US 6,487,470 B1 · Method and apparatus for determining magnet wire production die sets

Abstract

A method for determining optimum enamel die sizes for each of a plurality of dies for fabricating magnet wire includes a series of calculations based upon an empirically determined build factor for each of the enamel coatings used in the fabrication process. The build factor is a measure of the effective diameter increase of a wire passed through a coating die when the diameter of the wire entering the die is known and a selected thickness of wet enamel coating exiting the die is known. The build factor a given enamel coating is primarily dependent upon only the solids content of the enamel coating solution, and is largely independent of the chemistry of the coating solution. A simple relationship between build factor, die size, and wire size allows consistent fabrication of magnet wire in accordance with pre-selected specifications and with virtually no scrapped wire due to oversized final wire diameters.

Claims15

Dependent claims

A method for determining optimum enamel die sizes for each of a plurality of dies for fabricating magnet wire with reduced amounts of undercoating and overcoating enamel in a multi-stage fabrication process including at least one undercoating stage utilizing at least one undercoating enamel and an undercoating enamel die and at least one overcoating stage utilizing at least one overcoating enamel and an overcoating die, the wire fabricated in accordance with pre-selected specifications including minimum enamel coat build thickness and percent margin thickness of each of said undercoat and overcoat enamels;

said method comprising the steps of:
obtaining a build factor constant for each undercoat and overcoat enamel used in the process;
and
calculating desired die set criteria for at least one of the stages based upon a relationship:
Dpf(n)=D0(n)+Kpass(n)(Ddie(n)−D0(n))
where Dpf(n)=final wire diameter after the nth pass;
D0(n)=initial wire diameter at the nth stage;
Kpass(n)=build factor for the nth pass;
and
Ddie(n)=die throat diameter of the nth stage.

7 more elements

A system for determining optimum enamel die sizes for each of a plurality of dies for fabricating magnet wire with reduced amounts of undercoating and overcoating enamel in a multi-stage fabrication process including at least one undercoating stage utilizing at least one undercoating enamel and an undercoating enamel die and at least one overcoating stage utilizing at least one overcoating enamel and an overcoating die, the wire fabricated in accordance with pre-selected specifications including minimum enamel coat build thickness and percent margin thickness of each of said undercoat and overcoat enamels, and each undercoat and overcoat enamel having a build factor constant, said system comprising:

a microprocessor and a memory together configured to accept calculation inputs comprising nominal bare wire diameter used to produce the magnet wire, undercoat and overcoat specification minima, undercoat and overcoat percentage margins, build factors for each undercoat and overcoat material, and a number of undercoat dies and a number of overcoat dies, said microprocessor further configured to calculate undercoat and overcoat die sizes based upon said inputs.

Dependencies are inferred from the claim text.

Method and apparatus for determining magnet wire production die sets

Life of this patent

Method and apparatus for determining magnet wire production die sets

Life of this patent

Abstract

Claims15