Foreword: This article reviews the definition, characteristics, and analysis of the industry chain of the enameled wire industry, as well as the development status of domestic and foreign enameled wire, future development direction and domestic enameled wire market demand dynamics, and puts forward some problems existing in the current enameled wire industry in my country.
Keywords: enameled wire industry, market demand, development direction
1、Introduction to China's enameled wire industry
1.1 Definition and classification of enameled wire industry
Enameled wire is coated with a layer of insulating varnish on a high-purity, high-conductivity conductor.
Classification of enameled wire: General purpose enameled wire (ordinary wire): Mainly used for winding wires in general motors, electrical appliances, instruments, transformers, etc., such as: polyester enameled wire, modified polyester enameled wire.
Heat-resistant enameled wire: It is mainly used for winding wires in working places such as motors, electrical appliances, instruments, and transformers that work in a temperature environment of 180°C and above. Such as: polyesterimide enameled wire, polyimide enameled wire, polyesterimide/polyamideimide composite enameled wire.
Special-purpose enameled wire: refers to the enameled wire with certain quality characteristics, and is used for winding wires on specific occasions. Such as: polyurethane enameled wire (direct solderability), self-adhesive enameled wire, anti-corona enameled wire.
1.2 Characteristics of the enameled wire industry
With the continuous progress of society and the continuous development of industry, enameled wire has a very broad application field and has become an indispensable main supporting raw material for products such as motors, electrical appliances, household appliances, electronics, communications and transportation, especially in recent years. The rapid development of household appliances, the advancement of electronic technology, and the rise of the communications industry have provided new space for the application of enameled wires, adjusted the application proportions in various fields, and will also put forward higher and newer technical requirements for enameled wires, and adjust enameled wires. The proportion of the structure. After joining the WTO, the enameled wire industry will face competition in the domestic and international markets, which adds a layer of thinking and pressure to the leaders of the enterprise.
1.3 Industry chain analysis of enameled wire industry
Enameled wire products belong to the basic material industry that provides supporting materials for the motor, electrical appliances, home appliances, communications, electronic information, instrumentation, power tools, automobiles and other industries. It is a long-term product with many downstream industries. The upstream industries of enameled wire mainly include copper, aluminum, insulation varnish and other industries.
2、Prospects of relevant policies in the enameled wire industry
2.1 Development Trend of National "Eleventh Five-Year" Industrial Policy
China's wire and cable industry’s "Eleventh Five-Year" development plan requires that the country’s wire and cable industry and its mid- to long-term development direction are taken from a scientific development point of view, and the coordinated development of environmental protection, safety, and economy is emphasized, and people-oriented, and focus on the key tasks and development goals of the industry’s development. , And grasp the major issues in the "Eleventh Five-Year Plan" and mid- to long-term development, put forward effective development ideas, and actively promote the technological progress and sustainable development of the industry.
2.2 Policy trend of enameled wire industry
In the "Eleventh Five-Year Plan", the state puts forward the goal of "building a resource-saving and environment-friendly society", and requires "speeding up the technological transformation of energy saving and consumption reduction of enterprises, and implementing high-consumption, heavy-polluting, technologically backward processes and products. Mandatory elimination system".
Not long ago, the National Development and Reform Commission launched the ten key energy-saving projects proposed in the "Medium and Long-term Special Plan for Energy Conservation", and made detailed arrangements for the energy-saving projects of the motor system: "Energy-saving transformation of the motor system, improved operation efficiency, reasonable matching, and accelerated the elimination of backward and low-quality projects. High-efficiency motors, promote high-efficiency and energy-saving motors; promote variable-frequency speed regulation and energy-saving technologies, and use variable-frequency speed regulation and energy-saving measures for general mechanical systems such as fans, pumps, and compressors. During the "Eleventh Five-Year Plan" period, the operating efficiency of the motor system will be increased by 2 Percentage points to form an annual power saving capacity of 20 billion kilowatt-hours.
3、The current development history of China's enameled wire industry
3.1 The development history of China's enameled wire industry
After decades of development to 1980, the national enameled wire output was only 50,000 tons. Although there are many manufacturers, there are about 500, but the production scale is extremely small. In the 1960s and 1970s, as the leading manufacturer of enameled wire industry-Shanghai China The annual output of the electric plant was only about 3,000 tons. At that time, the Fuzhou Wire Factory (the predecessor of Chase Company) had an annual output of less than 1,000 tons of enameled wires. All the enameled wires that China needs for other varieties rely on imports, and its output accounts for only 4.55% of the global output, which is less than 5%.
