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Joyal® – A Division of AWE, Inc.Manufacturers of resistive welding/fusing machines to connect magnet wire for all
types of electro-magnetic devices including motors, generators,
transformers and bobbins.
The AWE Family Includes
Overview
Review Traditional Methods Disadvantages of Traditional Methods Technology Behind Fusing Fusing vs. welding Different Fusing Methods Fusing Advantages Summary
Traditional Lead Connect Methods
Strip and Cold Crimp Termination Magnet wires have enamel removed and the
wire bundle is crimped into a terminalStrip and Braze Magnet wires are stripped and connected by
the application of heat and a brazing material
Insulation Displacement Connector (IDC) Magnet wires are pierced by a terminal which
penetrates the enamel insulation to connect to the copper wire
Disadvantages of Traditional Methods
Strip/Crimp Mechanical strippers
reduce cross sectional area of magnet wire
Tooling for mechanical strippers expensive and difficult to maintain
Exposed copper can oxidize and increase resistance
No process control Increased labor required
to remove insulation
Disadvantages of Traditional Methods
Brazed Connection High degree of variability &
inconsistency of operator No process control Excessive heat can cause
the wires to become brittle High cost (gas, brazing
material, operator training, warranty returns, rejects)
Disadvantages of Traditional Methods
Insulation Displacement Results in point contact only
with higher resistance• Mechanical strength• Limited current carrying
capacity Relatively high part cost Lack flexibility for a wide
range of wire sizes in single terminal or cavity
Fusing Versus Welding
Fusing Process Pass current through high resistance electrodes and
heat is generated at this point Heat is dissipated into the part without melting the
copper Evaporate insulation and make a Diffusion Bond of
the wires
Welding Process Pass current through a low resistance electrode Interface between the metals is the highest
resistance and heat is generated at this surface Metal melts and produces a weld
Tin (Sn) Fusing
Addresses all the concerns of today’s manufacturer
RoHS compliant Fast and efficient Highest quality connection Feedback for process control and SPC Minimal safety and environmental risks Use standard tubes from various sources Connection is strong, low resistance and
most of all consistent.
AC Fusing Technology Transformer shorted across work piece Apply low voltage (2.0 to 3.5V) and high
current (1,000 to 40,000Amps)
AC Fusing Technology Time controlled by line crossings –
50/60 Hz increments Current upslope controlled by phase
shift
Tin (Sn) Fusing Process
Initial Heat to Form Tube• Approximately 180ºF
Enamel Insulation Starts to Evaporate• Approximately 450ºF
Further Heat Causes Tin to Melt & Clean Magnet Wire• Approximately 600ºF
Tin Will Eventually Evaporate• Approximately 1,000ºF
Further Heat and Pressure Creates a Diffusion Bond Between Copper Wires• Approximately 1,800ºF
Tin Fusing Methods
Methods Available for Variety of Applications
Tang Termination Fuse-A-Wire Tube Fusing Thermal Crimp
Tang Termination Method
Magnet wire is captured in a tang terminal Terminal typically half hard brass and Tin
coated Typically used in bobbin and some armature
applications, but can be applied to stators
Tang Termination Advantages
Large range of wire sizes from 0.1mm to 1.5mm
Low labor content. • Wire can be automatically placed into tang
by winder and automatically fused. Very reliable
• Millions of connections made every day using some sort of tang termination
• Quality improved when using Tin coating
Fuse-A-Wire Method
Makes direct connection between insulated
magnet wire and Tin coated lead wire• Tin in process comes from lead wire
Patented Joyal Fusing Process
Fuse-A-Wire Advantages
Makes direct connection without need of crimp or external terminal
Process can accommodate a wide range of magnet wire/lead wire sizes
Can connect up to three (3) magnet wires to a lead wire
Process control of current, force and displacement
Tube Fusing Method
Wires held in a Tin coated copper tube Compatible with hundreds of existing tubes Capable of accommodating a large variety of
wire bundles Patented Joyal Technology
Tube Fusing Advantages
Can be used either as a splice connection or as a lead connection
Capable of Up to 120 x 1.0mm wires in parallel
Fast – Lead bundle of 48 x 1.0mm wires can be fused within 5 – 8 seconds
Lower resistance and more consistent wire to terminal resistance than Strip and Crimp or Brazed connection
Very little operator training required
Thermal Crimp Method Connection captured in a Tin coated copper
terminal Terminal automatically made from flat strip Patented Castech technology
Thermal Crimp Advantages
Capable of terminating larger wire bundle compared to Fuse-A-Wire
Inexpensive terminal material available from a variety of sources
Flexible - Single terminal strip can accommodate wide range of wire bundles
Fast Change-over Between Wire Bundles
Summary
While many manufacturers are reluctant to change, fusing is a proven technology
Tin fusing offers more opportunities to improve product consistency and quality
Manufacturing processes would be simplified with improved flexibility
Fusing would resolve many safety and environmental issues
Feedback for process control and SPC not offered with present methods
Summary (cont.)
Justifications based on these improvements would be difficult with today’s “Rate of Return” and “Payback” requirements
With the additional benefits of reduced labor, training, setup, repair and warranty costs, the justifications should be simple
The variety of Tin fusing methods available, can be applied to wide range of applications