Product standard and test method standard of enameled wire;
1. Product standard of enameled round wire;
Gb6109-90 Series standard:
Product standard for enameled flat wire: GB/ T7095-I995 series
Standard test Method for enameled round and flat wire: GB/T4074-1999
Inspection and test of enameled wire
The contents of enameled wire inspection include;
Inspection and measurement of appearance and dimensions, performance testing.
The properties include mechanical, chemical, thermal and electrical properties.
Now we mainly explain the appearance and size.
1. (look) should be enameled wire surface smooth, colour and lustre is uniform, no particles, no oxidation, horror, Yin and Yang, black spots, affect the performance of the defects such as paint, row line should be neat, smooth, closely around the online tray, not on, freely and there are lots of factors affect the surface it and raw materials, paint, equipment, technology, environment and other factors.
Size of 2.
2.1 Enameled round wire dimensions include: external dimensions (warp)D
Conductor diameter D
Conductor deviation △ D
The roundness of the conductor F
The thickness of the paint film t
2.1.1 Outer diameter refers to;
The diameter of a conductor as measured by coating it with an insulating film.
2.1.2 Conductor diameter;
Refers to the removal of the insulation layer after the metal wire
2.1.3 Conductor deviation;
Is the difference between the measured and nominal diameter of the guide body.
2.1.4 The non-state (f) value is the maximum difference between the maximum and minimum readings measured on each section of the guide body.
2.2 Measurement method;
2.2.1 Measuring tools;
Micron dry scale, accuracy 0.001mm
Enameled round wire, d<0.100mm measuring force 0.1-1.0n
D I - 8 n acuity 0.100 mm measured force
The measuring force of enameled flat wire is 4-8n
2.2.2 diameter
2.2.2.1 (circular line) When the nominal diameter of the conductor D ≤0.200mm, measure the outer diameter at 3 positions 1m apart, record 3 measured values, and take the average value as the outer diameter.
2.2.2.2 when the nominal diameter of the conductor is d>0.200mm, the outside diameter is measured for 3 times at the average circumference along the line of each position 1m apart, 6 measured values are recorded, and the average value is taken as the outside diameter.
2.2.2.3 (Flat line) The dimensions of wide edge and narrow edge were measured once at 100mm3 positions, and the average value of the three measured values was taken as the external dimensions of wide edge and narrow edge.
2.2.3 Conductor size
2.2.3.1 (circular line) When the nominal diameter of the conductor d≤0.200mm, remove the insulation at 3 locations 1m apart by any method that does not damage the conductor, and measure the diameter of the secondary conductor each: take its average value as the conductor diameter.
2.2.3.2 when the nominal diameter of the conductor is d>0.200mm, remove the insulation by any method that does not damage the conductor, measure separately along the three positions of the mean partition of the circumference of the conductor, and take the average of the three measured values as the conductor diameter.
2.2.2.3 At 100mm3 (flat lines) apart, remove the insulation by any method that does not damage the conductor, measure the size of the wide side and the narrow side once respectively, and take the average of the three measured values as the size of the wide side and the narrow side.
2.3 calculation
2.3.1 Deviation =d actual measurement - D nominal
2.3.2 F value = the maximum difference of any diameter reading measured at each section of the conductor
2.3.3 t = D - D measurement
Example 1. There is a plate of qZ-2/1300.710mm paint;
Cladding wire, the measured values are as follows
Outer diameter.
0.780 0.778 0.781;
0.776 0.779 0.779;
Conductor diameter;
0.706 0.709 0.712;
Calculate its outer diameter, conductor diameter, deviation, F value, paint film thickness, and judge whether qualified.
Solution: D = 0.780 + 0.778 + 0.781 + 0.776 + 0.779 = 0.7796
D = 0.706 + 0.709 + 0.712 = 0.709 mm
Deviation =d actual measurement - D nominal =0.709-0.710=-0.001mm
F = 0.712 0.706 = 0.006
T = D - D = 0.779-0.709 = 0.070 mm measured
After measurement, the size of enameled wire conforms to the standard requirements.
2.3.4 flat wire.
Thickened paint film 0.11<&≤0.16mm
Ordinary paint film 0.06≤&≤0.11mm
Amax = a + delta + & Max
BmaX = b + delta + & maX
The paint film thickness is allowed to exceed & Max when the outside diameter size of A and B does not exceed Amax Bmax
Deviation of nominal size A (b)
A (b) 3.15 0.030 mm or less
3.155
6.30
12.5
For example 2, there is flat qZYB-2/180 2.36×6.30mm, the measured size,
A;
2.478, 2.471, 2.469 a;
2.341, 2.340, 2.340
B;
6.450, 6.448, 6.448, b;
6.260, 6.258, 6.259,
Find the film thickness, outer diameter, conductor, and judge.
Solution: A = 2.478 + 2.471 + 2.469 = 2.473
B = 6.450 + 6.448 + 6.448 = 6.449
A = 2.341 + 2.340 + 2.340 = 2.340
B = 6.260 + 6.258 + 6.259 = 6.259
Film thickness;
A, edge.