Since the early 1980s, China has entered a market economy and implemented an open policy. 21 companies in my country have successively introduced 155 enameled wire production lines from Austria, Japan, Italy and Taiwan, and introduced more than 620 enameled wire machines and inspections. The total production capacity of these instruments is more than 250,000 tons. The introduction of these equipment has the current international advanced level. Among them, the equipment produced by Austria MAG company accounts for the most, accounting for more than 80%, which makes my country's enameled wire industry product structure, equipment level and manufacturing technology The rapid improvement, approaching or reaching the international advanced level, has greatly shortened the gap between my country and the international enameled wire industry. With the rapid development of my country's household appliance industry, electronic information, and communication industries, the scale of enameled wire production enterprises has expanded rapidly, with an annual output of several thousand tons to 10,000 tons. Old companies are constantly being eliminated, new companies are constantly being produced, and a new type of enameled wire industry has basically taken shape in our country. From the perspective of product structure, quality and market demand scale, it basically meets the demand for enameled wire in emerging industries such as domestic home appliances.
3.2 Analysis of domestic enameled wire market demand
Enameled wire is an indispensable main supporting raw material for products such as motors, electrical appliances, household appliances, electronics, communications and transportation. Now we will conduct a statistical analysis on the demand profile of enameled wire in major industries.
⑴Small and medium-sized motors.
Small and medium-sized motors are widely used in equipment requiring electric motors as power sources such as fans, compressors, rolling mills and electric vehicles; radiation-resistant motors used in nuclear power plants, new, high-speed, and heavy-duty locomotive traction motors; medium-sized high-voltage motors with full fins And variable-frequency speed-regulating motors will become the key development products during the "10th Five-Year Plan" period. Motor output was 37.616 million kW in 2000; 37.548 million kW in 2001. According to market analysis, during the "Tenth Five-Year Plan" period, the demand for small and medium-sized motors will remain at 45-60 million kW, and the amount of enameled wire used for small and medium-sized motors will be 40,000 to 50,000 tons per year. With the development of motor miniaturization and lightweight technology, enameled wire products of class B and below will gradually be replaced by enameled wire products of class F, H and above, which provides a broader market prospect for high-grade enameled wires.
⑵Electrical tools.
Power tools are an industry that has sprung up in recent years, especially the increase in exports. With the improvement of people's living standards, various electric tool products are used in homes. The total output of power tools in 2000 was 43 million units, and 37.86 million units were exported; in 2001, the total output was 63.64 million units and 56 million units were exported. The export destination is mainly developed countries. Calculated with 5k different enameled wire, the consumption in 2001 was 31,820 tons.
⑶Household appliances.
The development of the home appliance industry in the 1990s has made the consumption of magnet wires exceed the annual consumption of magnet wires for motors and transformers, and has become the largest user of magnet wires. According to statistics, in 2001, it produced 18.26700 air conditioners, 12.784 million refrigerators, 3.84 million freezers, 12.5716 million microwave ovens, 10.1 million vacuum cleaners, 76.616 million electric fans, 14.429800 washing machines, and 3.6615 million range hoods. station. The development of household appliances has led to the development of enameled wires. Calculated from the above main products, the annual consumption of enameled wires has exceeded 140,000 tons. Among them, refrigerators, freezer refrigeration compressors (each using 0.85kg enameled wire), air-conditioning refrigeration compressors (each Use 1.5kg enameled wire), air conditioner plastic-sealed motors (each uses 0.5kg enameled wire), drum washing machine motors (each uses 0.5kg enameled wire), and vacuum cleaner motors (each uses 0.4kg enameled wire) all use special enameled wires.
⑷Automobile and transportation.
