Profiled Litz Wires for Renewable Energies
Automated Winding Solutions with PACK LitzWire
PACK LitzWire supported a manufacturer of solar and wind power plants in implementing profiled HF litz wires that facilitate automated winding processes and increase the efficiency of inverters and generators.
The Challenge
For a manufacturer of renewable energies, PACK LitzWire worked on optimizing the windings in inverters and generators. The customer's requirement was clear: the litz wires had to be reproducibly processed in large quantities without creating uneven loads or hotspots, and at the same time efficiently handle high AC frequencies.
The profiled HF litz winding is designed for stable layer guidance and consistent quality in automated winding processes and supports efficient series production in renewable energy applications.
The defined layer structure of the profiled HF litz wire contributes to a uniform load on the winding and supports a thermally stable and reproducible design in series production.
Solution Strategy
PACK LitzWire recommended the use of profiled RUPALIT® HF litz wires with a flattened or square cross-section. This profile increased the copper fill factor, stabilized the position in the windings, and facilitated handling in automated winding machines. The fine individual wires reduced skin and proximity effects, which kept the windings thermally stable and efficient.
Result
Thanks to this solution, the manufacturer was able to scale up series production of its inverter and generator windings, maintaining consistent quality, and significantly improving the efficiency of the components. At the same time, the profiled litz wire facilitated the automated manufacturing process, increasing the economic efficiency of production.
RUPALIT® Plus Profil
This solution combines precise outer insulation wrapping with a square or rectangular profile geometry for maximum space utilization. The reinforced insulation offers the highest dielectric strength and reliably protects against voltage breakdowns in the smallest installation spaces.
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