Boockmann GmbH
New Setup for
Lubrication of Fine Wire
With HELILUB®
Reliable solvent-free lubrication now available also for fine and ultra fine magnet wire
Issues with Older Versions of Fine Wire Lubrication
- Wire getting trapped under the yarn on heated pulleys causing
kinks,
elongation, and even
wire breaks
- Lubricant quantity not calculable due to drip loss of wax from the heated pulleys
New HELILUB® Setup for Fine Wire Provides
-
Good consistency
Low coefficient of friction even with small lubricant quantities
No kinks
Neither elongation nor wire breaks
No solvent attack to the enamel
Precisely calculable lubrication due to elimination of drip loss
HELILUB® Main Principle
The HELILUBRICATION technique is based on the application of lubricant by an impregnated yarn to the
surface of the winding wire. Correct dosage is adjusted by yarn calibration and the corresponding setting of
the yarn speed relative to the wire speed.
The lubricant from the yarn is extracted and applied to the wire. The friction caused by the speed difference
between the wire and yarn may heat up the wire surface in some cases, and applies and polishes the lubricant to the wire surface.
Lubricant yarn spools
Take-up spool
Motor case
Traverse range and
dancer for the take-up
Drive roll
Application
zone
®
Fine wire HELILUB applicator
Application zone for fine wires
BF002.0512
BE1476/131002
Sitz der Gesellschaft:
Boockmann GmbH
Sonnenstraße 12
97618 Niederlauer
Tel.: +49 (0) 97 08 – 70 46 0
Fax: +49 (0) 97 08 – 5 71
E-Mail: [email protected]
Geschäftsführer:
Gerhard Boockmann
Annedore Boockmann
Dr.-Ing. Kai Boockmann
Handelsreg.: Amtsgericht SW HRB 892
USt-Ident-Nr.: DE 133890654
Web: http://www.boockmann.com
Bankverbindung:
Bank Schilling & Co. AG, Bad Neustadt a. d. Saale
BLZ: 790 320 38
Kto.: 4700 7000
BIC: BSHADE71
IBAN: DE42 7903 2038 0047 0070 00
Zertifiziert nach DIN EN ISO 9001 – ISO/TS 16949
Commerzbank AG Bad Kissingen
BLZ: 793 400 54
Kto.: 672055100
BIC: COBADEFF794
IBAN: DE39 7934 0054 0672 0551 00
Boockmann GmbH
Challenges in Lubrication of Fine Wire
Lubrication of fine and ultra-fine enamelled wire with diameters of 0.02 – 0.1 mm, compared to lubrication of
medium-sized diameters (0.15 - 1mm), is particularly critical. Fine wire is almost always coated with
solderable or even self-bonding enamels. These coatings are very sensitive towards any impact of solvents,
such as swelling and softening or crazing. Oil as a lubricant is easier to apply and does not cause these
issues, but on the other hand does not provide as good friction properties as wax applied correctly. In
contrary to solid waxes, oil at high differential velocity causes high friction resistance. This attributes to the
viscose flow according to the Poisson equation. Sliding on wax does not show this dependency of speed. On
the other hand, a local over-concentration of wax is critical, as windings on the spool may adhere to each
other and cause elongation or even breakage of the wire. Punctual accumulations of wax often appear in
solvent-free lubrication, when wax particles first deposit on the felt at the wire outlet side or on pulleys, then
are carried along by the wire. Besides that, the desired very even and thin coating of 6 to 10 mg/sqm is
difficult to obtain due to the low heat capacity of fine wire, which does not provide sufficient time for
consistent flow and wetting before solidification of the wax.
New String-up Solves Old Problems
On both pulleys, the yarn must run onto the small front flange before the first wire contact. The wire must run
below the first pulley, and above the second pulley. The yarn on both pulleys must leave the pulley at the
larger rear flange before the wire does (see pictures below). This can be achieved by stringing up beginning
at the take up. This is very important in order to avoid the wire running underneath the yarn and getting
elongated or even breaking.
How to correctly string-up the HELILUBRICATOR for fine wire lubrication
Average Quantity and Consistency
If the temperatures of wire and environment are low, distribution of wax may be difficult although it is
considerably better with our new setup and hardly a problem anymore.
®
However, although distribution may not be even, measurements prove that using HELILUB with heated
pulleys provides very precise control of the average amount of lubricant on the wire surface.
If consistency of the coefficient of friction is unsatisfactory, it can be improved by tempering the finished
spools for a few hours at a temperature slightly above the melting point of the wax (M wax or P50/54: about
60 - 70 °C). In many cases, intermediate storage of the spools under a hood on top of the enamelling ovens
will be sufficient. This tempering lets the wax melt and, due to interfacial surface tension between the enamel
and wax, disperse evenly. If the average amount of lubricant applied was correct, sticking of wire windings
will not appear.
BF002.0512
BE1476/131002
Sitz der Gesellschaft:
Boockmann GmbH
Sonnenstraße 12
97618 Niederlauer
Tel.: +49 (0) 97 08 – 70 46 0
Fax: +49 (0) 97 08 – 5 71
E-Mail: [email protected]
Geschäftsführer:
Gerhard Boockmann
Annedore Boockmann
Dr.-Ing. Kai Boockmann
Handelsreg.: Amtsgericht SW HRB 892
USt-Ident-Nr.: DE 133890654
Web: http://www.boockmann.com
Bankverbindung:
Bank Schilling & Co. AG, Bad Neustadt a. d. Saale
BLZ: 790 320 38
Kto.: 4700 7000
BIC: BSHADE71
IBAN: DE42 7903 2038 0047 0070 00
Zertifiziert nach DIN EN ISO 9001 – ISO/TS 16949
Commerzbank AG Bad Kissingen
BLZ: 793 400 54
Kto.: 672055100
BIC: COBADEFF794
IBAN: DE39 7934 0054 0672 0551 00