Systems and methods for detecting defects in magnet wire insulation

A fault detection system comprising:

• an outer housing;
• and
• a detection component positioned within the outer housing, the detection component comprising:
• at least six emitter and detector pairs positioned around an examination area through which a wire is traversed, wherein each detector is positioned across the examination area from a corresponding emitter,
• wherein each emitter is configured to emit a signal that is measured by a corresponding detector and the detection component is configured to detect one or more defects on a surface of the wire based upon changes in the signals measured by one or more of the detectors.

A fault detection system comprising:

• an outer housing;
• and
• a detection component positioned within the outer housing, the detection component comprising:
• a plurality of emitters and detectors positioned around an examination area through which a rectangular wire with rounded corners is traversed, wherein each detector is positioned across the examination area from a corresponding emitter,
• wherein each emitter is configured to emit a respective signal across a respective portion of an outer surface of the wire, each detector is configured to detect the respective signal of a corresponding emitter, and the detection component is configured to detect one or more defects on the outer surface of the wire based upon changes in the signals measured by one or more of the detectors,
• wherein the detection component is configured to detect one or more defects having respective amplitudes of 20 microns on any portion of the outer surface.