1 Introduction
Fiberglass covered wire is composite insulated winding wire formed by wrapping electrical grade continuous filament glass yarn on enameled copper wire, enameled aluminum wire, copper wire, aluminum wire conductor, is the core winding material for motor, transformer, home appliance, special equipment and other key electrical equipment. Fiberglass covered wire by insulation layer structure is divided into single layer fiberglass covered wire, double layer fiberglass covered wire, fiberglass covered enameled wire, fiberglass paper covered wire four major categories, by heat resistance class divided into B class 130℃, F class 155℃, H class 180℃, C class above 200℃, N class 220℃, R class 240℃ six grades.
Fiberglass covered wire bulk purchasing is the key link for industrial motor factory, transformer factory, home appliance factory, special equipment factory scale production. Based on NEMA MW 1000-2018, IEC 60317, GB/T 7672, JB/T 4074 and other international and domestic standards, this article systematically describes the technical specification, process standard, quality control and development trend of fiberglass covered wire bulk purchasing from seven dimensions including product system, application field, purchasing specification parameters, supplier evaluation, procurement process contract, application notes and future trends.
2 Fiberglass Covered Wire Product System
2.1 Fiberglass Covered Wire Concept and Structure
Fiberglass covered wire is composite insulated winding wire with electrical grade continuous filament glass yarn as external insulation material, enameled copper wire or copper wire, aluminum wire as internal conductor. Fiberglass covered wire structure from inside to outside is conductor, inner varnish film, fiberglass yarn layer, outer varnish film or adhesive layer.
Conductor, copper, aluminum, copper alloy, aluminum alloy. Copper conductor resistivity 1.72×10⁻⁸ Ω·m, aluminum conductor resistivity 2.65×10⁻⁸ Ω·m. Inner varnish film, polyester PEW, polyurethane UEW, polyester imide EIW, polyamide imide AIW, polyimide PI. Fiberglass yarn layer, electrical grade continuous filament glass yarn, fiber diameter 4 to 9 micron, yarn fineness 5 to 200 tex. Outer varnish film, epoxy, polyester, silicone, acrylic.
2.2 Fiberglass Covered Wire Product Type
Fiberglass covered wire product type covers fiberglass covered round copper wire, fiberglass covered flat copper wire, fiberglass covered enameled round copper wire, fiberglass covered enameled flat copper wire, fiberglass paper covered round copper wire, fiberglass paper covered flat copper wire, fiberglass mica tape covered wire, fiberglass film composite wire eight major categories.
Fiberglass covered round copper wire, conductor diameter 0.50 to 5.00 mm, fiberglass layer thickness 0.10 to 0.50 mm. Fiberglass covered flat copper wire, width 1.00 to 16.00 mm, thickness 0.50 to 5.60 mm, fiberglass layer thickness 0.15 to 0.60 mm. Fiberglass covered enameled round copper wire, conductor diameter 0.20 to 4.00 mm, varnish plus fiberglass total thickness 0.15 to 0.70 mm.
Fiberglass paper covered flat copper wire, width 1.00 to 12.50 mm, thickness 0.80 to 5.60 mm, fiberglass paper total thickness 0.30 to 1.50 mm. Fiberglass mica tape covered wire, mainly applied in high temperature high voltage motor, transformer. Fiberglass film composite wire, fiberglass and film composite, dielectric strength 8000 to 25000 V/mm.
2.3 Fiberglass Covered Wire Technical Standard
Fiberglass covered wire technical standards cover NEMA MW 1000-2018 Glass Fiber Covered, NEMA MW 43-C, IEC 60317 enameled wire specification, IEC 60851 enameled wire test method, GB/T 7672 glass fiber covered winding wire, GB/T 11021 electrical insulation heat resistance class, JB/T 4074 enameled round winding wire, JB/T 5331 glass fiber covered flat winding wire.
