1、NEMA Standards PublicationNational Electrical Manufacturers AssociationNEMA MW 785-2000 (R2011)Simulated Insertion Force Test for Film Insulated Round Magnet WireNEMA Standards Publication No. MW 785-2000 Simulated Insertion Force Test for Film Insulated Round Magnet Wire Published by National Elect
2、rical Manufacturers Association 1300 North 17th Street, Suite 1752 Rosslyn, Virginia 22209 www.nema.org Copyright 2001 by the National Electrical Manufacturers Association. All rights including translation into other languages, reserved under the Universal Copyright Convention, the Berne Convention
3、for the Protection of Literary and Artistic Works, and the International and Pan American Copyright Conventions. NOTICE AND DISCLAIMER The information in this publication was considered technically sound by the consensus of persons engaged in the development and approval of the document at the time
4、it was developed. Consensus does not necessarily mean that there is unanimous agreement among every person participating in the development of this document. The National Electrical Manufacturers Association (NEMA) standards and guideline publications, of which the document contained herein is one,
5、are developed through a voluntary consensus standards development process. This process brings together volunteers and/or seeks out the views of persons who have an interest in the topic covered by this publication. While NEMA administers the process and establishes rules to promote fairness in the
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8、curacy or completeness of any information published herein, and disclaims and makes no warranty that the information in this document will fulfill any of your particular purposes or needs. NEMA does not undertake to guarantee the performance of any individual manufacturer or sellers products or serv
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10、g this document should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given circumstances. Information and other standards on the topic covered by this publication may be available from
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12、ions for safety or health purposes. Any certification or other statement of compliance with any health or safetyrelated information in this document shall not be attributable to NEMA and is solely the responsibility of the certifier or maker of the statement. MW 785-2000 (R2006) Page i Copyright 200
13、1 by the National Electrical Manufacturers Association. TABLE OF CONTENTS Page Forewordii Introduction .iii History .iii Section 1 GENERAL 1.1 Scope 1 1.2 References 1 1.3 Definitions of Terms 1 1.4 Description of Test and Equipment. 2 1.5 Discussion. 6 Section 2 SIMULATED INSERTION FORCE TEST METHO
14、D 2.1 Safety Statement. 9 2.2 Summary of Method9 2.3 Significance. 9 2.4 Apparatus 9 2.5 Test Specimen 11 2.6 Procedure 11 2.7 Report . 11 2.8 Precision and Accuracy 11 2.9 Inspection of Test Equipment . 11 MW 785-2000 (R2006) Page ii Copyright 2001 by the National Electrical Manufacturers Associati
15、on. Foreword This standards publication was prepared by the NEMA Magnet Wire Section Technical Committee and reflects the input of various industries that use magnet wire. All information in this publication is Authorized Engineering Information. NEMA magnet wire publications are periodically review
16、ed by the NEMA Magnet Wire Section and revised as necessary, to keep them current with technological changes. Proposed revisions should be submitted to: Vice President, Engineering National Electrical Manufacturers Association 1300 N. 17th Street, Suite 1847 Rosslyn, Virginia 22209 This standards pu
17、blication was developed by the Magnet Wire Section. Section approval of the standard does not necessarily imply that all section members voted for its approval or participated in its development. At the time it was approved, the Magnet Wire Section was composed of the following members: American Wir
18、e CorporationSandy Hook, CT AXA CablesMonterrey, NL Mexico The Bridgeport Insulated Wire CompanyBridgeport, CT Elektrisola, Inc.Boscawen, NH Essex Group, Inc.Fort Wayne, IN Femco Magnet Wire CorporationFranklin, IN Magnetek Lighting ProductsGallman, MS Nexans Magnet Wire, Inc.Markham, ON Canada PD W
19、ire and CableFort Wayne, IN Rea Magnet Wire Company, Inc.Fort Wayne, IN Southwire Specialty ProductsOsceola, AR Sumitomo Electric Magnet Wire AmericaEdmonton, KY Von Roll IsolaDouglasville, GA The standards or guidelines presented in a NEMA standards publication are considered technically sound at t
