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What are the factors that affect the quality of enameled magnet wire?

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The quality of enameled magnet wire depends to a large extent on the quality of raw materials such as paint and wires and the objective conditions of the machinery and equipment. However, if issues such as baking, annealing, and machine speed are not taken seriously in operation, high-quality enameled magnet wire cannot be produced.

 

quality of enameled magnet wire

 

The following are the factors that affect enameled magnet wire during the production process:

 

1. There are strict requirements on the structure and quality of bare copper wire spools.
The surface should be smooth to ensure that the wire is not scratched;
There are r-angles with a radius of 2-4mm on both sides of the shaft core and the inside and outside of the side plates to ensure balanced release during the pay-off process;
After the bobbin is processed, dynamic and static balance tests must be performed;
The brush pay-off requires shaft core diameter: side plate diameter is less than 1:1.7; over-end pay-out requires less than 1:1.9, otherwise wire breakage will occur when the wire is paid to the shaft core.
2. The water quality in the annealing tank is very important. Impurities in the water will make the wires dirty and affect the painting, making it impossible to form a smooth paint film. The chlorine content of the water used must be less than 5 mg/l, and the conductivity must be less than 50 μΩ/cm. Chloride ions attached to the surface of the copper wire will corrode the copper wire and the paint film over a period of time, causing black spots on the surface of the wire within the paint film of the enameled magnet wire. To ensure quality, the sink must be cleaned regularly.
3. The water temperature in the sink also has requirements. High water temperature is conducive to the generation of water vapor to protect the copper wire during annealing. The wire leaving the water tank is not easy to carry water, but it is not good for the cooling of the wire. Although the water temperature is low, it has a cooling effect, but there is a lot of water on the wire, which is not good for painting. Generally, the water temperature for thick wires is lower and the water temperature for thin wires is higher. When the copper wire makes the sound of water vaporizing and splashing when it leaves the water, it means that the water temperature is too high. Generally, the thick wire is controlled at 50~60℃, the middle wire is controlled at 60~70℃, and the thin wire is controlled at 70~80℃. Due to the high speed, thin wires have a serious water problem, so it is better to use hot air drying.
4. The first paint layer is critical. If it is too thin, the paint film will have a certain air permeability and the copper conductor will be oxidized, eventually causing the surface of the enameled magnet wire to become shiny. If it is too thick, the cross-linking reaction may not be sufficient and the adhesion of the paint film will decrease, and the paint will shrink after being pulled off.
5. A thinner final paint film is beneficial to the scratch resistance of the enameled magnet wire. When producing fine gauge wire, the number of paint passes directly affects appearance, pinholes and other properties. Different types of enameled magnet wires have different requirements for the curing process of the paint film. Most enameled magnet wires must be fully baked every time they are painted to make the paint film well cured.

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