NEMA MW 1000-2018 divides fiberglass covered wire into Class 155 fiberglass covered bare copper wire, Class 180 fiberglass covered enameled copper wire, Class 200 fiberglass covered enameled copper wire, Class 220 fiberglass covered enameled copper wire, Class 240 fiberglass covered enameled copper wire five heat resistance classes. GB/T 7672 divides fiberglass covered wire by heat resistance class into B class, F class, H class, C class four grades.
2.4 Fiberglass Covered Wire Technical Features
Fiberglass covered wire technical features embody six dimensions, high temperature resistance, high dielectric strength, high mechanical strength, chemical resistance, long life, good processability.
High temperature resistance, long term working temperature 130 to 240℃, short term overload temperature 250 to 350℃, thermal stability excellent. Dielectric strength, breakdown voltage 5000 to 25000 V/mm, fiberglass layer improves overall dielectric strength 30% to 50%. Mechanical strength, fiberglass layer tensile strength 2000 to 3500 MPa, tensile strength improved 30% to 50% versus pure enameled wire.
Chemical resistance, transformer oil, mineral oil, synthetic ester oil resistant, weak acid weak alkali corrosion resistant. Long life, H class fiberglass covered wire 180℃ life 20000 to 50000 hours, C class fiberglass covered wire 220℃ life 10000 to 30000 hours. Good processability, winding, embedding, shaping, impregnation process mature.
3 Fiberglass Covered Wire Application Field
3.1 Motor Application
Fiberglass covered wire in motor application covers small medium motor, large motor, special motor, traction motor four major categories.
Small medium motor, including Y series, Y2 series, Y3 series three phase asynchronous motor, power 0.55 to 315 kW, adopt F class or H class fiberglass covered enameled round copper wire, conductor diameter 0.50 to 2.50 mm. DC motor, power 0.5 to 500 kW, adopt H class fiberglass covered enameled round copper wire, conductor diameter 0.30 to 2.00 mm.
Large motor, including high voltage motor 6 to 10 kV, power 1000 to 50000 kW, adopt F class fiberglass covered enameled flat copper wire, width 2.00 to 8.00 mm, thickness 1.00 to 3.15 mm. Synchronous motor, power 1000 to 50000 kW, rotor fiberglass covered round copper wire, stator fiberglass covered flat copper wire.
Special motor, including marine motor, mining motor, chemical motor, explosion proof motor, adopt H class or C class fiberglass covered enameled wire. Traction motor, used for electric locomotive, metro, EMU, adopt H class fiberglass covered enameled flat copper wire, width 1.50 to 6.00 mm, thickness 1.00 to 2.80 mm.
3.2 Transformer Application
Fiberglass covered wire in transformer application covers distribution transformer, power transformer, special transformer, dry type transformer four major categories.
Distribution transformer, capacity 10 to 2500 kVA, voltage 10 to 35 kV, adopt F class fiberglass covered enameled round copper wire, low voltage side conductor diameter 0.50 to 2.50 mm, high voltage side enameled round copper wire, with fiberglass layer improving insulation strength.
Power transformer, capacity 50 to 1500 MVA, voltage 110 to 1000 kV, adopt F class fiberglass paper covered flat copper wire, width 2.00 to 12.50 mm, thickness 1.00 to 5.60 mm, fiberglass paper total thickness 0.50 to 1.50 mm.
Special transformer, including rectifier transformer, electric furnace transformer, traction transformer, adopt H class fiberglass covered enameled flat copper wire. Dry type transformer, capacity 100 to 2500 kVA, adopt F class or H class fiberglass covered enameled wire, flame retardant low smoke.
3.3 Large Equipment Application
Fiberglass covered wire in large equipment application covers turbo generator, hydro generator, wind generator, rail transit four major categories.
Turbo generator, capacity 100 to 1800 MW, voltage 10 to 27 kV, adopt F class fiberglass covered enameled flat copper wire, stator bar width 8.00 to 16.00 mm, thickness 2.00 to 5.60 mm, fiberglass layer plus mica tape.
