Ultra-thin transposed conductor
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Product Description
It refers to a winding conductor formed by arranging a specified number of ultra-thin enameled copper flat wires into two parallel columns with their wide faces in mutual contact, performing turn-reversing transpositions on the narrow faces of both columns in the same direction as required, and inserting insulating paper of a specified thickness between the two columns. The entire assembly is then continuously wrapped with electrical insulating paper, tape, or mesh band to form the final winding.
Ultra-thin transposed conductors can reduce eddy-current losses in the windings, lower stray losses in the transformer, decrease load losses, mitigate hotspot temperature rise in the windings, enable a more compact transformer design, and reduce overall transformer cost.
This product can be widely used in various windings of AC and DC transformers with voltage ratings of 110 kV and above.
Main technical specifications:
Number of cores in a single transposed conductor: 5 to 35.
Enamelled flat wire specifications (mm): side a: 0.8–1.0; side b: 5.00–11.00.
Enamel-coated flat wire width-to-thickness ratio: b/a ≤ 7.
Core dimensions of the crossover conductor (mm): W1 ≤ 28; H1 ≤ 25;
Aspect ratio of the transposed conductors: ≤5.5.
Other technical specifications that comply with paper-insulated, self-adhesive/acetalden-coated, transposed conductors.
Any requirements beyond the above may be determined through negotiation between the supplier and the buyer.
Product Advantages
Leveraging more than two decades of technological expertise and industry-leading manufacturing capabilities, the company has developed core product advantages characterized by high electrical conductivity, low loss, corona resistance, and exceptional reliability. By employing high-purity oxygen-free copper and state-of-the-art insulation processes, the products deliver outstanding mechanical and electrical performance, meeting the stringent requirements of high-voltage transmission and transformation applications as well as emerging sectors such as new-energy vehicles. This comprehensive approach enhances equipment operational efficiency, extends service life, reduces overall energy consumption, and provides customers with a stable, efficient, and secure one-stop electromagnetic wire solution.
Higher electrical conductivity
● Excellent electrical conductivity and low copper losses, enhancing motor efficiency and service life.
● Hongyuan Company Standard: Copper purity ≥ 99.99%, resistivity at 20°C ≤ 0.01710 Ω·mm²/m.
Control measures: High-purity Class A copper plates are self-cast to ensure excellent electrical performance.
Lower oxygen content
● Low oxygen content ensures high welding quality, thereby extending the service life of the motor.
● Hongyuan Company Standard: Oxygen content < 8 ppm.
Control measures: High-quality Grade A copper plates are self-drawn and cast, and process technical requirements are established for the charging frequency of electrolytic copper plates, smelting temperature, cooling rate, and protective measures during the melting process in the upward-drawing production process, to ensure that the copper rods have high purity and low oxygen content.
Smaller fillet radius
● A smaller fillet radius results in a higher packing density and higher motor efficiency.
● Hongyuan Company Standard: Minimum corner radius of 0.30 mm.
Control measures: Molds are manufactured using precision CNC technology and inspected with a projector, ensuring that the round-corner radius deviation is within ±10%.
Smaller coating film eccentricity
● The smaller the eccentricity, the more uniform the coating film and the better its electrical properties, such as corona resistance.
● Hongyuan Company Standard: Coating film eccentricity: maximum thickness/minimum thickness ≤ 1.3.
Control measures: Maintain optimal baking temperature, varnish bath temperature, and viscosity; conduct projection inspection on both bare-wire molds and coating molds to ensure that the fillet radii are properly matched, thereby guaranteeing uniform coating.
Better film flexibility and adhesion
● Excellent flexibility and adhesion to prevent cracking of the coating at the ends during bending.
● Hongyuan Company Standard:
Film flexibility: The coating film shall not crack when rolled up to twice its original thickness and twice its original width.
Coating adhesion: After cutting and stretching by 15%, the distance at which the coating loses adhesion shall be no greater than 0.5 times the conductor width.
Control measures: Employ the optimal painting process and precisely control the thickness of each paint layer.
Higher partial discharge inception voltage (PDIV)
● The higher the PDIV value of the winding, the longer the insulation system’s service life under aging conditions.
● Hongyuan Company Standard: Single-coat film thickness of 0.13 mm, PDIV (Vp) ≥ 1900 V.
Control measures: use PI varnish with a low dielectric constant, increase the varnish film thickness, and enhance the degree of varnish curing.
Higher corona resistance
● Enhancing corona resistance can reduce partial-discharge-induced coating degradation, thereby extending the service life of electric motors.
● Hongyuan Company Standard: Single-coat film thickness of 0.12 mm, corona resistance life ≥ 500 hours.
Control measures: modify the properties of the insulating varnish, increase the coating thickness, reduce coating eccentricity, and enhance coating cure.
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