Joyal offers machines for multiple processes and applications.

• Wire to Wire - Fuse-A-Wire Technology
• Wire to Lead - Tube Fusing Technology
• Wire to Terminal - Lead Fusing Technology
• Wire to Commutator - Armature Fusing Technology

The machines can process copper, aluminum and Litz wire. The controls have been developed for speed, repeatability and monitoring so that the process can be tracked in an SPC database.

ROUND and RECTANGULAR Magnet Wire

• Industrial Motor Leads/Neutrals
• Large Alternator Leads/Neutrals
• Traction/Hybrid Motor Leads/Neutral – Rings and Custom Power Lugs
• Aerospace Wound Component – HML and Litz Wire
• Small AC Motor Leads or Pre-Connect Rings – Aluminum Magnet Wire
• Armature Commutators
• Bobbin Spades/Pins
• Rotor Slip Rings
• Hairpin Lead/Neutral Rings
• Diode Bridge

Tube Fusing Technology

Our wire fusing technology eliminates the need for an operator to strip the magnet wire before fusing the lead bundle. Capable of fusing up to 150 x #18 AWG (1.0mm) wires in parallel, the heat of the fusing operation burns off the wire enamel while the tin from the tube cleans the area to be connected. The head’s force in tandem with the electrode-controlled heating, creates a reliable connection.

Robotic Fusing and Automation

Custom assembly systems for wire fusing are available for a variety of processes. Joyal incorporates multi-axis servo motions, allowing quick changeover of different products.

Armature Fusing Technology

Joyal offers a variety of machines to meet any style of armature wire fusing requirements. Machines are available in manual and automatic transfer designs. In addition, Joyal offers our unique thermal monitor controller to ensure that the wire fusing operation does not excessively heat the commutator bar, causing distortion.

Armature Fusing/Brazing Systems

Joyal Commutator Wire Fusing Machines deliver bar-to-bar control, automatic weld current control, and data collection for SPC tracking for universal and DC motor manufacturers' requirements. The latest wire fusing technology allows more parameters to be automatically recalled, reducing the operator's involvement in the setup process.

Fuse-A-Wire Technology

Fuse-a-wire technology is unique in that it eliminates the need for a splice connector between the magnet wire and the tinned lead wire. This lowers the material cost of your product and eliminates the need to stock different connectors sized specifically to the wire bundle size. This technology allows wire fusing the connection in less than 1 second and is extremely economical compared to traditional splice or insulation displacement connectors.

All Joyal machines have advanced process and control features that are unavailable from traditional connection methods. Machines can accurately control electrode current, temperature, force, fusing head displacement, and fusing time while monitoring the process many times per second. Not only does this level of control significantly improve the quality of the connection, but a wire fusing machine requires much less training for an operator. These parameters result in less maintenance and no need for expensive, specialized connectors. Along with controlling the process, we offer computer and Ethernet/USB communication for specification storage/diagnostic, which can be integrated into a customer S.P.C. package.