Hydro generator, capacity 10 to 800 MW, voltage 6 to 20 kV, adopt F class fiberglass covered enameled flat copper wire, stator bar width 6.00 to 12.00 mm, thickness 2.00 to 4.50 mm.
Wind generator, onshore 1 to 10 MW, offshore 5 to 18 MW, adopt H class or C class fiberglass covered enameled flat copper wire, width 4.00 to 12.00 mm, thickness 1.50 to 4.00 mm.
Rail transit, electric locomotive, metro, EMU traction transformer and traction motor, adopt H class fiberglass covered enameled flat copper wire.
3.4 Special Equipment Application
Fiberglass covered wire in special equipment application covers aerospace, ship, weapon, nuclear power plant, medical five major categories.
Aerospace, flight control motor, servo motor, generator, adopt C class or R class fiberglass covered enameled flat copper wire, fiberglass mica tape composite insulation. Ship, ship propulsion motor, auxiliary motor, adopt H class fiberglass covered enameled wire, waterproof anti salt fog.
Weapon, tank motor, warship motor, missile launch motor, adopt H class or C class fiberglass covered enameled wire. Nuclear power plant, nuclear island safety class motor, control rod drive mechanism motor, adopt C class fiberglass covered enameled wire, radiation life 40 years plus.
Medical, MRI coil, CT slip ring, X ray readout, adopt F class fiberglass covered enameled round copper wire, non magnetization.
4 Fiberglass Covered Wire Bulk Purchasing Specification Parameters
4.1 Conductor Specification
Fiberglass covered wire bulk purchasing conductor specification covers conductor material, conductor cross section, conductor diameter, conductor tolerance four items.
Conductor material, copper TU1 99.97%, copper TU2 99.95%, copper T2 99.90%, aluminum 1060 99.60%, aluminum 1050 99.50%, aluminum 1350 99.50%. Priority select TU1 oxygen free copper, low voltage motor, transformer, home appliance. T2 ordinary pure copper, general motor, home appliance.
Conductor cross section, round wire 0.20 to 25.00 square mm, flat wire width 1.00 to 16.00 mm, thickness 0.50 to 5.60 mm.
Conductor diameter, round copper wire 0.50 to 5.00 mm, diameter tolerance plus minus 0.005 to 0.030 mm. Round aluminum wire 0.50 to 5.00 mm, diameter tolerance plus minus 0.010 to 0.050 mm.
Conductor tolerance, round wire diameter tolerance plus minus 1% to 3%, flat wire width tolerance plus minus 0.05 to 0.15 mm, flat wire thickness tolerance plus minus 0.03 to 0.10 mm.
4.2 Insulation Specification
Fiberglass covered wire bulk purchasing insulation specification covers varnish film system, fiberglass layer thickness, fiberglass layer number, insulation total thickness four items.
Varnish film system, F class 155℃ select PEW, EIW. H class 180℃ select EIW, EIW/AIW composite. C class 200℃ select AIW. N class 220℃ select AIW, PI. R class 240℃ select PI.
Fiberglass layer thickness, single layer 0.10 to 0.30 mm, double layer 0.20 to 0.50 mm, four layer 0.40 to 0.80 mm.
Fiberglass layer number, single layer fiberglass, double layer fiberglass, four layer fiberglass, fiberglass plus mica tape, fiberglass plus film.
Insulation total thickness, round wire varnish plus fiberglass 0.15 to 0.70 mm, flat wire varnish plus fiberglass 0.20 to 0.80 mm. Breakdown voltage greater than or equal to 5000 V/mm, insulation resistance greater than or equal to 1000 MΩ·km, PDIV greater than or equal to 2 times rated voltage.
4.3 Mechanical Specification
Fiberglass covered wire bulk purchasing mechanical specification covers tensile strength, elongation, softness, wear resistance four items.
Tensile strength, copper conductor 200 to 280 MPa, aluminum conductor 70 to 110 MPa, fiberglass layer tensile 2000 to 3500 MPa, fiberglass covered wire overall tensile 250 to 400 MPa.
