But that’s not all!
More than these basic requirements, copper winding wires should have some finer features that can increase your production efficiency and thus reduce your operating cycles.
Read on to know what all they are:
Special Features of Premium Quality Copper Winding Wires
1. Softness
The copper winding wires should have a good softness so that it is formable and can be bent without cracking the conductor or breaking the insulation. Soft wires reduce the chance of imperfections due to stress in the winding, which could otherwise affect performance or lead to short circuits.
This in turn increases the winding efficiency as it allows for tighter coiling around cores. Such tight coiling maximises the amount of wire that can fit in a given space which translates to better performance.
An optimum softness is achieved by using high-quality copper as raw material and undergoing multiple rounds of drawing and annealing. An experienced copper winding wire manufacturer like GEEKAY can strike the perfect balance between desired softness for windability while maintaining enough strength to avoid excessive deformation.
2. Fill Factor
Fill Factor refers to the amount of copper in the given space. A higher fill factor translates to potentially higher current carrying capacity and improved performance.
By maximizing space utilization within the coil, you can potentially use less wire to achieve the desired performance. This can lead to faster production cycles and reduced material costs.
To achieve high fill factor, thinner enamel coatings are needed without compromising on voltage insulation. In high-performance applications, using rectangular enamelled copper wires and following special winding patterns, you can achieve a better fill factor. Further, by incorporating proper tension control and wire guidance in automated winding you can optimise packing density.
At GEEKAY we have a strong R&D team to help you with the most suitable enamel insulation that can offer a higher fill factor. Our customer support team is always ready to help you with the best winding practices and precautions to be followed to achieve the best packing density and reduce scrappages.
3. Elongation
Elongation refers to the amount a material can stretch before breaking. During winding, the wire experiences stress from bending and tension. High elongation allows the wire to absorb this stress by stretching slightly instead of breaking. This translates to increased production efficiency – thanks to minimised downtime due to wire breaks.
Tightly packed windings can trap heat. Higher elongation allows the wire for slight flexing, creating minor gaps between turns. These small gaps can aid in heat dissipation, keeping the windings cooler and maintaining optimal operating temperatures.
The purity of copper, drawing ratio and annealing techniques used during manufacturing affects the elongation. Presence of trace elements can affect the grain structure, lowering the elongation. [Read More: Impact of Purity of Copper in Copper Winding Wires]
Similarly high drawing ratio (that is larger reductions in diameters per pass) also reduces the elongation. Higher annealing temperatures and longer duration generally lead to higher wire elongation.
At GEEKAY we take utmost care to get the perfect elongation as per your recommended specifications.
4. Windability
The enamelled copper wire should support high-speed automated winding for increasing production speed. For this, the enamel adhesion strength should be very good to avoid enamel peel-offs or crack formations.
Similarly, high elongation also supports better windability as wires get slightly stretched rather than breaking. Moreover, the wire diameter and surface finish should be uniform throughout the length to ensure predictable behaviour during machine winding.
To achieve high windability that can increase the production volume, the enamel used in manufacturing the winding wire should have good flexibility and adhesion strength. AT GEEKAY we offer copper winding wires with various enamel coatings to suit different winding speeds as per your requirements. [Read More: Why enamel adhesion strength is critical for winding wire?]
In comparison to aluminium winding wires, the benefits of enamelled copper wire are immense, making them suitable for a variety of applications. Striking a perfect harmony of softness, windability, elongation and fill factor without affecting the electrical, mechanical and thermal specifications of the copper winding wire is the need of the hour to improve your production efficiency. [Read More: Ways to check if the Copper winding wire is of Premium Quality]
GEEKAY as a Premium Copper Winding Wire partner for your manufacturing needs
GEEKAY is an experienced winding wire manufacturer since 1975. We have 4 manufacturing units and multiple suppliers spanning across the Indian sub-continent to meet your copper winding wire needs. We understand your requirements and offer customised winding wires to suit that.
Contact us today with your specifications for a sample.