin effect, neighbor effect, the conductive stability of the wire to put forward higher requirements.
Based on the above conditions, the transformer winding wire must meet the four major hard standards: ultimate insulation, low-loss conductive properties, high temperature and anti-aging properties, stable mechanical and physical properties. Enameled wire is the only wire on the market that can simultaneously take into account these four core requirements, which is the fundamental reason why all transformers without exception use enameled wire to wind coils.
The core advantage of enameled wire over ordinary wires and bare copper wires lies in the precise composite structure of its conductor + ultra-thin insulating varnish film, which is perfectly adapted to the core requirements of high-density winding and electromagnetic conversion of transformers, and solves the many pain points of ordinary wires.
Enameled wire core structure is divided into two layers, the inner layer of high-purity metal conductor, the mainstream use of oxygen-free copper conductor, part of the large low-voltage transformer will be used in the aluminum conductor; the outer layer of single-layer or multi-layer polymer insulating varnish film, after high-temperature baking and curing molding, varnish film thickness uniformity, adhesion is very strong.
From the conductor level, the transformer on the wire conductivity requirements are extremely high. High purity oxygen-free copper enameled wire conductivity up to 58.14 × 10⁶ S / m, very low resistance, in the current transmission process, power loss, heat loss is far lower than ordinary copper wire. The core value of the transformer is efficient power transmission, voltage stabilization, if the resistance of the wire is too large, it will cause a serious waste of power, while overheating of the coil will accelerate the aging of the equipment, significantly reducing the efficiency of the transformer. The enameled wire used in the high-precision conductor process, very low impurity content, stable conductivity, can minimize the copper loss of the transformer, enhance the overall energy efficiency of the equipment.
From the insulation layer level, this is the enameled wire adapted to the core of the transformer key. Ordinary wire insulation for PVC, rubber and other thick insulation materials, thickness, flexibility, poor, can not tightly wound, will greatly occupy the transformer core slot space, reduce the slot fullness rate, resulting in the transformer volume bloated, power density is extremely low; and bare copper wire without insulation, winding turns direct contact, will directly cause a short circuit, the equipment can not work properly.
Enameled wire insulation paint film is only micron thickness, divided into 1 level of thin paint, 2 level of medium paint, 3 level of thick paint three kinds of specifications, in order to ensure high voltage withstand, high insulation performance at the same time, almost does not take up extra space. This ultra-thin insulation design allows transformer coils to realize high-density, multi-layer tight winding, significantly increasing the core slot fullness, so that the same volume of transformers can carry more power, the same power transformer volume is more compact, more compact structure, perfectly suited to industrial equipment, home appliances, new energy equipment, lightweight, miniaturization development needs.
Transformer is a long-term continuous operation equipment, most of the industrial, power transformers need to work 24 hours a day, complex working conditions and high stability requirements. The four core performance of enameled wire precisely solves the core pain points of heat, short circuit, wear and tear, aging, loss and so on during the operation of the transformer, and guarantees the long-term stable operation of the equipment.
Transformer coil by hundreds or even thousands of turns of wire tightly wound from, turn to turn, there is a fixed potential difference between the layers, especially high-voltage transformers, high-frequency transformers, transient voltage impact is very great, once the insulation fails, there will be a short-circuit between the turns, between the layers of the breakdown, which will directly lead to the transformer burned out, tripped, and even caused electrical safety accidents.
Enameled wire using polyurethane, polyesterimide, polyimide and other high-end polymer insulating resin, after multi-layer coating, high-temperature curing process molding, dense and uniform film, no pinholes, no breakage, with a very strong voltage insulation capacity. Different materials of enameled wire can be adapted to different voltage levels of the transformer, conventional 180 ℃ polyesterimide enameled wire can meet the needs of industrial low voltage transformer voltage, high-end polyimide enameled wire can be adapted to high-voltage, high-frequency transformer transient high-voltage impact, the whole process of eliminating the problem of turn-to-turn, interlayer short-circuit is the basis of the protection of safe operation of the transformer.
Transformer continues to work, the current through the coil produces copper loss, iron core work produces iron loss, double loss will continue to produce heat, resulting in coil internal temperature continues to rise, long-term high temperature operation state. Ordinary wire insulation layer of high temperature resistance is poor, high temperature is easy to soften, melt, brittle crack, rapid aging failure, can not be used for a long time.
Enameled wire has a perfect temperature level system, can accurately match the different types of transformer requirements: 155 ℃ polyurethane enameled wire suitable for small household electronic transformers, low-frequency precision transformers; 180 ℃ polyesterimide enameled wire balanced performance, is the industrial power distribution transformers, conventional frequency transformers mainstream selection; 220 ℃ polyimide high temperature enameled wire, can withstand extreme high temperature, suitable for new energy Vehicle-mounted transformers, high-frequency and high-voltage industrial transformers, outdoor power transformers.
The core value of high temperature resistance is not only to avoid insulation layer damage, but also to ensure that the transformer in high temperature load, overload conditions, stable performance, insulation aging, performance degradation, significantly extend the service life of the transformer, reduce equipment failure rate and maintenance costs.
