Winding wires — Test methods — Part 3: Mechanical properties

Technical Analysis of the IEC 60851-3:2023 Standard for Mechanical Properties of Winding Wire

The IEC 60851-3:2023 standard, published by the International Electrotechnical Commission, is a key component of the winding wire test method series. It provides detailed technical specifications specifically for mechanical properties testing of winding wire. This fourth edition of the standard incorporates significant technical revisions to the previous version, particularly clarifying distance measurement for adhesion testing.

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Scope of Application and Test Items

This standard specifies five core mechanical property test methods for winding wire: Test 6: Elongation, Test 7: Resilience, Test 8: Flexibility and Adhesion, Test 11: Abrasion Resistance, and Test 18: Thermal Adhesion. These test methods are applicable to various specifications of enameled round wire and flat wire, covering the conductor diameter range from 0.050mm to 2.000mm.>Test ItemsScope of ApplicationMain Test ParametersApplication SignificanceElongation TestAll Winding WiresElongation at Break, Tensile StrengthEvaluate the Deformation Capacity of Winding Wires During StretchingRebound Resilience TestRound Wires 0.080-1.600mm and Larger DiametersSpring Constant, Permanent DeformationDetect the Recovery Performance of Winding Wires After BendingFlexibility TestDifferent Types of Winding WiresMandrel Winding , stretching, quick pull, and strippingEvaluate the winding wire's resistance to cracking during processingAbrasion Resistance TestingEnameled Round WireAbrasion Times, Insulation IntegrityInspect the durability of the insulation layer under friction conditionsHot Bond TestingEnameled Round and Flat WireVertical Bond Retention, Twisted Coil Bond StrengthEvaluate the bonding performance of thermally bonded winding wire

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In-Depth Analysis of Key Technical Requirements

Elongation Test Technical Requirements

The elongation test is divided into two parts: elongation at break and tensile strength. A tensile testing machine that meets precision requirements must be used for this test, and the loading speed must be controlled within an appropriate range to ensure the accuracy of the test results. The standard specifies fixture requirements and specimen lengths for winding wires of varying diameters. Rebound testing equipment specifications: Rebound testing is divided into two test methods based on winding wire diameter: for round wires with diameters between 0.080mm and 1.600mm, a specific spring test apparatus is used; for round and flat wires with diameters exceeding 1.600mm, different test apparatuses are employed. The standard also details the mandrel dimensions and loading procedures.

Comparison of Flexibility and Adhesion Test Methods

Test 8 includes a variety of test methods to suit different application scenarios: Mandrel Winding Test is suitable for evaluating the insulation integrity of winding wire during bending; Tensile Test is for enameled round wire with a diameter exceeding 1.600mm; Jerk Test is suitable for enameled round wire with a diameter up to 1.000mm; Strip Test is used for winding wire with a diameter exceeding 1.000mm.

< No damage to the insulation layer. Quick pull test: ≤1.000mm. Rapidly applied impact load. Insulation layer remains intact. Peel test: 1.000mm. Measurement of the force required to peel the insulation layer. Compliance with specified minimum peel force. Test 18 is a key innovation in the standard, specifically designed to evaluate the performance of thermally bonded winding wire. This test includes two methods: the vertical bond retention test for spiral coils and the bond strength test for twisted coils. The standard specifies detailed requirements for the accuracy of the test equipment, specimen preparation procedures, and evaluation criteria for the results.

For fine wires with a conductor diameter not exceeding 0.050mm, special test procedures are used; for winding wires with a diameter of 0.050mm to 2.000mm, standardized test methods are used. Appendix A provides a calculation method for the bond strength of thermally bonded winding wires, including the calculation of the temperature of twisted coil specimens and the determination of the heating cycle.

Technical requirements for test equipment

The thermal bond test requires the use of a dedicated coil winding machine, twisting device and heating control system. The equipment should be able to accurately control the heating temperature and time to ensure consistency of test conditions. The standard's accuracy requirements for the equipment include temperature control accuracy of ±1°C and time control accuracy of ±0.1s.

