Winding Wire Production and Quality control

1.Wire drawing process

Aluminum (copper) rod from 8mm is drawn through a series of dies to a finer size. Additional wire drawing equipment is utilized to draw wire to finer sizes if necessary.

2.Wire annealing

The bare wire is annealed to achieve necessary softness of the aluminum (copper).

3.Supposed it is enamelled winding wire, then start enamelled process and lubrication process.

The enamel is applied in many single layers by the applicator to guarantee good adhesion of the enamel to the aluminum (copper) conductor and to ensure good insulation properties.

In the oven solvents are driven out of the enamel by heat, then lubrication is applied to the finished enamel surface to obtain good silidability.  During the enameling process, the outer diameter is continuously controlled by laser, then the wire is evenly spooled on a supply spool with the consistent tension. The whole process is monitored by the camera, and provide the production data to operator.

4.Supposed it is fiberglass/paper/Polyimide Film winding wire, then wrap the fiberglass on the conductor, then sintering and baking to form a smooth and tight insulation layer.

5.Quality inspection

State of art production machines with closed loop quality system developed and produced by Chalco by our exclusive use. More than 200 sensors continuously control 50 quality parameters in every production line.

Tight specifications and demanding incoming controls are a prerequisite to ensure the quality of the final products.

All plants are certified ISO9001 for the automotive industries, all the products are tested in our lab before delivery.

6.Spools and Packaging

Enamelled winding wire is wound on spools of different sizes and shapes, the wire diameter determines the spool size which can be used. Ultra fine wire typically is produced on smaller spools while heavy wire is wound on very large spools.

Different global standards specify different spool types which are typically associated with each continents standard.