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

Microscope Image of Fused Connection Using Tube Fusing Process

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

Fusing Schedule Temp (ºF) vs. Time

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

Tube Fuse Operations

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