Why choose enameled wire?

The wire fill factor is defined as the ratio of the amount of conductor material copper (without insulation) to the available winding space lot, and it has a significant impact on the power density, thermal conductivity, manufacturability, and overall cost of a motor. Fill rate is directly related to the current density limit, which is related to torque and power. The cross-section of enameled wire defines two major categories as round wire and rectangular wire. The inherent characteristic of the round shape is that the filling factor is low, and the rectangle matches the groove shape well. It is characterized by a high filling factor. . Due to their rectangular cross-section, the fill factor can reach values ​​of 80-85% in machines using them. Compared with the traditional round enameled wire motor, the winding motor with rectangular cross-section can increase the slot full rate by 20%~30%, and the copper ratio per unit cross-sectional area is higher, which effectively reduces the winding resistance and thus reduces the copper loss. The thicker and smaller the resistance, the less energy will be lost on the wire due to heat generation. The length of the motor end of the rectangular cross-section is 5~10mm shorter than that of the round wire, which effectively reduces the copper consumption of the end winding and further improves the motor efficiency. The rectangular cross-section motor has a higher slot full rate. Under the same volume, the rectangular cross-section winding motor has a larger effective stator winding area, and the rectangular cross-section winding motor can output higher power and torque under the same loss. The rectangular cross-section winding motor flat wire has a more regular shape, fits closely in the stator slot, and has better contact with the stator core teeth and yoke, reducing the thermal resistance in the slot and improving the heat conduction efficiency. The motor using the flat enameled wire structure has better rigidity, and the whole machine will also have better rigidity. The flat enameled wire winding is inserted through the end of the iron core, and does not need to be inserted from the slot. In the electromagnetic design, a smaller slot design can be selected to effectively reduce the cogging torque pulsation.

What is the difference between insulated wire and ordinary cable? Insulated wires and cables are commonly used conductors in power engineering. 1. Data discrepancies There are many forms of the former display, such as solid, stranded, braided and so on. A conductive metal wire mainly used to carry current. Others can be divided into bare wire and insulated wire according to the insulation, the latter is an insulated wire with one or more insulated wires placed in a sealed sheath, which can increase the protective covering. 2. Structural differences The size and specifications of the two are quite different. The latter is larger and has a complex structure. It is mainly composed of four parts. The wire core is made of high conductive data; the insulating layer, as the insulation data of the cable, should have high insulation resistance and high breakdown electric field strength. , so cables are usually classified as insulation data. 3. Differences in use The two are divided into many categories depending on their use. The former can not only be used as a wire for transmitting electric energy and information, but also can be used to manufacture motors, electrical components and connecting wires, as well as various insulated wires suitable for special requirements, such as automotive low-voltage wires, automotive high-voltage ignition wires, motor electrical leads, and aviation wires. , compensation wires, etc., the latter can be divided into power cables, communication cables and control cables.

 

Enameled wire is a category of magnet wire, generally refers to the insulated wire used to make coils or windings in electrical products. Also called winding wire.

Magnet wire meets a variety of application and manufacturing process requirements. The former includes its shape, specification, ability to work at high temperature for short and long periods of time, as well as to withstand intense vibration in some occasions and centrifugal force at high speed, resistance to corona and breakdown under high voltage, and resistance to special atmospheres. Chemical corrosion, etc.; the latter includes the requirements of stretching, bending and abrasion during winding and embedding, as well as swelling and erosion during dipping and drying.

Magnet wires can be classified by their basic composition, conductive core, and electrical insulation. Generally, it is divided into enameled wire, wrapped wire, enameled wrapped wire and inorganic insulated wire according to the insulating material and production method used in the electrical insulating layer.

The enameled wire is made by coating the conductor with the corresponding lacquer solution, and then through the evaporation of the solvent and the curing of the lacquer film and cooling. The enameled wire can be divided into polyester enameled wire, polyesterimide enameled

 

wire, polyamideimide enameled wire, polyimide enameled wire, polyesterimide/polyamideimide enameled wire, corona-resistant enameled wire, and oily enameled wire according to the insulating paint used. Paint, acetal paint, polyurethane enameled wire, etc. Sometimes it is also classified according to the particularity of its use, such as self-adhesive enameled wire, refrigerant resistant enameled wire, etc.

The early enameled wire was oily enameled wire, made of tung oil and so on. The paint film has poor properties and cannot be directly used to make motor coils and windings. It needs to be wrapped with cotton yarn when using. Later, the polyvinyl formal enameled wire was introduced, and its mechanical function was greatly improved, and it could be directly used in the motor winding, which is called high-strength enameled wire.

With the development of weak current technology, self-adhesive enameled wires have emerged, which can obtain coils with better integrity without dipping and baking. However, its mechanical strength is poor, and it can only be used in micro motors and small motors. In addition, in order to avoid the trouble of removing the paint film first during welding, the straight-solderable enameled wire is developed, and the paint film can fall by itself in the high-temperature tin enamel tank, so that the copper wire can be easily welded.

Because the application of enameled wire is becoming more and more extensive, and the requirements are becoming more and more severe, composite enameled wire has also been developed. The inner and outer paint films are composed of different polymer materials, such as polyesterimide/polyamideimide enameled wires.

An important type of winding wire. In the early stage, cotton yarn and silk, called yarn-covered wire and silk-covered wire, were used in motors and electrical appliances. Because of the large insulation thickness and low heat resistance, most of them have been replaced by enameled wires. Now only used as high frequency winding wire. In the large and medium-sized winding wires, when the heat resistance level is high and the mechanical strength is high, the glass-wrapped wire is also used, and appropriate adhesive paint is used in the production.

The paper-covered wire still occupies an appropriate position in the wrapped wire, and is mainly used in oil-immersed transformers. The oil-paper insulation formed at this time has excellent dielectric function, low price and long service life.

Hey buddy,

I have also used enamelled wire before, so I can tell you that it offers several advantages for electrical appliances. Also known as magnet wires, these enamelled wires refer to copper or aluminium wires that have been given a coating. This thin layer of insulation makes the wires useful for building transformers, electromagnets, speakers, hard disk actuators, motors, inductors, etc. They are also useful because they can be soldered easily.

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