Elongation, round copper wire elongation 25% to 40%, flat copper wire elongation 25% to 35%, round aluminum wire elongation 15% to 25%.
Softness, round copper wire softness less than or equal to 5 times diameter, flat copper wire softness less than or equal to 10 times thickness, winding without crack.
Wear resistance, fiberglass covered wire wear resistance times greater than or equal to 50, varnish film wear resistance greater than or equal to 50, scratch resistance times greater than or equal to 80.
4.4 Thermal Specification
Fiberglass covered wire bulk purchasing thermal specification covers heat resistance class, thermal stability, thermal shock, thermal aging four items.
Heat resistance class, B class 130℃, F class 155℃, H class 180℃, C class 200℃, N class 220℃, R class 240℃.
Thermal stability, H class 180℃ long term 20000 to 50000 hours, C class 200℃ long term 10000 to 30000 hours, N class 220℃ long term 5000 to 20000 hours, R class 240℃ long term 3000 to 10000 hours.
Thermal shock, H class 180℃ to room temperature 5 times without crack, C class 200℃ to room temperature 10 times without crack.
Thermal aging, H class 180℃ aging 5000 hours, tensile retention rate greater than or equal to 80%, breakdown voltage retention rate greater than or equal to 70%.
5 Fiberglass Covered Wire Supplier Evaluation
5.1 Supplier Qualification Evaluation
Fiberglass covered wire supplier qualification evaluation covers business license, production license, industry certification, quality system four items.
Business license, registered capital greater than or equal to 5 million yuan, production site greater than or equal to 2000 square meters, established years greater than or equal to 5 years.
Production license, national industrial product production license, mandatory certification CCC, voluntary certification CQC.
Industry certification, ISO 9001 quality management system, ISO 14001 environment management system, ISO 45001 occupational health safety system, IATF 16949 automotive industry quality system.
Quality system, incoming inspection, process inspection, finished product inspection, batch traceability, quality analysis report.
5.2 Supplier Capacity Evaluation
Fiberglass covered wire supplier capacity evaluation covers capacity scale, equipment ability, personnel configuration, delivery period four items.
Capacity scale, monthly capacity greater than or equal to 100 tons fiberglass covered wire, annual capacity greater than or equal to 1000 tons.
Equipment ability, fiberglass wrapping machine greater than or equal to 10 sets, enameled machine greater than or equal to 5 sets, varnish film curing furnace greater than or equal to 5 sets, flat wire rolling machine greater than or equal to 3 sets, continuous extrusion production line greater than or equal to 2 lines.
Personnel configuration, technical R&D personnel greater than or equal to 10 people, quality inspection personnel greater than or equal to 8 people, production workers greater than or equal to 50 people.
Delivery period, regular order 15 to 30 days, custom order 30 to 60 days, urgent order 7 to 15 days.
5.3 Supplier Quality Evaluation
Fiberglass covered wire supplier quality evaluation covers quality level, inspection equipment, process control, traceability ability four items.
Quality level, finished product qualified rate greater than or equal to 99%, customer complaint rate less than or equal to 0.5%, return rate less than or equal to 0.1%, batch qualified rate greater than or equal to 99.5%.
Inspection equipment, varnish film breakdown voltage tester, conductor resistance tester, varnish film wear resistance tester, varnish film thermal shock tester, varnish film softening breakdown tester, micrometer thickness gauge, varnish film flexibility tester.
Process control, first article inspection, patrol inspection, last article inspection, key process SPC statistical process control.
Traceability ability, each batch product unique number, raw material traceability, production process traceability, inspection record traceability, traceability response time less than or equal to 24 hours.
5.4 Supplier Certification Evaluation
Fiberglass covered wire supplier certification evaluation covers product certification, international certification, industry certification, customer recognition four items.
Product certification, CCC mandatory certification, CQC voluntary certification, CE European Union certification, UL American certification, CSA Canadian certification.