20、he time they are approved for publication. They are not a substitute for a product sellers or users own judgment with respect to the particular product referenced in the standard or guideline, and NEMA does not undertake to guarantee the performance of any individual manufacturers products by virtue
21、 of this standard or guide. Thus, NEMA expressly disclaims any responsibility for damages arising from the use, application, or reliance by others on the information contained in these standards or guidelines. MW 785-2000 (R2006) Page iii Copyright 2001 by the National Electrical Manufacturers Assoc
22、iation. Introduction As magnet wire is used to manufacture various electrical devices, particularly electric motors, it is quite often wound on a coil pre-form and then inserted into the proper stator slot through the use of various kinds of coil injection equipment, which provides the mechanical fo
23、rce to place the coil in its final position. The insertion force required to place the coil in its proper position can have a dramatic effect on the quality of the finished electrical device. Excessive insertion forces may be related to excessive magnet wire insulation damage, which can lead to elec
24、trical failures. Past investigation into the factors related to the coil insertion force have shown that it depends upon the dimensions of the magnet wire, the softness or formability of the conductor, and the coefficient of friction and/or the smoothness of the outside surface of the film insulatio
25、n. History Various devices and test methods have been used to measure some of the magnet wire characteristics that affect the coil insertion force independent of one another. Round film coated magnet wire dimensions can be determined using NEMA MW 1000 Test Procedure 3.2.1.1, listed on page 1 of Par
26、t 3. The softness characteristics of various round film coated magnet wire samples (sizes 1430 AWG) can be compared using NEMA MW 1000 Springback Test Procedure 3.7.1, listed on page 5 of Part 3. The coefficient of friction of various film insulated magnet wire samples (sizes 14-44 AWG) can be compa
27、red using the Dynamic Coefficient Test method as described in MW 750. However, the correlation of the various magnet wire test results with manufacturing performance to predict acceptably low coil insertion forces in motor manufacturing operations is difficult and has not always been successful. Als
28、o it is relatively expensive and inconvenient to evaluate various wires on production motor manufacturing equipment. In a paper presented at the 1984 International Coil Winders Association (ICWA) Conference, Schmidt and Knoll described a Simulated Insertion Force Test (hereafter “SIFT“) for magnet w
29、ire that identified differences between various film insulated magnet wires in their ability to be inserted into stators and in the forces associated with this insertion (See 1.6, Ref. No. 4). Test results using the method described were shown to correlate with actual measured coil insertion forces
30、on production motor manufacturing equipment. In a paper presented at the 1985 ICWA Conference, Schmidt and Knoll further explored the effects of test parameters and magnet wire characteristics on “SIFT“ results (See 1.6, Ref. No. 5). Additional test results using the method over a broader range of s
31、izes and types of magnet wire were shown to correlate with measured coil insertion forces while producing several sizes of motors. As a result of the aforementioned presentations, several members of the NEMA Magnet Wire Technical Committee became interested in the test procedure, and in 1986 a decis
32、ion was reached to conduct a round robin test series among four technical committee member companies to determine if the “SIFT“ was capable of differentiating magnet wire construction in terms of insertion force. The results of the round robin testing were published in a paper presented by Schmidt a
33、nd Scherrer at the 1987 Electrical/Electronic Insulation Conference (E/EIC) (See 1.6, Ref. No. 6). At that time it was determined that the “SIFT“ could indeed differentiate between wire samples, but there were differences in the level of test values between different test fixtures that could be attr
34、ibuted to dimensional or other design characteristic differences between test fixtures. MW 785-2000 (R2006) Page iv Copyright 2001 by the National Electrical Manufacturers Association. In an effort to resolve previously mentioned differences in simulated insertion force between test fixtures, a seri
35、es of four test fixtures were produced in one machine shop. The results of this testing were published in a paper presented by Schmidt and Scherrer at the 1989 E/EIC (See 1.6, Ref. No. 7). It was concluded that three of the four test fixtures showed no significant difference in test results when tes
