⚠️ The Problem with Traditional Enamel Wire Testing
PINHOLES & BLISTERS (SPOT) ON WIRE SURFACE
Most Common Problem Face by Enamel Wire Manufacturer
🛑 Consequences
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Defective wire reaches the customer.
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Products fail in the field (motors, transformers, electronics).
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Manufacturer's reputation suffers.
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Shorter life of customers product like fan ,motor ,pump ,transformer
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Customer complaints, warranty claims, and rework costs increase.
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Most Important Trust is lost — and it's hard to win back.
In the traditional method, we typically take out only 30 to 50 meters of wire from a finished spool for lab-based pinhole testing. However, in reality, each spool contains hundreds of thousands of kilometers (lakhs of kilometers) of wire.
But what if a problem occurs somewhere in between production?
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A felt pad wears out…
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A die gets damaged…
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The enamelling line or enamel pump breaks down…
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Dust particles
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Surface damage due to wire touching somewhere
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Wire damage due to friction with pulley because of damage bearings
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Bad enamel
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Or worse, an operator misses it, especially during night shifts when fatigue and inattentiveness are common...
These issues can result in defective enamel coating, which, without online monitoring, gets wound up with the rest of the wire — completely undetected which results in bad or uneven insulation and blisters on wire
MWT-Online High Voltage Pinhole and Blister Detection System
We need an specially design MWT-online High Voltage pinhole and blister detection system that checks every millimetre of wire during production using high voltage pulse and sophisticated sensors for blister detection . This system ensures:
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Real-time detection of any enamel fault.
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Immediate alarms and alerts.
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No dependency on operator alertness or shift timing.
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Full traceability and logging.
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Zero-defect delivery to the customer.
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Every single spool data is saved with its parameters and alarms
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Complete detailed dashboard for easy understanding of of running wire data with graph
✅ The Solution:
🧠 Final Thought
Investing in online pinhole detection is not just about catching defects — it's about protecting your brand, ensuring customer trust, and maintaining consistent quality round the clock, even when no one’s watching.