The rapid development of the automobile industry has led to an increase in the demand for electromagnetic wires for automotive electrical appliances. Generators, various motors, solenoid valves, fans, coils, and audio equipment in automobiles all require electromagnetic wires. According to reports, a high-end car needs electromagnetic wires. There are more than 40 places where electromagnetic wires are used. The requirements are not exactly the same. There are fine wires, high-voltage wires, high-temperature resistant wires, etc. Not only are the electromagnetic wires used in each newly produced car, but also a large number of car repairs and maintenance require electromagnetic wires in the same fashion. line. During the "Ninth Five-Year Plan" period, the total domestic demand for automobiles was 11,300,000-11.6 million, and the annual demand was from 1.6 million to 3 million. The demand for high temperature resistant electromagnetic wires for automotive electrical appliances is conservatively estimated to be 2400-4500 tons. In 2000, the total demand for automobiles was 2.52 million, and the number of vehicles held was 17.97 million. In 2001, the total demand for automobiles was 3.51 million, of which the demand for cars was 1.5484 million, and the number of vehicles was 19.61 million. The amount of high temperature resistant electromagnetic wire is 15,000 tons. The largest use of electromagnetic wire in automotive electrical appliances is the high temperature resistant electromagnetic wire of 180 and above. With the update of technology, the commonly used 155 electromagnetic wire will definitely be used by 180 and 200. Class replacement, such as: solenoid valve, ignition coil, starter motor, oil pump motor, ABS motor, generator, etc., so that the demand for high-temperature electromagnetic wires for automotive electrical appliances is greater. With the development of the transportation industry, the electrification and air conditioning of trains and locomotives, the motors and air conditioners used all use high temperature resistant and special electromagnetic wires. According to reports, there are 50,000 motors in operation across the country. If 10,000 motors are repaired every year, if each unit uses 350-400kg enameled wire, the amount of enameled wire used per year exceeds 5,000 tons. Today, when environmental protection is getting more and more attention, the scooters and motorcycles used in the streets and alleys emit a lot of exhaust gas and are strictly restricted. Therefore, in the future, they will be gradually replaced by electric scooters, and electric flat motors will be used. The high-temperature self-adhesive enameled wire, the quantity is also very considerable.
⑸Frequency conversion motors and other special motors.
The development of frequency conversion technology has brought about the technological innovation of household appliances. The use of frequency conversion technology has brought about the technological innovation of household appliances. The use of frequency conversion technology to produce frequency conversion air conditioners, frequency conversion refrigerators and frequency conversion washing machines can achieve numerical control, high efficiency and energy saving. The purpose of low noise and cost reduction. In the special motor industry, the application of frequency conversion speed regulation technology is more extensive, and its biggest advantage is energy saving and reliability. The frequency conversion speed regulation can save about 25-35% of the electric power of the motor, which is a big energy-saving spring. The popularization and development of variable frequency motors have their own inherent advantages and are irresistible. Therefore, variable frequency speed regulation has broad application prospects in metallurgy, mining, petroleum, petrochemical, machinery, light industry, building materials, medicine, papermaking, railways, transportation, chemical industry, elevators, home appliances and other fields, and will gradually replace DC speed regulation. , Is one of the top ten high-tech promoted in my country. With the popularization and development of variable frequency motors, winding wires suitable for it will face broad market opportunities. According to industry experts, the anti-corona magnet wire is a product that must be promoted in the first two decades of the 21st century, and its development prospects are very promising. The wire and cable industry regards the anti-corona magnet wire project as one of the key projects in the "Tenth Five-Year Plan". According to industry statistics: in 2001, the demand for anti-corona magnet wires in my country's motor industry was about 8,500 tons, and its demand is rapidly expanding, and it is expected to reach 18,000 tons by 2009. At present, the product is completely dependent on imports, and only one or two companies in the United States have developed mature products in the world, and other countries such as Germany and Japan are studying. Traction motors, metallurgical motors, hoisting motors, explosion-proof motors, DC motors, mining motors, etc. due to special occasions, large load, high power, especially the chance of overload, generally use F, H class or even higher heat For these motors, in order to ensure reliable operation, the thermal class of the selected winding wire is generally specified to be 1-2 higher than the thermal class used by the motor. Therefore, in industrially developed countries, the heat-resistant enameled wires of F, H and above developed rapidly from the 1980s to the 1990s. There is indeed a gap in the enameled wire industry in my country, but it also indicates a development direction. In general, in recent years, the development of the motor and transformer industries has been stable, with no major fluctuations, while the development of the household appliance industry has brought strong vitality to the enameled wire industry. The enameled wire used has greatly exceeded that of other industries, and basically all are F, H and above enameled wire, this is one of the important reasons that China's enameled wire industry has maintained rapid development for many years. The development of household appliances has also driven the development of enameled wire varieties. The rise of frequency conversion motors has promoted the development of special enameled wires. , Microwave oven has promoted the development of heat-resistant self-adhesive enameled wire, and electric bicycles require self-adhesive enameled wire. The improvement of vacuum cleaner performance requires high-grade enameled wire to be equipped with it. The demand for enameled wire for large-screen color TV deflection coils has not yet met the demand for enameled wire harnesses will increase. It can be seen that, due to the high proportion of domestic products with low technical content, high-level products cannot meet the needs, the development of composite coating enameled wire will be a mainstream development direction
3.3 Technology development status of China's enameled wire industry
⑴Thinning
Due to the miniaturization of electrical products, enameled wires used in camcorders, electronic clocks, miniature relays, automobiles, electronic meters, washing machines, TV components, etc. are all developing in the direction of thinner diameter. For example, when the high-voltage package for color TV, the enameled wire for integrated line output flyback transformer, originally adopted the segmented slot winding method for insulation, the specification range is 0.06～0.08 mm and all are thickened insulation. Now the design is changed to flat winding method. After the insulation winding structure, the wire diameter is changed to 0.03～0.04 mm, and the thin varnish layer is enough.
