Production Process Flow of Electromagnetic Wire

　　1. Prepare materials

　　Electromagnetic wire

　　The raw materials for enameled wire are delivered to the production site by cart. The insulating varnish is prepared in the varnish mixing room. Depending on the insulation class of each type of enameled wire, the appropriate proportions of varnish and thinner are thoroughly mixed and then fed into the enameling machine.

　　2. Drawing

　　Drawing is carried out in a wire-drawing machine and can be performed in a single pass or multiple passes, depending on the desired wire diameter. During drawing, the temperature typically ranges from 60 to 100°C, with water-soluble lubricants used for both lubrication and cooling; when the temperature exceeds 100°C, additional cooling and heat removal are implemented.

　　3. Water washing

　　Water washing involves rinsing the enameled wire with high-pressure water that has been purified using hydrochloric acid and caustic soda, thereby removing surface oil and dirt.

　　4. Annealing

　　Annealing is typically carried out in an annealing furnace using electric heating, with the annealing temperature generally controlled between 300 and 600°C. During annealing, steam is used as a protective atmosphere to prevent oxidation. After annealing, the material is air-cooled using a blower until its temperature reaches approximately 40°C, at which point it proceeds to the impregnation stage.

　　5. Impregnation

　　The impregnation process is carried out in the enameling machine and is repeated multiple times to meet the requirements of the insulation layer. During impregnation, an appropriate proportion of diluent is added as needed for the coating. The diluent contains flammable and toxic liquids such as cresol and xylene.

　　6. Drying

　　The drying of enameled wire is carried out in a baking oven, with the drying temperature determined by the drawing speed and typically ranging from 300 to 400°C, though it can reach as high as 670°C. Drying is conducted concurrently with the removal of exhaust gases, which, at temperatures of 300–400°C, contain toxic and flammable vapors such as cresol, phenol, and xylene. After undergoing catalytic treatment to meet regulatory standards, these exhaust gases are discharged into the atmosphere by an exhaust fan.

　　7. Wire Collection

　　Winding involves using a winding device to coil the dried, finished enameled wire onto spools. A small amount of lubricant (such as 974 gasoline or cyclohexane) should be added during the winding process.

　　8. Packaging and Warehousing

　　After passing inspection, the wound wire reels are wrapped in plastic film and packed into cartons or paper tubes; they are then packaged as wire spools according to customer requirements and loaded/unloaded into a dedicated warehouse.