PROCESS EXPERTISE

 

Terminations 

We are expert at maintaining precise control of winding tension, winding pitch, and wire position at high winding speeds, leading to cost-effective, precision layer wound coils. 

Careful design and process control of the magnet wire termination is critical to the reliability and longevity of the circuit.  Guardian’s highly-skilled technicians have years of experience with termination processes, including:  SPC controlled resistance welding, nozzle and dip soldering, and IDC (Insulation Displacement Connection).  Thermal shock testing is available and utilized to qualify lot-to-lot production runs of the connection joint.  High temperature encapsulated coil designs rated at 220°C have been qualified and approved via thermal shock testing passing 200 cycles at temperatures from -40°C to +180°C. 

Guardian Electric is proud that the combination of our state-of-the-art multi-spindle winding machines and our critical technical experience has produced a “Zero Defect” quality level for electrical connections made on over a million coils delivered to our customers.                              

        


Coil Encapsulation

Conventional injection molding is a tried and true process with standard methods utilized across the industry.  However, this is not the case for encapsulation or overmolding of coils.  Only years of experience can guarantee achievement of the precise balance of pressure, along with other key mold process variables, required to produce a fully uniform and dimensionally stable part, uncompromised by wire movement within. 

Guardian Electric’s core philosophy is governed by Lean Manufacturing with an emphasis on single piece assembly line flow to maintain the highest level of quality control and process efficiency….leading to 100% on time delivery.

Guardian Electric’s 30+ years of in-house coil encapsulation experience, coupled with our mold tooling expertise and attention to quality has earned us a “Zero Defect” quality rating for electrical defects in the millions of coils delivered to our customers. 

 

 

Quality Control

Quality control and qualification are critical components in manufacturing.  Guardian has ISO 9001 and AS9100 accreditation, together with a culture of excessive attention to quality.  Electrical testing for resistance, inductance, shorted turns and hipot is available for final part qualification. 

Guardian Electric’s 30+ years of in-house coil encapsulation experience, coupled with our mold tooling expertise and attention to quality has earned us a “Zero Defect” quality rating for electrical field defects in the millions of coils delivered to our customers.  

 

        

 

Guardian Engineering and Manufacturing
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