Enameled copper wire is an essential component of electric motor windings. During motor manufacturing, reliable wire connections are important to the quality and performance of the finished motor.

Wolong Electric Drive Group Co., Ltd. is an established manufacturer in the electric motor and electric drive industry. Its publicly available product information covers a wide range of industrial motors, including multiple series of three-phase induction motors.

For its motor manufacturing applications, Wolong Electric worked with Okay Energy on an oxyhydrogen flame welding solution for enameled copper wire welding.

The application demonstrates how oxyhydrogen welding technology can be used for localized heating and wire connection in electric motor manufacturing.

Customer Profile

Customer: Wolong Electric Drive Group Co., Ltd.
Industry: Electric Motor Manufacturing
Application: Enameled Copper Wire Welding
Process: Motor Winding / Copper Wire Welding and Brazing
Heat Source: Oxyhydrogen Flame
Equipment Supplier: Okay Energy

Wolong Electric develops and manufactures a broad range of electric motor and drive products. Its public product database includes multiple motor series for industrial applications.

With different motor structures and winding configurations, the welding process needs to be matched to the wire size, insulation coating and specific production requirements.

Okay Energy provided an oxyhydrogen welding solution for the customer's enameled wire welding application.

Challenges in Enameled Copper Wire Welding

Enameled wire consists of a copper conductor covered with an insulating enamel coating.

Before the copper conductor can be effectively connected, the enamel coating around the welding area needs to be appropriately treated according to the selected welding process.

For motor manufacturers, several factors are important.

1. Enamel Coating Treatment

The insulation coating around the welding area needs to be treated before or during the welding process.

2. Localized Heating

Motor windings are often compactly arranged. Excessive heat outside the target area can affect surrounding components or insulation.

A concentrated heat source is therefore valuable for localized wire welding.

3. Consistent Copper Wire Connection

The flame position, heating time, temperature and filler material need to be properly controlled to achieve the required joint quality.

4. Production Efficiency

For large-scale motor manufacturing, the welding process needs to balance welding quality, operator convenience and production efficiency.

Okay Energy's Oxyhydrogen Welding Solution

For the Wolong Electric application, Okay Energy uses an oxyhydrogen generator with a dedicated oxyhydrogen welding torch.

The generator produces hydrogen and oxygen through water electrolysis. The gases are supplied to the torch to create an oxyhydrogen flame for localized heating.

During enameled copper wire welding, the operator can direct the flame to the welding area to heat the wire, treat the enamel coating where applicable, and complete the required brazing or welding process.

This configuration is particularly suitable for applications requiring localized and concentrated heating, such as motor winding connections, enameled copper wires and motor lead wires.

Step 1: Position the Enameled Copper Wire

The wires or motor winding leads are positioned and secured according to the production process.

Step 2: Heat the Welding Area

The operator uses the oxyhydrogen torch to heat the target area.

The concentrated flame provides localized heat for the copper wire and welding area.

Step 3: Treat the Enamel Coating

Depending on the enamel material, wire diameter and welding process, the flame can be used to thermally treat the enamel coating around the welding area.

The exact process parameters should be determined through actual welding trials.

Step 4: Complete the Wire Joint

The operator controls flame position, heating time and filler material to complete the copper wire connection.



Why Use an Oxyhydrogen Welding Machine for Motor Enameled Wire?

Concentrated Heat for Localized Welding

Motor winding structures can have limited working space.

An oxyhydrogen torch provides a concentrated flame that can be directed toward a specific welding area, making it suitable for motor winding and copper wire applications.

Suitable for Enameled Wire Welding Applications

Under suitable process conditions, oxyhydrogen flame can be used as part of the enamel treatment and copper wire welding process.

Flexible Equipment Selection

Different motors may use different wire diameters, winding structures and production processes.

Okay Energy can evaluate equipment requirements based on:

• Wire diameter
• Number of wires
• Motor size
• Welding process
• Number of welding stations
• Production volume

On-Demand Oxyhydrogen Generation

Instead of relying on stored fuel gas cylinders, an oxyhydrogen generator produces hydrogen and oxygen from water and supplies the gas to the welding torch as required.

This provides motor manufacturers with an alternative gas supply method for flame welding applications.


From Single Welding Stations to Multi-Station Production

For motor repair, laboratory testing or small-volume production, a compact oxyhydrogen generator can be paired with one welding torch.

For large motor manufacturers with multiple welding stations, Okay Energy can evaluate a centralized oxyhydrogen gas supply system.

The system configuration can be evaluated according to:

Number of machines → Number of welding stations → Gas consumption per torch → Simultaneous usage → Operating hours

This allows oxyhydrogen welding technology to be considered for both individual motor welding operations and larger-scale production environments.

Wolong Electric Customer Case

Wolong Electric has extensive experience in electric motor and drive manufacturing, with publicly available product information covering multiple industrial motor series and applications.

The cooperation between Wolong Electric and Okay Energy demonstrates a practical application of oxyhydrogen flame technology in electric motor enameled wire welding.

For other motor manufacturers, this application may be relevant to processes such as:

• Enameled Copper Wire Welding
• Motor Winding Welding
• Motor Lead Wire Welding
• Copper Wire Brazing
• Enameled Wire Treatment and Welding
• Electric Motor Brazing

The suitability of oxyhydrogen welding should be evaluated according to the actual wire material, diameter, enamel coating and welding requirements.

Okay Energy — Oxyhydrogen Welding Solutions for Motor Manufacturing

Okay Energy is an oxyhydrogen generator and oxyhydrogen welding equipment manufacturer with more than 20 years of industry experience.

For electric motor manufacturers, Okay Energy provides support covering:

Equipment Selection → Welding Torch Configuration → Sample Testing → Process Evaluation → Production Application

If you are looking for an:

Enameled Wire Welding Machine, Enameled Copper Wire Welding Machine, Motor Winding Welding Machine, Electric Motor Brazing Machine or Oxyhydrogen Welding Machine,

contact Okay Energy with your wire samples and welding requirements. Our technical team can evaluate the application and recommend a suitable oxyhydrogen welding solution.