High-Speed Camera Monitoring for the Highest Quality Standards in Litz Wire Production
Our high-frequency litz wires (HF litz wires) are indispensable in demanding applications within the electrical industry. However, particularly when insulating with yarns or films, minimal defects can occur that compromise safety and functionality. To proactively solve this challenge, we rely on state-of-the-art high-speed camera monitoring. This technology detects even the smallest irregularities in real-time and thus guarantees consistently high product quality at the highest technical level.
The Challenge
In many production processes, HF litz wires are insulated with fine materials such as natural silk or special films. However, as an organic material, natural silk is subject to dimensional fluctuations, which complicates precise control of the insulation. Without gapless monitoring, "open spots" can occur – areas where the insulation is not completely closed or films do not overlap optimally. Since these defects can impair the electrical reliability of the end product, a conventional testing process is often insufficient to ensure the required zero-defect rate.
The integrated high-speed camera captures the insulated HF litz wire during the ongoing process and monitors the yarn or film overlap in real-time – for gapless documentation and immediate reaction to deviations.
Solution Strategy
We have revolutionized our production process by integrating high-speed camera technology. This system monitors insulation in real-time, detecting even the slightest deviations in film overlap or yarn defects. By providing immediate video monitoring and continuous logging of every centimeter of the litz wire, we can correct deviations instantly and guarantee seamless quality assurance. Especially when processing natural silk, this allows us to proactively compensate for dimensional fluctuations. The result for our customers: A forward-looking production technology that ensures maximum process reliability for every application.
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Product Manager
Internal sales team