In the year 2017, the Tesla Model S P100DL outperformed all other cars in both Electric Vehicles (EV) and Internal combustion engine (ICE) categories. Tesla’s feat was attributed to the crucial role played by winding wire in its electric engines.
As the automobile industry is moving towards clean mobility, manufacturers are always on the lookout for innovative solutions that meet their specifications to aid driving performance. Choosing the right kind of winding wire becomes a very important decision for EV manufacturers to ensure the efficiency of electric motors.
Motors in EVs require flat winding wires as they need to be compact but also be highly efficient in converting electric energy into mechanical energy. These magnet wires are made of copper which is coated with a heavy insulation material. The insulation material should be quite effective towards developing a high-voltage winding wire.
Leading winding wire manufacturers are innovating by creating technology for producing lighter and thinner wires for EVs. They are also tackling the challenges relating to heat resistance by designing high-voltage wires which improve output.
The motor and battery are the most essential parts of EVs and copper winding wires enable the functioning of these parts. Therefore, you should select the most reliable wire supplier which suits your requirements and offers products that deliver high performance.
5 Point Checklist for Choosing the Right Copper Winding Wire Supplier for EV Manufacturing Needs
Here are some points that you should consider while selecting a magnet wire supplier which meets your specification and quality standards.
1. Customization as per your needs
The supplier should design wires that are customizable based on the features stipulated by your team. They should manufacture wires with a thickness (or height and width) suiting your provisions. A few things that need to be kept in mind while checking a supplier’s credibility are:
- They manufacture thinner and lighter copper insulated winding wires which are rectangular or square.
- They have a wire with appropriate insulation to manage heat resistance which could work at a constant 180-240 degrees environment.
- Their winding wire should be able to endure voltage at high frequency.
- They have an excellent understanding of PDIV (Partial Discharge Inception Voltage)
- They have technical expertise in special products like PAI, Self Bonding, PI class 240
At Geekay, we manufacture enamelled winding wires of different technical specifications customised to your needs.
2. Supplying capabilities of the manufacturer
It is important to gauge the supplier’s potential of meeting your wiring needs by looking at the following:
How well-diversified their product portfolio is
They should be able to provide solutions for all the wiring needs for making EVs and be a one-stop shop. You would, typically, require them to provide winding wires for –
o Traction motors and electric engines
o Controller and inverter
o Regenerative braking
o Stability controls
o Air conditioning and heating systems
o Power locks for door
o Ignition coils
At Geekay, we provide winding wires for every need of electric vehicles. Check out the product type, standards and applications of winding wires.
Can they fulfil your demands without any geographic and capacity constraints?
The supplier should have factories at feasible locations geographically, which satisfies your procurement concerns. Their warehouses and sales depots must be positioned in a way that your production requirements are delivered seamlessly.
They should also be able to scale their production as per your demands. Checking their partnerships with other businesses will determine their operating credibility.
3. Judging the quality aspects
The quality of the winding wire should not be compromised as it is a key component in the EV manufacturing process.
Quality of copper and insulation –
The supplier must use virgin copper, which is the main raw material, with a minimum purity of 99.95%.
Depending on your temperature range requirement, they should be able to provide suitable insulation – polyvinyl formal (Formvar), polyurethane, polyamide, polyester, polyester-polyimide, polyamide-polyimide (or amide-imide), and polyimide. Enquire with them whether they offer the type of insulation you need for the wires.
Geekay follows a strict raw material quality policy by procuring them from the best sources available worldwide.
World Class Quality Testing Capability –
The company with a system for routine testing procedures for quality assurance of wires would be an added advantage for inspections at different stages of the manufacturing process. Some of the critical quality testing processes that you should look for in a magnet wire manufacturer are:
- Concentricity Testing
- UTS (Ultimate Tensile Strength) Testing
- Inline Testing
- Pinhole Testing
- Tan Delta Testing
You must check whether they are certified as per the relevant Quality management system standards such as IATF 16949, ISO 9001:2015, ISO 14001:2015, ISO 45001:2018.
The company which is in the business of manufacturing enamelled copper wires should be a UL-approved supplier (Under Writers Laboratories, USA). This would ensure consistency in the quality of their products.
Their magnet wires need to be RoHS (Restriction of Hazardous Substances) and REACH compliant.
Packaging Quality –
The delivery spools for wires used by the supplier must be as per industry-accepted standards, to avoid any damage to insulation. Leading suppliers offer customised spooling solutions based on buyers’ specifications – be it taper or parallel spools. The reels used for supplying wires should have accurate dimensions based on their diameter and length.
Geekay offers packaging solutions customised to your electric vehicle needs.
4. Competitive Pricing
You should consider partnering with suppliers who offer top-notch winding wire which meets global standard norms, along with competitive pricing for their products. Occasionally, EV manufacturers tend to zero in on suboptimal wire suppliers who offer a lower price in a bid to cut down on their costs. Look for suppliers who meet your specifications and then finalise on the one that offers the best price.
Geekay provides the best quality winding wires at the best price.
5. Reducing carbon footprint
Assessing the Product carbon footprint (PCF) for a particular supplier’s wire will tell you about its level of greenhouse gas emissions. As the manufacturing industry is a significant contributor to carbon emissions, collaborating with carbon-conscious suppliers will be a wise step for the environment. Choose a supplier that incorporates raw materials with a lower carbon footprint and mainly uses renewable energy for manufacturing.
GK sources 40% of its power from a solar plant, thus reducing its effective carbon footprint.
G.K. Winding as your EV Manufacturing Partner
We are a leading manufacturer of Copper & Aluminium Enamelled Winding Wires in India with four decades of experience. We understand our customers’ requirements and provide solutions accordingly with unmatched quality.
Our enamelled wire products – ranging from self-solderable wires, poly-vinyl wires, nylon-coated wires, polyester-coated wires, and self-lubricated wires among others, meet global standards. Also, we are IATF 16949, ISO 45001:2018, and ISO 14001:2015 certified. We offer UL-approved and 100% ROHS & REACH compliant wires. Quality assurance in terms of customised solutions, packaging and delivery is our motto and we strive to improve our processes to satisfy our customers.
So, if you are looking for a trusted partner for your EV wiring needs, G.K. Winding wires is your one-stop destination.