Understanding the Process Flow of Enameled Wire Production: From Bare Conductor to Final Product

The general enameled wire production process is as follows: pay-off → annealing → painting → baking → cooling → lubrication → take-up.
The following is a detailed introduction to each step of the production process.

Pay off Line
The key to paying off the line is to control the tension. When the tension is high, it not only thins the conductor and makes the surface of the wire lose its brightness, but also affects many properties of the enameled wire. From the appearance, the enameled wire produced by the thinned wire has a poor luster. From a performance perspective, enameled wire elongation, resilience, flexibility, and thermal shock are all affected.
If the pay-off tension is too small, the thread will jump easily, causing the thread to merge or hit the furnace mouth. When unwinding the wire, the biggest fear is that the tension in half a turn is too high and the tension in half a turn is too small. This will not only cause the wire to become loose and broken, but also make the wires become thinner one by one. It will also cause large jumps in the oven’s internal wires, causing parallel and collision failures. The pay-off tension should be uniform and appropriate.
Large-sized and large-capacity spools generally use radial rotating pay-off devices; medium-sized wires generally use over-end or brush-type pay-off devices; fine-sized wires generally use brush-type or double-taper-type pay-off devices.

Annealing
The purpose of annealing is to heat the conductor, which has become hardened due to lattice changes during the mold stretching process, to a certain temperature so that the molecular lattice can be rearranged and the softness required by the process can be restored. At the same time, the lubricant, oil stains, etc. remaining on the surface of the conductor during the stretching process are removed, making the conductor easy to paint and ensuring the quality of the enameled wire. The most important thing is to ensure that the enameled wire has appropriate softness and elongation during use as a winding, and at the same time helps to improve the conductivity.

Paint
Painting is the process of applying enameled wire paint on metal conductors to form a uniform paint layer with a certain thickness. Generally, enameled wire paint must be coated and baked multiple times to fully evaporate the solvent and completely react with the paint-based resin to form a good paint film. When producing fine gauge wire, the number of paint passes directly affects appearance, pinholes and other properties.

Baking
After the wire is painted, it enters the oven. The solvent in the paint solution is first evaporated and then solidified to form a paint film. Then paint and bake, repeating this several times to complete the entire baking process of the enameled bag.

Lubricating
The lubrication of the enameled wire has a great relationship with the tightness of the wire take-up. The lubricant used for enameled wire must be able to make the surface of the enameled wire slippery, be non-harmful to the wire, and must not affect the strength of the take-up reel and the user’s use. The ideal amount of oil should be such that the enameled wire feels smooth to the touch, but no obvious oil is visible on the hands. Quantitatively speaking, just apply 1 gram of lubricating oil on the surface of 1M2 enameled wire.
Common lubrication methods include: felt oiling, leather oiling and roller oiling. During production, different lubrication methods and different lubricants are selected to meet the different requirements of enameled wire during winding use.

Take up line
The purpose of winding and arranging the wire is to wind the enameled wire onto the spool continuously, tightly and evenly. The take-up mechanism is required to have smooth transmission, low noise, appropriate tension and regular cable arrangement. Among the quality problems of enameled wire, a large proportion of returns are caused by poor take-up and arrangement. The main manifestations are that the take-up tension is high, the wire diameter is thinned or the wire reel bursts; the take-up tension is small, and the thread on the reel is broken. Loose threads cause messy threads, and uneven wiring leads to messy threads.

Only by controlling every step of production can we make high-quality enameled wires. We provide factory inspection, please contact us if you are interested.