Modern winding wires improve the power density and efficiency of electric motorsWinding wires with enhanced gliding properties
Winding wires have two functions in electric motors: they conduct electricity (copper) and they are coated with polymer layers which act as insulators. These wires are now coated with paraffin for the purpose of being workable and for filling out the given space. However, the resulting friction coefficients are not optimal and are subject to fluctuations. It is therefore usually not possible to achieve an optimal fill factor. Innovative, glide-optimised winding wires can drastically reduce detectable friction coefficients and produce low fluctuation margins. This is advantageous to electric motor builders for the following reasons: the given space is better utilised and more active material (copper) is incorporated. Depending on the motor design, it is therefore possible to significantly increase efficiency standards. Alternatively, motors with the same specifications can be manufactured at a cheaper price by minimising resources and changing their design (e.g. shortening of the lamination stack). The procedural advantages are particularly important: if wires glide better, they endure less stress in winding machines and can therefore be processed in a faster and more reliable manner. The performance and availability of systems is increasing. Furthermore, if the outer paraffin layer is not applied, it saves the hassle of regularly having to clean the resulting contaminants. Pilot projects and the calculations of a professional institute show typical efficiency standard increases of 2% (with an initial value of 82%) and cost savings of at least 5% for a permanently excited synchronous motor. These winding wires therefore simultaneously contribute to increasing the efficiency of electric motors and greater manufacturing efficiency. For new developments, the more attainable specifications can already be considered when designing the motor. However, simply replacing conventional wires with glide-optimised enamelled wires can often produce useful benefits.