Wavewound

Wavewound refers to a phenomenon that can occur in certain types of coiled electrical components, such as transformers, inductors, and motor windings. It describes a condition where the insulation material between adjacent turns of wire becomes damaged or degraded, leading to unintended electrical connections. This damage can be caused by various factors, including mechanical stress during manufacturing, thermal cycling, or exposure to environmental contaminants.

When wavewound insulation breaks down, it can create short circuits between individual turns of wire. This can have several detrimental effects on the performance and longevity of the component. Internally, these shorts can lead to increased power loss due to eddy currents and resistive heating. This can result in a rise in temperature, further exacerbating the insulation degradation and potentially leading to a runaway failure.

In transformers, wavewinding can disrupt the magnetic coupling between windings, reducing efficiency and potentially causing output voltage irregularities. For inductors, it can alter inductance values and increase series resistance. In motor windings, it can lead to uneven magnetic fields, reduced torque, increased vibration, and eventually motor failure. Identifying and preventing wavewinding often involves careful control of manufacturing processes, including winding tension, insulation application, and curing procedures, as well as quality control inspections to detect early signs of damage.