International certification, ISO 9001, ISO 14001, ISO 45001, IATF 16949, AS9100 aerospace.
Industry certification, power industry certification, railway industry certification, ship industry certification, nuclear power industry certification, medical industry certification.
Customer recognition, domestic and foreign large motor factory supplier, transformer factory supplier, home appliance factory supplier, special equipment supplier, annual order amount greater than or equal to 5 million yuan customer greater than or equal to 5 companies.
6 Fiberglass Covered Wire Procurement Process and Contract
6.1 Procurement Process
Fiberglass covered wire procurement process covers requirement determination, supplier screening, inquiry comparison, technical confirmation, contract signing, order release, acceptance warehousing, payment settlement eight steps.
Requirement determination, technical specification, quantity, delivery, quality requirement, special requirement. Supplier screening, qualification review, capacity evaluation, quality evaluation, price evaluation, transportation evaluation. Inquiry comparison, greater than or equal to 3 suppliers inquiry, technical specification corresponding, commercial term comparison.
Technical confirmation, sample test, small batch trial, process verification, final confirmation. Contract signing, commercial contract, technical agreement, quality agreement, confidentiality agreement. Order release, PO order, delivery confirmation, batch quantity, receiving address.
Acceptance warehousing, batch inspection, appearance inspection, dimension inspection, electrical inspection, mechanical inspection, thermal inspection. Payment settlement, invoice issuance, payment cycle 30 to 90 days, corporate transfer, acceptance bill.
6.2 Procurement Contract Term
Fiberglass covered wire procurement contract term covers technical specification, commercial term, quality term, default term four items.
Technical specification, conductor specification, varnish film system, fiberglass layer number, insulation total thickness, heat resistance class, breakdown voltage, tensile strength, elongation, PDIV.
Commercial term, unit price, quantity, total price, currency, payment method, delivery period, transportation method, trade term FOB/CIF/DDP.
Quality term, qualified standard, inspection method, sampling rule GB/T 2828.1, non-conforming disposal, return exchange term, quality guarantee period greater than or equal to 12 months.
Default term, delayed delivery penalty 0.5% per day, quality non-conforming penalty 5% to 20%, quantity shortage penalty, intellectual property infringement compensation.
6.3 Acceptance Method
Fiberglass covered wire acceptance method covers appearance inspection, dimension inspection, electrical inspection, mechanical inspection, thermal inspection five items.
Appearance inspection, surface smooth, no damage, no impurity, color uniform, wrapping neat, overlap rate 50% plus minus 10%.
Dimension inspection, conductor diameter, varnish film thickness, fiberglass layer thickness, insulation total thickness, outer diameter tolerance plus minus 3%.
Electrical inspection, conductor resistance, insulation resistance, breakdown voltage, PDIV, tanδ, dielectric loss.
Mechanical inspection, tensile strength, elongation, softness, wear resistance, adhesion, rebound angle less than or equal to 5 degree.
Thermal inspection, thermal shock, thermal aging, thermal life, thermal stability, softening breakdown.
6.4 Payment Settlement
Fiberglass covered wire payment settlement covers advance payment, progress payment, final payment, retention money four methods.
Advance payment, 7 to 15 days after contract signing, advance ratio 10% to 30%, wire transfer or acceptance bill.
Progress payment, production completion 50%, 30 days before shipment, payment ratio 30% to 50%, corporate transfer.
Final payment, 30 to 60 days after acceptance warehousing, payment ratio 60% to 80%, corporate transfer or acceptance.
Retention money, 90 to 180 days after acceptance qualified, retention ratio 5% to 10%, one time payment after expiry without quality issue.
7 Fiberglass Covered Wire Application Notes and Future Trends
7.1 Application Notes
Fiberglass covered wire application notes cover seven dimensions, storage condition, transportation protection, winding process, impregnation process, insulation coordination, operation maintenance, safety protection.
