Vertical Winding of Film-coated Aluminum Wire

Analysis of Common Problems in Vertical Winding of Film-Coated Aluminum Wire: Pugu Electromechanical Technology (Suzhou) Co., Ltd. provides answers for you

In electrical equipment and power electronic systems, film-coated aluminum wire vertical winding coils are widely used in various high and low voltage devices such as transformers, reactors, inverter power supplies, and charging piles due to their outstanding advantages of lightweight, voltage resistance, and cost performance. The vertical winding of film-coated aluminum wire significantly enhances the insulation performance while ensuring lightweight by covering the surface of the aluminum conductor with a layer of highly insulating film material. However, during the design, production, installation and usage processes, users often encounter various problems. If not handled properly, it may affect the performance stability and service life of electrical equipment. This article will draw on the years of production and technical service experience of Pugu Electromechanical Technology (Suzhou) Co., Ltd. to comprehensively sort out the common problems and solutions of vertical winding of membrane-coated aluminum wire, and help customers' equipment operate efficiently and stably.

I. Common inter-turn short circuit problems in vertical winding of film-coated aluminum wire

Inter-turn short circuit is one of the common and difficult problems in the vertical winding of film-coated aluminum wire. It is mainly manifested as damage to the adjacent coil layers or inter-turn insulation inside the coil, causing mutual short circuits, which in turn leads to abnormal electrical performance and even burns out the equipment. Pugu Electromechanical Technology (Suzhou) Co., Ltd. points out that the common causes of inter-turn short circuits include:

Local damage to the film layer: Mechanical damage such as scratches and indentations on the film layer during production or installation was not detected in time.

High-temperature environment failure: When the working environment temperature exceeds the membrane insulation grade, the insulation performance deteriorates.

The quality of insulating film does not meet the standards: Low-grade, aged or inferior film materials are used, which cannot withstand working voltage and environmental stress for a long time.

Solution

Pugu Electromechanical Technology uses high-strength and high-temperature resistant film materials such as PET and PI in production, and combines vacuum impregnation curing process to enhance the protection of the film layer. Meanwhile, through the full-process optical inspection equipment, minor defects in the film packaging process are detected and corrected, effectively reducing the occurrence rate of inter-turn short circuits.

Ii. Cracking and film layer peeling issues of film-coated aluminum wire

During the winding, forming or subsequent use of film-coated aluminum wires, phenomena such as cracking and peeling of the film layer may occur, resulting in a decline in insulation performance. The main causes include:

The surface pretreatment of aluminum conductors is insufficient, resulting in inadequate adhesion of the film layer.

Mechanical fatigue occurs when aluminum wires are repeatedly subjected to force or have an excessively small bending radius.

External force impact during production or transportation.

Solution

Before production, Pugu Electromechanical Technology uses a special cleaning agent to thoroughly degrease and surface activate the aluminum wire to ensure that the film layer adheres firmly. During the winding process, strictly control the bending radius of the aluminum wire to prevent excessive stretching of the film layer. In addition, multiple protections are adopted during the product packaging and transportation stages to prevent damage to the film layer.

Iii. The problem of insufficient voltage resistance performance of film-coated aluminum wire

The important function of film-coated aluminum wire is its insulation withstand voltage capacity. However, some users have reported that they found the withstand voltage test unqualified during use, which is manifested as insulation breakdown and excessive leakage current, etc. The common causes of this problem include:

The film thickness is uneven or there are bubbles.

The voltage resistance performance of insulating film materials is low.

Excessive tension during winding causes the film layer to be thinned.

Solution

Pugu Electromechanical Technology (Suzhou) Co., Ltd. strictly controls the uniformity of film thickness in accordance with the process and adds multiple online laser thickness measurement systems to the production line. At the same time, imported insulating film materials with high voltage resistance grades are selected to ensure that the inter-turn voltage resistance performance of the product meets the requirements of high-voltage working conditions.

Four. Poor contact problems caused by oxidation on the surface of the aluminum wire

Aluminum is prone to react with oxygen in the air, forming an oxide film on its surface. Although this film protects aluminum from further oxidation, it also leads to an increase in contact resistance at the terminal blocks, affecting the reliability of electrical connections. Especially during the later welding or crimping process, if the oxide layer is not treated thoroughly, it may cause poor contact or overheating.

Solution

Pugu Electromechanical Technology offers professional pretreatment solutions for the end of film-coated aluminum wires, including mechanical grinding, chemical film removal, and anti-oxidation protective coating processes, to ensure low contact resistance and stability at the connection parts.

Five. The problem of uneven wire arrangement occurred during the winding of film-coated aluminum wire

During the vertical winding process of film-coated aluminum wire, uneven wire arrangement can cause significant changes in the coil's external dimensions, reduce its high-frequency performance, and even lead to local stress concentration, resulting in damage to the insulating film. Common causes include:

Tension fluctuation of the vertical winding equipment;

The precision of the cable arrangement mechanism is insufficient.

The operator's operation was not standardized.

