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Mastering Litz Wire: Winding and Welding Techniques for Enhanced Performance

Litz wire is constructed from individually insulated copper strands that are twisted together. Its specific design is intended to reduce the skin effect and proximity effect losses in applications where high frequency or high current is used. These reductions lead to increased efficiency of the wound component, making litz wire an appealing choice for both coils and motors.

While its usage is relatively easier with coils, the complexity of production operations increases when motors are considered, and the challenges in profiling, winding, and soldering processes can be obstacles to its use and adoption. These challenges require careful attention and specific methods to overcome.

This presentation commences with an introduction to Litz wire by Mr. Benjamin Braggins. He will explore various types of Litz wire, discuss VDE and UL certifications, cover coating options such as serving and taping, and provide valuable insights into the best design practices for electric motors and magnetic components. Mr. Rajasekhara will continue highlighting the main obstacles in winding and welding processes that involve litz wire and how they can be overcome. From how to control tension to get perfect layering despite the variable morphology of the wire, how to avoid wire untwisting, up to how to get clean and solid wire/terminal welding points with wire with high thermal class and composed of many tiny, twisted wires.

This insightful look into litz wire's potential and challenges will shed light on its growing importance in various industries. The aim of this presentation is to demystify the complexities of litz wire winding and welding processes, offering practical solutions. Ultimately, this exploration may pave the way for broader adoption of litz wire, leveraging its unique attributes to enhance efficiency in a wide range of technological fields.

The insights from this presentation will benefit professionals involved in the design and manufacture of electrical coils and motors. These individuals often grapple with the intricacies of litz wire in their daily operations and look for best practices to use it efficiently. Moreover, industry decision-makers and those contemplating the adoption of litz wire for their motor projects will also find value in these insights.


Benjamin Braggins

Elektrisola Inc.

Project Engineer

Kumar Rajasekhara

Marsilli North America


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