⑵Lightweight
According to the design requirements of electrical products, the lightweight method used in some less demanding occasions is to select materials to be lightweight instead of thinner, such as some low-demand micro motors, speaker voice coils, and artificial cardiac pacemakers , Microwave oven transformers, etc., the products are processed with enameled aluminum wire and enameled copper-clad aluminum wire. Compared with our ordinary enameled copper wire, these materials have the advantages of light weight and low price, but also have processing difficulties and poor weldability. , Shortcomings such as low tensile strength. The microwave oven transformer alone is quite impressive based on our country’s annual production of 10 million units.
⑶Self-bonding
The special performance of self-bonding enameled wire is that it can be wound without skeleton coils or without impregnation. Mainly used for color TV deflection, speaker voice coil, buzzer, micro motor, electronic transformer and other occasions. According to the different combination of primer and top coat, different materials also have different heat resistance grades, which can meet different application occasions. This variety has considerable usage in electro-acoustic and color TV deflection.
⑷High tension characteristics
Due to the thinner diameter of enameled wire, the market demand for micro wires is increasing. Considering the characteristics of small wire in the winding process that the safety tension is small and the winding is easy to break, in order to improve the safety tension and take into account other characteristics, consider the use of processing materials The alloy copper mixed with other components greatly improves the safety tension. At the same time, the decrease in conductivity is not too large. For example, the safety tension of HTM wire from Japan Tote Corporation is 125% of that of ordinary copper wire, the conductivity is 93%, and the wire specification is 0.015～0.10mm.
⑸Consistency of winding parameters
For the occasions where the resistance, inductance, distributed capacitance and other parameters of the wound coil have batch consistency requirements, the conductor tolerance and outer diameter tolerance of the enameled wire can not only meet the standard but must be strictly controlled to reduce the tolerance zone. This is for the production of enameled wire Technology and production equipment have put forward higher requirements. The general production technology and domestic enameled wire equipment are still unable to meet this production requirement.
⑹High frequency and high voltage resistance characteristics and high Q value characteristics
In addition to the development of electrical products in the direction of miniaturization, more attention should be paid to meeting multiple needs and adapting to multiple environments. For example, for enameled wire, increase the frequency of use, the high peak-to-peak voltage between the winding coil wire and the wire, and the assessment of the winding coil is to test the high-frequency inter-turn withstand voltage and so on.
⑺Thermal fuse
Because the special outer insulating layer of thermal fuse enameled wire has thermal fuse protection characteristics, it is widely used in power transformers and is mostly used to wind the primary coil. When the coil overcurrent or the temperature rise exceeds a certain value, the outer insulating layer of the enameled wire melts quickly, causing partial short-circuit protection of the power supply, so as not to damage the heart of the machine.
⑻Heat resistance, refrigerant resistance, direct solderability
For now, the mainstream of domestically produced products of this type are: Heat-resistant wire: modified polyester enameled wire F grade; polyester imide enameled wire: H grade; refrigerant resistant wire: polyester imine/polyamideimide C grade; direct welding wire: polyurethane enameled wire B, F grade
The above-mentioned products have basically matured and are gradually beginning to occupy the dominant position in the use of household appliances. However, as far as the insulating paint is concerned, the domestically produced paints for the above-mentioned products have more or less problems to be solved, such as: resistance The wet crack resistance of hot enameled wire, the wet crack resistance of polyurethane enameled wire, self-lubricating property, solder residue-free, softness, etc. are quite different from those of similar foreign products and need to be improved.
