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Steps Of Making Copper Enameled Wire
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On a normally operating magnet wire, most of the operator's energy and physical strength are consumed in the pay-off part. Changing the pay-off reel makes the operator pay a lot of labor, and the joints are prone to quality problems and operation failures when changing the wire. An effective method is large-capacity pay-off. The key to pay-off is to control the tension. When the tension is high, it will not only draw the conductor thin, make the surface of the wire lose its brightness, but also affect many properties of the enameled wire. From the appearance point of view, the enameled wire coated with thinner wire has poor gloss; from the performance point of view, the elongation, resilience, flexibility, and thermal shock of the enameled wire are all affected. If the pay-off tension is too small, the line will easily jump and cause the line to merge and the line to touch the furnace mouth. When paying off, the most fear is that the half-turn tension is high and the half-turn tension is small. This will not only cause the wires to loosen, break, and be thinned section by section, but also cause large jumps of the wires in the oven, resulting in merging and wire bumping failures. Pay-off tension should be even and appropriate. Installing a booster wheel in front of the annealing furnace is very helpful for tension control. The maximum non-extension tension of soft copper wire at room temperature is about 15kg/mm2, the maximum non-extension tension at 400℃ is about 7kg/mm2; the maximum non-extension tension at 460℃ is 4kg/mm2; the maximum non-extension tension at 500℃ The extension tension is 2kg/mm2. In the normal enameled wire coating process, the tension of the enameled wire is significantly less than the non-extension tension, which is required to be controlled at about 50%, and the pay-off tension should be controlled at about 20% of the non-extension tension.
Large-size and large-capacity spools generally use radial rotary pay-off; medium-size wires generally use over-end or brush-type pay-offs; fine-size wires generally use brush-type or double-cone pay-off devices.
The surface should be smooth to ensure that the wire is not scratched
There are 2-4mm radius r angles on both sides of the shaft core and inside and outside of the side plate to ensure balanced release during the pay-off process
After the spool is processed, dynamic and static balance tests must be performed
The copper enameled wire brush pay-off device requires the diameter of the shaft core: the diameter of the side plate is less than 1:1.7; the over-end pay-off requires less than 1:1.9, otherwise the wire will be broken when the wire is paid to the shaft core.