Storage condition, temperature -10 to 40℃, humidity less than or equal to 80%, light avoidance, heat avoidance, corrosive gas avoidance, storage period less than or equal to 12 months.
Transportation protection, light loading light unloading, collision avoidance, moisture prevention, rain protection sun protection, pallet transportation.
Winding process, tension 5 to 50 N, winding speed 5 to 30 rpm, bending radius greater than or equal to 2 times wire diameter, sharp angle bending avoidance.
Impregnation process, vacuum impregnation less than or equal to 50 Pa, pressure 0.2 to 0.5 MPa, impregnation time 8 to 24 hours, impregnant 25 or 45 transformer oil.
Insulation coordination, fiberglass covered wire with slot insulation, phase insulation, layer insulation, end insulation coordination, creepage distance greater than or equal to 25 mm.
Operation maintenance, motor temperature less than or equal to 120℃, winding temperature less than or equal to 155℃, vibration less than or equal to 10 g, regular inspection, regular maintenance.
Safety protection, wear insulation glove, insulation shoe, insulation tool, obey electrical safety regulation, prevent electric shock.
7.2 Future Trends
Fiberglass covered wire future development trend embodies five directions, high heat resistance class, high dielectric strength, high mechanical strength, composite insulation, environmental material.
High heat resistance class, develop N class 220℃, R class 240℃, S class 250℃, above 250℃ fiberglass covered enameled wire, satisfy new generation motor and transformer high temperature demand.
High dielectric strength, develop fiberglass mica tape composite insulation, fiberglass film composite insulation, PDIV greater than or equal to 3 times rated voltage, breakdown voltage greater than or equal to 30000 V/mm.
High mechanical strength, develop high strength fiberglass yarn, high strength varnish film composite, fiberglass covered wire tensile greater than or equal to 400 MPa, vibration resistance greater than or equal to 20 g.
Composite insulation, develop fiberglass plus mica tape, fiberglass plus film, fiberglass plus mica plus film, composite insulation high temperature high voltage resistance.
Environmental material, develop solvent free varnish film, water based varnish film, bio based varnish film, recyclable fiberglass covered wire, comply with RoHS, REACH.
8 Summary
Fiberglass covered wire bulk purchasing is the key link for motor factory, transformer factory, home appliance factory, special equipment factory scale production. Fiberglass covered wire product system covers round copper wire, flat copper wire, fiberglass covered enameled wire, fiberglass paper covered wire, fiberglass mica tape covered wire, fiberglass film composite wire eight major categories, heat resistance class B to R six grades, conductor diameter 0.20 to 5.00 mm, width 1.00 to 16.00 mm.
Fiberglass covered wire application field covers small medium motor 0.55 to 315 kW, large motor 1000 to 50000 kW, distribution transformer 10 to 2500 kVA, power transformer 50 to 1500 MVA, turbo generator 100 to 1800 MW, hydro generator 10 to 800 MW, wind generator 1 to 18 MW, aerospace ship weapon nuclear power plant medical special equipment.
Bulk purchasing specification parameter covers conductor specification, insulation specification, mechanical specification, thermal specification four major categories. Supplier evaluation covers qualification, capacity, quality, certification four items. Procurement process covers eight steps, contract term covers four items, acceptance method covers five items, payment settlement covers four methods.
Future development direction includes high heat resistance N class 220℃/R class 240℃/S class 250℃, high dielectric PDIV greater than or equal to 3 times/breakdown greater than or equal to 30000 V/mm, high mechanical tensile greater than or equal to 400 MPa/vibration resistance greater than or equal to 20 g, composite insulation fiberglass mica film, environmental material solvent free water based bio based.
Reference standards: NEMA MW 1000-2018, NEMA MW 43-C, IEC 60317, IEC 60851, GB/T 7672, GB/T 11021, JB/T 4074, JB/T 5331.
Contact Information: E-mail office@cnlpzz.com, WhatsApp 0086-19337889070, Zhengzhou LP Industry Co., Ltd.
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