2.473-2.340 = 0.133 mm
B;
6.499-6.259 = 0.190 mm
In addition to semi-finished conductors with hidden defects or non-uniform specifications, the main reason for conductor size disqualification is the painting-process wire tension: the tightness of each part of the felt clip is not adjusted properly or the wire and regulating wheel rotation is not flexible, drawing the wire fine.
Paint film insulation size is not qualified mainly felt elastic adjustment is not appropriate or improper mold and the mold is not installed.
In addition, the process speed, the viscosity of the paint, solid content and other changes will also affect the film thickness.
3. Performance of enameled wire
3.1 Mechanical properties: including elongation, rebound Angle, softness and adhesion, paint scraping, tensile strength and other items.
3.1.1 Elongation reflects the plastic property of the material, which is used to evaluate the strict ductility of enameled wire.
3.1.2 Springback Angle, softness reflects the elastic deformation of the material: it is used to evaluate the softness of enameled wire.
Elongation, springback Angle and softness reflect the influence of copper material quality and enameled wire annealing degree on enameled wire elongation: the main factors of springback Angle are (1) wire quality: (2) the influence of external force.
(3) The degree of annealing is related.
3.1.3 Toughness of paint film includes winding and drawing, that is, the allowable amount of drawing deformation of paint film without breaking with the tensile deformation of the conductor.
3.1.4 Adhesion of paint film includes: snap break and peel, mainly examining the adhesion ability of paint film to conductor.
3.1.5 Scratch resistance test of enameled wire film, reflecting the strength of the film against mechanical scratch.
3.2 Heat resistance;
Thermal shock and softening breakdown tests are included
3.2.1 Thermal shock of enameled wire is the thermal endurance of enameled wire film under the action of mechanical stress.
Factors affecting thermal shock;
(1) The influence of the paint, (2) the influence of copper wire, (3) the influence of the coating process
3.2.3 The softening breakdown performance of enameled wire measures the ability of enameled wire's paint film to withstand thermal deformation under the action of mechanical force, that is, the ability of the paint film under pressure to plasticized and become soft under high temperature.
The thermal softening and breakdown performance of enameled wire film depends on the molecular structure of the film and the intermolecular forces of the film.
3.3 Electrical performance;
Include breakdown voltage: continuity of paint film, DC resistance test.
3.3.1 Breakdown voltage refers to the capacity of voltage load borne by enameled wire paint film.
Main factors affecting breakdown voltage :(1), film thickness :(2) film roundness, (3), curing degree.
(4) External impurities in the paint film.
3.3.2 Continuity test of paint film is also called pinhole test
Its main influencing factors, (1) the influence of raw materials :(2) the influence of operation process :(3) the influence of equipment.
3.3.3 DC resistance refers to the resistance value measured per unit length.
The current resistance is mainly affected by :(1) annealing degree, (2) enameling equipment.
3.4 Chemical resistance: solvent resistance and direct welding resistance.
3.4.1 Solvent resistance refers to the general enameled wire after winding into the coil: after the impregnation process, the solvent in the impregnated paint has different degrees of swelling action on the paint film at higher temperature is more.
The chemical resistance of enameled wire film mainly depends on the characteristics of the film itself: under certain conditions of paint coating process has a certain effect on the solvent resistance of enameled wire.
3.4.2 The direct welding performance of enameled wire reflects the solder ability of enameled wire in the process of winding without removing the paint film.
The main factors affecting the direct welding property are: (1) the influence of process, (2) the influence of paint.
Self-inspection of 3.
In order to improve the quality of crystal production, prevent and reduce the occurrence of non-conformance, and solve the nonconformance factors in the production process, operators are especially encouraged to carry out self-inspection: self-inspection is the inspection of the dimensions, wiring and surface quality of the products (finished products, semi-finished products and wire-in-process products) according to the technological procedures.
6.1 First piece inspection;
In the pan;
Specifications: change the mold, change the raw materials;
Specification of crystal production during process adjustment;
Dimensions: Surface and wiring shall be inspected.
For example, wire drawing for mold;
First of all, you should confirm the reasonable mold, wear the mold after the trial pull;
Check whether the size meets the specified requirements and whether the surface is smooth and clean;
Check it again after a while;
Enameled wire operators at the joint;
First, the size of the bare wire should be measured.
Whether the surface is smooth and clean;
Whether there are defects, whether the line is in good condition.
6.2 During the production process, the process and equipment operation rules shall be strictly observed and "frequent inspection", "frequent testing" and "frequent inspection" shall be carried out to ensure the consistency of the product inside and outside.
6.3 Completion inspection;
After the product is manufactured, each plate is inspected for size, surface, line and label.
Also simulated some tests to make a preliminary judgment, such as small specifications with both hands to grasp a wire, pull hard, touch the wire with the hand, whether the surface hair;
If hair shows the paint film elasticity of this line is bad, the line of big specification is folded in half, bend whether craze.
6.4 Mutual inspection. Products in process, semi-finished products and products handed over from the previous process shall be inspected. Qualified products shall be accepted, and unqualified products shall be rejected.
6.5 Only those that pass the self-inspection and are considered qualified can be sent to full-time inspectors for inspection, and only one ring shall be attached to the other ring;
Layer upon layer check: in order to reduce the occurrence of unqualified, only joint efforts, everyone check, in order to achieve zero defect quality, in order to make customers satisfied, in order to make our products in the fierce market competition in a place.