Transformer coil production process, need to go through high-speed machine winding, artificial embedded wire, shaping, extrusion and other procedures, the wire will be subjected to bending, stretching, friction, extrusion and other mechanical forces; at the same time, the transformer is running, the alternating magnetic field will produce electromagnetic vibration, long-term operation of the equipment will be continuous vibration, the coil is always in a dynamic state of force.
Enameled wire paint film and conductor adhesion is very strong, with excellent scratch resistance, bending resistance, tensile resistance, vibration resistance, high-speed winding process, the paint film will not fall off, cracking, breakage, perfect fit for automated winding equipment production process. In the process of long-term operation of the equipment, it can resist the friction loss brought about by continuous vibration, avoid the insulation failure caused by the paint film abrasion, and guarantee the long-term stable operation of the transformer, which is suitable for the industrialized mass production and harsh operating conditions.
Energy saving is the core design index of modern transformer, and also the mainstream trend of industry development. Enameled wire adopts high purity conductor, excellent conductivity, thermal conductivity, conductor resistance is uniform and stable, eddy current loss and copper loss in the process of current transmission are extremely low, which can effectively reduce the heat loss of the transformer and improve the efficiency of power conversion.
At the same time, the excellent thermal conductivity of enameled wire, can quickly conduct the heat generated by the coil work, to avoid the accumulation of heat caused by the local high temperature overheating, reduce the temperature rise of the transformer, not only to enhance the stability of the equipment operation, but also effectively reduce energy consumption, to help the transformer to meet the national energy-saving standards, suitable for industrial energy saving, green power industry requirements.
Transformer categories, according to the power, frequency, voltage, application scenarios can be divided into a variety of types, the working conditions of different transformers differ greatly, the corresponding enameled wire selection also has a clear standard, which is the enameled wire can be comprehensively adapted to the core reason for all types of transformers.
Small high-frequency electronic transformers, mostly used in home appliances, communications, precision electronic equipment, high operating frequency, small size, precision winding, generally use 155 ℃ polyurethane enameled round wire, the core advantage is free of paint directly welding, high-frequency performance and stability, fine wire diameter, adaptable to micro-coil winding needs.
Conventional industrial industrial frequency transformers, distribution transformers, mostly used in factories, power distribution, civil power transmission, moderate power, stable working conditions, long-term continuous operation, the mainstream selection of 180 ℃ polyesterimide enameled wire, comprehensive insulation, heat resistance, excellent mechanical properties, cost-effective, is the general selection of industrial transformers.
High-power power transformers, new energy vehicle transformers, high-voltage frequency transformers, high power, high current, temperature rise, harsh conditions, more than 180 ℃ / 220 ℃ enameled flat wire, high temperature polyimide enameled wire. Flat enameled wire groove full rate is higher, the conductive cross-section is bigger, can carry large current, high temperature resistance can withstand extreme temperature rise, suitable for high power, high load of harsh conditions.
The core quality indicators of the transformer, including energy efficiency, stability, service life, failure rate, almost all by the winding enameled wire quality decision, enameled wire is the transformer’s “heart material”.
From the service life point of view, high-quality enameled wire aging resistance, resistance to heat and humidity, solvent resistance, high temperature resistance, long-term operation will not appear insulation failure, conductor oxidation and other problems, so that the transformer service life of 10-30 years, to meet the long-term use of electric power, industrial equipment needs; and poor-quality wire is easy to aging, easy to break, which will lead to frequent failure of the transformer, the life of the plummet, a substantial increase in the replacement of equipment and maintenance costs.
From the point of view of operational stability, enameled wire insulation uniformity, stable performance, able to withstand voltage fluctuations, overload, high temperature, vibration and other unexpected conditions, to ensure that the transformer voltage conversion is accurate, stable transmission of power, no noise, no heating abnormality, to avoid fluctuations in the power grid, equipment shutdowns and other production accidents.
From the energy efficiency upgrade point of view, with the national energy saving policy upgrades, transformer energy efficiency level requirements continue to improve, low loss, high conductivity of high-end enameled wire, is the transformer to achieve energy efficiency upgrades, reduce energy consumption of the core support, but also the core of the modern energy efficient transformer standard.
Comprehensive view, the reason why the transformer must use enameled wire, the core reason is that there is no other kind of wire, can at the same time to meet the transformer on insulation, heat resistance, electrical conductivity, mechanical properties, space utilization of multiple demanding needs.
From small civilian electronic transformers, to industrial high-power power distribution transformers, to new energy, power high-voltage transformers, enameled wire is always the core of the winding coil preferred material. This directly determines the energy efficiency, stability, safety and service life of the transformer.
In the power transmission, industrial manufacturing, new energy industry, the rapid development of high-quality enameled wire has become an important foundation for the high-quality development of the transformer industry, is an indispensable core strategic materials in the field of electromagnetic equipment. We provide professional one-on-one transformer selection enameled wire service, you can contact us at any time.