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Technical Specifications for Friction Test Methods

Appendix B provides four recommended friction test methods: Test A: Static Coefficient of Friction Test Method, Test B: First Kinetic Coefficient of Friction Test Method, Test C: Second Kinetic Coefficient of Friction Test Method, and Test D: Twisted Pair Friction Test. These methods are applicable to enameled round wires of varying diameters and provide a technical basis for evaluating the friction performance of winding wire during automated winding processes.

The testing equipment must use load blocks made of specific materials, such as synthetic sapphire, to ensure accurate and repeatable test results. The standard details the test specimen preparation requirements, test procedures, and result calculation methods.

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Recommendations for Standard Implementation and Key Quality Control Points

Testing Laboratory Construction Requirements

Implementation of the IEC 60851-3 standard requires the establishment of a qualified testing laboratory equipped with complete testing equipment and trained technicians. The laboratory environment should be controlled under standard conditions of a temperature of 23±2°C and a relative humidity of 50±5% to ensure the accuracy of test results.

Key Quality Control Points

• Equipment Calibration: All testing equipment must be calibrated regularly to ensure measurement accuracy meets standard requirements.
• Specimen Preparation: Specimens must be prepared strictly in accordance with standard requirements to prevent human factors from influencing test results.
• Test Procedure: Follow the test steps specified in the standard to ensure consistent test conditions.
• Result Assessment: Results are assessed based on the acceptance criteria specified in the standard, and a comprehensive quality recordkeeping system should be established.

Technical Update Response Strategies

Compared to the 2009 edition, the 2023 edition of the standard provides clearer instructions for measuring adhesion loss distance for fiber-covered cords and tape-wrapped cords. Implementing organizations should promptly update test procedures and record forms to ensure compliance with the latest standard requirements. It is recommended to establish a standards tracking mechanism to keep abreast of standard updates.

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Industry Applications and Development Trends

The implementation of the IEC 60851-3 standard is of great significance to the manufacturing industry of electrical equipment such as motors, transformers, and reactors. With the development of emerging fields such as new energy vehicles and high-efficiency motors, the requirements for the mechanical properties of winding wire are increasing. This standard provides a technical basis for product quality control, helping to promote technological progress in the industry and improve product quality.

In the future, with the emergence of new materials and new processes, winding wire testing standards will continue to evolve. Relevant companies are advised to closely monitor the development of international standards, actively participate in the formulation and revision of standards, and enhance their competitiveness in the international market.

6Frequently Asked Questions

What is IEC 60851-3:2023 RLV?

IEC 60851-3:2023 RLV — Winding wires — Test methods — Part 3: Mechanical properties is an international standard developed by International Electrotechnical Commission (IEC). IEC 60851-3:2023 RLV contains both the official IEC International Standard and its Redline version. The Redline version is available in English only and provides you with a quick and easy way to compare all the changes between the official IEC...

What does IEC 60851-3:2023 RLV cover?

This standard covers: IEC 60851-3:2023 RLV contains both the official IEC International Standard and its Redline version. The Redline version is available in English only and provides you with a quick and easy way to compare all the changes between the official IEC Standard and its previous edition. IEC 60851-3: 2023...

Who should use this standard?

This standard is intended for organizations, professionals, and stakeholders involved in various industries and sectors. It is applicable to manufacturers, service providers, regulatory bodies, and certification organizations.

What is the latest version of IEC 60851-3:2023 RLV?

The current published version is IEC 60851-3:2023 RLV, published on 2023-08-22. Always check for amendments or pending revisions.

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Test method	Applicable wire diameter range	Test principle	Qualification standard
Mandrel winding test	All specifications	Inspect insulation after winding on specified core diameter	No cracks, no peeling
Tensile test	>1.600mm	Inspect insulation after applying tensile load