Solution

Pugu Electromechanical Technology adopts servo-driven high-precision automatic vertical winding machines. Through a constant tension control system, it ensures consistent winding tension. Combined with photoelectric detection, it realizes automatic deviation correction and wire arrangement, making the coil turns tight and neatly arranged, thereby ensuring electrical performance and consistency.

Six. The problem of performance degradation of film-coated aluminum wire due to moisture absorption in a high-humidity environment

Some users found that the insulation resistance of the film-coated aluminum wire vertical winding coil decreased or even short circuits occurred after using it in coastal and high-humidity environments. This is because moisture enters the film layer or the interface between the aluminum wire and the film, and after long-term action, it leads to a decline in insulation performance.

Solution

Pugu Electromechanical Technology conducts vacuum impregnation and curing treatment after production, allowing the insulating varnish to fully penetrate into the winding gaps and form a waterproof protective layer. In addition, we provide customized moisture-proof packaging solutions for customers in high-humidity environments to effectively prevent moisture from entering.

Seven. The problem of difficult welding after vertical winding of film-coated aluminum wire

As the film layer covers the surface of the aluminum wire, when wiring or welding is required after the vertical winding is formed, the film layer will hinder the adhesion of solder, resulting in poor solder joint strength and poor contact.

Solution

Pugu Electromechanical Technology offers three methods for this issue: end film layer reservation, chemical film removal, and mechanical film peeling, to facilitate subsequent welding operations. It also provides corresponding technical support to help customers easily complete the back-end processes.

Viii. Misunderstandings in the Use of film-coated aluminum Wire and Traditional enameled Wire due to Performance Differences

Many users, when using film-coated aluminum wire for vertical winding instead of enameled copper wire, overlook the differences in mechanical properties and thermal expansion coefficients between the two, resulting in unreasonable product design, loose coils or stress cracking after thermal expansion and contraction.

Solution

In the process of cooperating with customers, Pugu Electromechanical Technology will thoroughly understand the application environment of the products, provide performance comparison data of film-coated aluminum wire and enameled copper wire as well as reasonable selection suggestions, and assist customers in completing product design optimization.

Ix. Frequent rework issues of vertical winding of film-coated aluminum wire

During production, assembly or later maintenance, if the vertical winding coil of the film-coated aluminum wire frequently malfunctions and needs to be disassembled or repaired, it will face a decline in insulation capacity due to irreversible damage to the film layer.

Solution

Pugu Electromechanical Technology suggests that during the initial design and production stages, strict process control and multiple full inspections should be implemented to ensure zero defects in the products and avoid frequent rework in the later stage. For coils damaged due to accidents, the company also offers efficient repair services and helps customers analyze the root cause of the problem based on the cause of the damage.

X. Noise problems occur during the use of film-coated aluminum wires

In some high-frequency working scenarios, the vertical winding coil of film-coated aluminum wire will generate electromagnetic noise, which is manifested as a slight "buzzing sound". This kind of problem is usually caused by loose windings or inter-turn gaps.

Solution

Pugu Electromechanical Technology, through the vertical winding and post-impregnation curing process, tightly fixes the windings, eliminates inter-turn vibration sources, effectively reduces electromagnetic noise, and at the same time optimizes electromagnetic compatibility in the design.

Xi. Full-process quality Assurance of Pugu Electromechanical Technology

The quality of the vertical winding of film-coated aluminum wire directly affects the safety and lifespan of electrical equipment. Pugu Electromechanical Technology (Suzhou) Co., Ltd. has established a complete quality control system from material selection, film wrapping process, vertical winding accuracy, impregnation curing to the final inspection stage:

We carefully select high-quality insulating film materials to ensure insulation performance and adhesion.

Constant tension high-precision automatic vertical winding machine is adopted to ensure consistency.

Carry out a full inspection of inter-turn withstand voltage, insulation resistance, appearance and dimensions.

Reliability is verified through environmental simulation tests such as high-temperature aging, thermal shock and vibration.

Twelve. The future Development direction of film-coated aluminum wire vertical winding

With the development of electrical equipment towards high efficiency, lightweight and intelligence, film-coated aluminum wire vertical winding will face more technical challenges and opportunities:

Develop thinner and more environmentally friendly film materials with higher insulation performance;

Optimize the film wrapping and vertical winding processes to enhance the electromagnetic performance under high-frequency conditions;

Combined with intelligent manufacturing, it realizes digital quality traceability and automated inspection.

Pugu Electromechanical Technology (Suzhou) Co., Ltd. will continue to invest in research and development, dedicated to the performance innovation and quality improvement of film-coated aluminum wire vertical winding products.

The editor of Pugu Electromechanical believes that the vertical winding technology of film-coated aluminum wire has become an important component of modern electrical equipment due to its lightweight, good voltage resistance performance and cost advantages. However, there are many details that need attention in design, production and use. Pugu Electromechanical Technology (Suzhou) Co., LTD., relying on its rich experience and complete quality assurance system, provides customers with high-quality film-coated aluminum wire vertical winding products. Through professional technical support, it helps customers solve various problems encountered during use, jointly promoting the development of electrical equipment towards high performance and high reliability.