Copper Wire Drawing and Enamelling. Manufacturing of Copper and Copper Products. Start Your Own Industry In Wire & Copper.

Copper wire is an essential material for motor and transformer winding. Copper wire is available in different gauges (32 gauge to 18 gauge).  The gauge of the copper wire depends upon the winding required for the specific motor or transformer. The wire having conductor diameter from 0.500 to 4.000 mm, is suitable for submersible motor winding. There is a heavy market for copper wire/enamelled copper wire in motor and transformer manufacturers and this wire is also used in rewinding of motors and transformers. Reasons for its wide use is that the copper has resistance to atmospheric corrosion because of the formation of uniform layer of oxide on the surface of metal.

Two types of enamelling furnaces are there. First one in which wire passes through oven with direct heating to required temperature with heaters. Second one in which wire passes through a Stainless Steel tube (just like annealing tube) which is heated to required temperature by heaters i.e. indirect heating. The size of Enamelled wire is 0.40 MM.

There is a heavy market for copper wire/enamelled copper wire in motor and transformer manufacturers and this wire is also used in rewinding of motors and transformers.

Reasons for its wide use is that the copper has resistance to atmospheric corrosion because of the formation of uniform layer of oxide on the surface of metal. Besides these, copper has good mechanical properties viz – good mechanical malleability & formability which.  It can easily welded or soldered.   The melting temperature of copper is 1083oC.

Copper is the most used conducting metal. There is a good market for enameled copper wire in motors and transformers industries for winding and rewinding of motors & transformers. Wire is made by cold drawing hot rolled wire/rod through on more dies, to decrease its size and increase the physical properties. In continuous drawing, the wire is fed through several dies and draw blocks arranged in series. Copper wire is used in all type of electric motor. It is used in the manufacture of auto electrical parts such as auto burn etc. According to an estimate over 40% of the total copper wire production of India goes to motor & transformer industries for winding & rewinding purposes. Electrical transmission line is another vital field where copper wires are heavily used along with its competitor metal like aluminium & steels.

Type of Enameled Copper Wires

·         Acetal Enamelled Wire

·         Polyester Enamelled Wire

·         Polyurethane Enamelled Wire

·         Composite Coating Enameled Wire

Benefits of Using Copper Wire

Copper wire is the most preferred wire today for umpteen critical industries, like electronics, telecommunications, construction, marine, and so forth. These great features of Copper wire have made it an obvious choice for these industries.

Ø  Flexibility: Flexible in nature, Copper wire can be Moulded, cut and blend to suit the needs. Such need is widely required in industries such as marine and construction.

Ø  Conductivity: Copper is the second highest conductivity element, with silver being the most. Because of the extremely high electrical and thermal conductivity features of Copper wire and less expensive than silver, make Copper wire the most sought-after wire for industries.

Ø  Melting Point: Since Copper displays absolutely high melting point, it suits to the needs of industries like-electrical and construction.

Ø  Strength: Copper wire is very strong as it is made out of high tensile Copper Ore. In industries like telecommunication where wire is used for signal transmission across long distance, wire of similar strength is required.

Ø  Compatible: Copper wires such as – bare copper wire and tinsel copper wire - are highly compatible with one another, and they can form brisk mixture should there be need

Applications:-

·         Electronic Information Industry

·         Power Industry

·         Machinery and Equipment Industry

The wire enamels market can be segmented into aluminum wires, copper wires, and others. The copper wires segment dominates the global wire enamels market, due to extensive usage of copper wires in various end-use industries such as electronics, power generation, and energy transmission.

Enamelled Aluminium Wire or Enameled Copper Wire is a wire coated with a thin layer of enamel (varnish) insulation to prevent the wire surfaces from being in a short circuit when wound into coils. Magnetic flux is created when current flows through the coil. Aluminum Enameled Wire and Copper Enamelled Winding Wire are used mainly in the construction of motors, electromagnets, transformers and inductors. For ease of manufacturing inductive components like transformers and inductors, most of these wires can be soldered.

Enameled Aluminum Wire or Enamelled copper wire, also called Magnet Wire, is widely used in various Electrical Applications due to its superior Electrical, Thermal and Mechanical Properties. Enameled Aluminium Wire /Enameled Copper Wire are insulated by coating it with enamel of different temperature class. Enamelled Aluminum Wire /Enamelled Copper Wire are primarily used in three types of applications in transformers to transform one kind of electrical energy into other kinds. Aluminum Enameled Wire and Copper Enameled Winding Wire are used in motors to transform electrical energy into mechanical energy. Enamelled Aluminium Winding Wire /Enamelled Copper Winding Wire are also used in generators to transform mechanical energy into electrical energy.

Enameled Aluminum Magnet Wire and Enamelled Copper Magnet wire are used as the wire in electromagnets that use electricity to generate a magnetic field. Enameled Rectangular or Flat Aluminium Wire and Enameled Rectangular or Flat Copper Wire /Strip is wrapped in a tight coil. When an electric charge is applied, the wires generate the magnetic field. Flat Enamelled Aluminium Wire and Flat Enamelled copper wire have a wide variety of applications, including use in automobiles, motors, transformers and industrial machineries. Round Enameled Aluminium Wire and Round Enameled copper wire are also found in smaller devices and home appliances, such as computers, televisions etc.