⑼Alienation, large volume occupancy rate
In the coil winding process, there is a problem of the volume occupancy rate of the enameled wire in the skeleton. The maximum occupancy rate of the round wire winding is 91%. The development of electrical products in the direction of miniaturization is bound to require the components to be miniaturized and improved. The volume occupancy rate has become one of the issues that must be considered in the coil design. Commonly used methods include the use of square wires and rectangular flat wires to increase the volume occupancy rate up to 96%. They are widely used in high-power speaker voice coils. In addition, in the use of LITZ wire to wind the switching power supply transformer, due to the thicker diameter of the LITZ wire, its volume occupancy rate is small.
⑽Non-magnetic and highly conductive
The copper materials we use in the production of enameled wires contain more or less a small amount of magnetic elements such as iron, nickel, cobalt and other impurities, and some applications need to eliminate these interferences or obtain high conductivity. Therefore, more copper materials are proposed. High requirements require not only good processing performance but also good electrical performance. In this regard, single crystal copper has been applied to some high-fidelity digital transmission and some precision instruments in foreign countries.
4、Problems facing the development of China's enameled wire industry
At present, my country's magnet wire production (including enameled wire and winding wire, the ratio is 85:l5) is increasing at a rate of 7.6%, becoming the world's largest magnet wire production country, has exceeded 300,000 tons, but due to the quality of products produced in my country Not high, still dominated by B-grade polyester thread, accounting for about 80% of the total, far behind the needs of the home appliance industry and other special occasions. The actual production volume of special enameled wire accounts for about 10-20%: the development of enameled wire technology is based on different application fields, with different focuses. Under the premise of continuously improving the temperature resistance level of enameled wire, the enameled wire used in the household appliance industry will focus on "environmental protection, Continuous technological innovation is required for high efficiency, energy saving and frequency conversion. The application of heat-resistant enameled wires of class F, H and above is related to the miniaturization and lightweight technology of motor development. The varieties of heat-resistant enameled wires of class F, H and above are mainly modified polyester, polyester imine, polyamide-imide, aromatic polyimide and related composite enameled wires.
Our country has begun to pay attention to the development of F and H enameled wires in the early 1970s. The efforts to adjust the structure of winding wire products for more than two decades are actually efforts to increase the proportion of F and H enameled wires from many aspects. By the 1990s, initial results have been achieved. According to investigations by industry associations, some factories in my country with better technical conditions have achieved the goal of focusing on F and H grade products. For example, Fuzhou Datong F, H grade and above products account for 60% of the total output, and Tongling Jingda's products are almost all H grade and above varieties. However, the vast majority of products in my country are still single grade B polyester enameled wire. At present, there are still many problems, such as the small scale of the enterprise, the single variety, the high energy consumption of equipment, serious pollution, the slow speed of domestic equipment, felt painting, low production efficiency, and small size bobbin take up.
5、Concluding remarks
In the field of enameled wire, a foreign professional manufacturer (Daiichi Denko) (OPTEC-DAIICHI-DENKO) has long been the number one in Japan for a long time. In 2002, Sumitomo Electric signed an agreement with Daiichi Denko to start the integration work. In October 2002, the production and sales of the two parties were unified worldwide and the "Sumitomo Electric WINTEC" company was established. Sumitomo Electric's shares account for 80%. Sumitomo Electric's integration in the above three areas has one thing in common: reducing production capacity, closing duplicate factories, scrapping redundant production equipment, and reducing surplus personnel; there is a common goal: to ensure Japan's number one in all fields , The world's leading position.
Japan's economy is stagnant and domestic demand continues to shrink. For Sumitomo Electric's operations, it can be said to be difficult in the world. In order to survive in the 21st century, Sumitomo Electric continues to develop diversified operations at home and abroad, and at the same time, it continues to transform the current industrial structure, including splitting and combining, and upgrading. Other manufacturers in Japan also use the same method to speed up the pace of integration. For example, in the field of high-voltage cables in Japan, for a long time, Furukawa Electric, Sumitomo Electric, Fujikura Electric Wire, Hitachi Electric Wire, Mitsubishi Electric Wire, and Showa Electric Wire competed in the Warring States Period; in the near future, it will become three. The powerful Three Kingdoms era. At present, the enameled wire industry around the world must firstly through business integration, adapt to changes in the environment, and continuously improve operating efficiency; secondly, through technological development, strive to develop products that meet future needs and increase the added value of the business. This is the way to The key to success tomorrow.