36、ting like wire samples. Furthermore, it was also demonstrated that the statistically higher “SIFT“ values attributed to the one test fixture of the four that did not agree with the others could be attributed to a slightly smaller dimensional opening in the test fixture exit hole. The 1989 paper also
37、 presented some test data showing differences in simulated insertion force between several different kinds of slot liner material. The test results from this paper and previous papers illustrated how the “SIFT“ can evaluate the effects that various characteristics of magnet wire have on insertion fo
38、rces. Because of these unique capabilities, the NEMA Magnet Wire Section Technical Committee decided to publish the test procedure as NEMA Authorized Engineering Information. As a result of the rather rigorous test program that was followed in developing and evaluating the “SIFT,“ a great deal of in
39、formation is available concerning the test procedure itself and the various wire test properties and other factors that affect the results. The primary advantage of this particular test is its ability to predict acceptable coil insertion performance once acceptable “SIFT“ standards have been determi
40、ned for a given stator coil injection process. MW 785-2000 (R2006) Page 1 Copyright 2001 by the National Electrical Manufacturers Association. Section 1 GENERAL 1.1 SCOPE This standards publication describes a method and the equipment used to determine the simulated insertion force of film insulated
41、 round magnet wire for wire sizes 1428 AWG. 1.2 REFERENCES National Electrical Manufacturers Association 1300 N. 17th Street, Suite 1847 Rosslyn, Virginia 22209 NEMA MW 1000 Dimensions Test Procedure, Clause 3.2.1.1 NEMA MW 1000 Springback Test Procedure, Clause 3.7.1 NEMA MW 750 Dynamic Coefficient
42、 Test Method, Section 2 A Simulated Insertion Test for Magnet Wire, Schmidt, Paul J. and Knoll, Alan H., Proceedings of the 1984 ICWA Coil Winding Exposition, page 83. Effects of Test Parameters and Magnet Wire Characteristics on Simulated Insertion Test Results, Schmidt, Paul J. and Knoll, Alan H.,
43、 Proceedings of the 1985 ICWA Coil Winding Exposition, page 127. Simulated Insertion Test Method Round Robin Results, Schmidt, Paul J. and Scherrer, Everett J., Proceedings of the 1987 Electrical Electronics Insulation Conference, page 55. Results from Continued Interlaboratory Simulated Insertion (
44、“SIFT”) Round Robin Testing, Schmidt, Paul J. and Scherrer, Everett J., Proceedings of the 1989 Electrical Electronics Insulation Conference, page 68. 1.3 DEFINITIONS OF TERMS This document contains a number of terms peculiar to the magnet wire and electric motor industry. The following definitions
45、are provided in an attempt to promote a better understanding of the information in this publication. coefficient of friction: A term relating to the slipperiness of a surface. Generally it is a dimensionless coefficient relating the force required to start (static) or sustain (dynamic) movement betw
46、een two surfaces to the force being exerted to hold the surfaces together. COFForceNormalForce=formability: A magnet wire property relating to the ease with which the wire may be shaped into a wound form. This property is related primarily to the metallurgical softness or state of anneal of the cond
47、uctor. Hard drawn wire that has not been annealed exhibits high yield and tensile strength and is springy and difficult to form. injection or insertion: The physical act of placing preformed coil windings into the proper slots in a stator through the use of mechanical force. Force Normal Force vMW 7
48、85-2000 (R2006) Page 2 Copyright 2001 by the National Electrical Manufacturers Association. insertability: A term relating to the ease with which a wire sample may be wound on a coil preform and then inserted into the proper slot in a motor stator. Generally this property depends on the softness of
49、the conductor and the coefficient of friction of the outside surface of the magnet wire. However, the relationship between the outside diameter of the conductor, combined with the number of turns required for the winding and the size of the stator slot, is also a critical consideration. preform or coil preform: With respect to motor manufacturing, a particular part of magnet wire winding equipment that the magnet wire is initially wound upon to provide a series of winding turns containing the proper length of magnet wire and correct physical winding dimens