Properties of Copper Wire

Ø  Tensile Strength

Ø  Electrical Conductivity

Ø  Strength and Ductility combination

Ø  Creep resistance (it doesn’t change much due to heat)

Ø  Corrosion resistance

Ø  Co-efficient of thermal expansion

Ø  Thermal conductivity

Ø  Ability to be soldered

Related Project: - Copper and Copper Products and Projects

Market Outlook

The enameled copper wire segment accounted for the maximum market share during 2016 and will continue to dominate the market for the next few years. Some of the major factors responsible for the growing demand for these wires is its excellent properties such as high resistance to processing and winding or pull-in techniques. The increasing adoption of energy-efficient motors will drive the growth prospects for the copper enameled and bare wire market in the forthcoming years. Some of the major factors responsible for the growing of adoption energy-efficient motors is the stringent electricity consumption standards and the increasing price of electricity products.

Enameled and bare copper wire are used in the electrical and power equipment sector to connect the generator to step-up transformers and the transformers to motors. One of the major factors responsible for the market’s growth is the increasing demand for transformers and motors due to the rising number of substations.

Wire enamels are applied on round and flat wires made of copper and aluminum. Wire enamels are cured onto these wires with the help of heat. They act as primary electric insulation. Wires coated with wire enamels are called magnet wires or enameled wires. These wires are widely used in transformers, generators, motors, and electric measuring instruments. Wire enamels reduce the chances of short circuit, which helps in extending the life of wires. Wires can be coated with up to 30 layers of enamel. Wire enamels offer thermal and chemical resistance along with improved mechanical stability. Materials such as polyurethane, polyesterimide, and polyester are used to insulate copper and aluminum wires.

Rise in the demand for wire enamels for use in electronic applications and increase in the usage of these enamels in power generation applications are expected to drive the wire enamels market in the next few years. This is prompting companies to increase the production of wire enamel. Additionally, easy availability of raw materials required to manufacture wire enamels is anticipated to boost the market. Technological advancements in wire enamels are increasing. Companies are striving to develop new and better methods to wire enamels. Development of new processes for the manufacture of wire enamels and rise in their utilization are expected to propel the market.

Based on type, the wire enamels market can be divided into polyurethane, polyesterimide, polyester, polyamide-imide, and others. Polyurethane wire enamels are employed in timers, relays, small transformers, small motors, and fly-back transformers due to their excellent solder-ability and good crazing and pin-hole resistance. Polyesterimide wire enamels possess outstanding thermal properties, which makes them a favorable electric insulation material for high-end applications. Polyesterimide enameled wires are extensively used for ballasts, explosion-proof motors, compressors, dry transformers, washing machine motors, and electric tools. The polyesterimide segment dominates the wire enamels market, due to extensive usage of polyesterimide enameled wires in industries such as power generation and electronics across the globe.

Based on geography, the global wire enamels market can be segregated into North America, Latin America, Asia Pacific, Europe, and Middle East & Africa. Asia Pacific and North America are anticipated to constitute a major share of the global wire enamels market. The wire enamels market in Asia Pacific is projected to expand at a significant pace from 2018 to 2026, due to rise in the demand for wire enamels market for use in the electronics industry in the region. Europe is anticipated to be an attractive wire enamels market between 2018 and 2026, owing to increase in the demand for wire enamels market from the power generation industry in the region.

The globe have been working tirelessly to find out the different ways to reap the optimal benefits of copper. They have been able to manufacture different types of copper wire that work almost any application for electrical current need. Other popular uses for copper wire includes, solid or stranded bare copper wire, copper wire cables and plated copper wire. Although, not all of them is involved in electricity, they are one of the most useful metals. The copper enameled market is anticipated to grow at a steady rate and will post a CAGR of more than 5%. The growing power and electrical equipment sector will drive the growth prospects for the copper enameled market in until the end of 2021.

The Wire Drawing Process

The process itself is actually quite simple.  To begin the wire drawing process, a spool of wire is placed at beginning of the machine on a spool.  In order to feed it through the machine, the end of wire must be cut or flattened.  It is fed through the machine and through a series of dies to achieve its final cross sectional area.  The end of the machine usually has a spool or coiler so the finished product is a coil of wire at the desired cross sectional area.  The end process may also be a barrel packer where a barrel is placed and the coiled wire is spooled directly into the barrel using a turntable.

It is vitally important the temperature of the machinery does not get too hot (primarily caused by the energy released while deforming of the metal) and the wire has a constant tension and speed as it moves through the series of dies.  Historically this was achieved solely by mechanical means.  However, DC drives began to be used to operate the motors at certain levels depending on the metal and cross section required.  As technology improved, software was added for winder applications which kept the material moving at the proper speed and tension to ensure a good product.  This removed some of the mechanics and transferred it to electronic technology.  With the introduction of high performance/ high efficiency ac drives with powerful processors for software, mechanical dependency on the machinery is greatly diminished.

Key Players:-

Bhagyanagar Metals Ltd., Bharat Insulation Co. (India) Ltd., C M I Ltd., Dharmadeep Powerdive Inds. Ltd., G K Winding Wires Ltd., Ganga Electrocast Ltd., Globus Corpooration Ltd., Hindustan Transmission Products Ltd., Indo American Electricals Ltd., M P Telelinks Ltd., Mardia Samyoung Capillary Tubes Co. Ltd., Paramount Communications Ltd., Patron Industries Pvt. Ltd., Powerflow Ltd., Precision Wires India Ltd., Ram Ratna Wires Ltd., Robot Systems Pvt. Ltd., Salzer Electronics Ltd., Shakti Insulated Wires Pvt. Ltd., Shalimar Wires Industries Ltd., Supreme Conductors Ltd., Translam Ltd., Vardhaman Wires & Polymers Ltd., Versatile Wires Ltd., Vidarbha Winding Wires Ltd.,

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