Gentlemen:

Two years ago, we announced the development of the “Fusion System” which would detect beads and insulation weakness (faults) on magnet wire at coating speeds. This followed years of success with bead or insulation fault systems. There were compelling reasons to combine the two.

Despite the “recess” in the magnet wire business, we have been busy installing these systems, worldwide, across a wide segment of the industry. The reason is simple. They enable your operators to make better wire with reduced scrap and returns. How?

1.  A clear picture of the running bead count and HVC fault count is graphically displayed to indicate the margin of safety between current conditions and alarm levels. A typical system does this for up to 24 lines.

2.  In most cases, corrective action can be taken to tweak the process when dangerous trends are developing. If the process cannot be corrected, at least a scrap spool can be put in place even before the wire crosses the good/bad threshold.

3.  Within a short time, the operator will equate excess beads or faults to previous experience and take immediate corrective action. The learning process continues with each event.

The first system is usually installed to salvage a customer who has had repeated surface problems. Initially, the motive is to prevent the shipment of bad wire to this customer while expecting more scrap. Invariably, the system helps improve the wire to the extent that the customer is happy and with less scrap.

Most of the larger magnet wire producers, worldwide, have become believers to the extent that the vast majority of our orders are now repeats.

No surprise that an increasing number of motor and transformer manufacturers now recommend (in some cases, require) the use of these systems to make their wire.

We would welcome an invitation from your company to set up an in-plant demonstration of this system on one line. No disruption of production will occur as the system can be set up and removed without stopping the line. Of course, there is no cost or obligation.

Sincerely:

LEAR ENGINEERING CORP