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Manufacture and sales of ultra-fine resistance wires such as nichrome wires (nickel-chromium alloy wires) and iron-nickel alloy wires Tokyo Resistance Wire Co.
Products Manufactured
Process and equipment for producing precise ultra-fine wires
Continuous drawing process
Continuous wire drawing is a process which wire is drawn through an small trumpet shaped hole called a diamond dies.
By using a constant reduction rate, wire are drawn to be thinner.
Several diamond dies are set in drawing machine for metal alloy wire to become thinner.
This is one of the important process in the production of resistance wire product.
Tokyo Resistance Wire have total of 19 continuous drawing machines.
We choose the most suitable machine and process by various customer requirements
and different alloys.
Diamond dies polishing
Diamond dies polishing is a process to polish diamond dies used in wire drawing process.
The accuracy of the holes in the polished diamond die is 1/1,000 to 5/10,000 mm, which is extremely precise.
The polishing process enables fine control of the wire diameter and conductor resistance to produce more precise resistance wires.
In the die polishing process, the metal wire through the hole is moved up and down with an abrasive containing diamond particles over a long period of time.
In addition, the die itself is rotated to achieve a uniform round and approach shape.
Rolling process
Rolling process are passing the metal wire between steel rolls set above and below to pressing the wire into a flat strip shape.
This process is repeated several times to gradually make the strip thinner and wider, and to adjust the strip thickness, width, and conductor resistance.
We use our own wire drawn in 1/1,000mm increments for more precise processing.
Our products are used in a variety of applications, such as flat strips for catheters, electronic tubes, resistance materials, and electric heaters.
Heat treatment
The heat treatment process is the process of finishing electric heating wire, resistance wire, and various metal wires and strips.
One of the features of the processing of Tokyo Resistance Wire is that the wire is passed one by one through a long special heat-resistant alloy pipe and then bright annealed (BA) while the wire is running.
In this process, the annealing temperature varies depending on the type of wire, but for high temperature wires, the environment is around 1,000℃.
In order to prevent the metal wire from oxidizing in this environment, redox gas are used into each pipe and traveling annealing is performed in the gas atmosphere. The purpose of traveling annealing is to stabilize the product quality.
For very thin wires, called fine wires and ultra-fine wires, we use a bobbin traverse winding system to achieve uniform winding.
In the electric furnace, the unwinder and winder are controlled by dancers at a constant wire speed and tension.
The wire runs in a stable state from the beginning to the end of winding.
Spiral processing
The spiral processing is mainly used for electric heaters.
We offer a wide variety of materials and wire diameters, including Kanthal wire, iron-chromium electric heating wire, and nickel-chromium electric heating wire.
We can manufacture from a wide variety of materials and wire diameters, such as Kanthal wire, iron-chrome electric heating wire, nickel-chrome electric heating wire, etc., in accordance with the desired outer diameter dimensions, voltage (V), power (W), characteristics, lead length, twisting, etc.
We can manufacture from a single product.
Finishing and winding process
The bobbins are winded according to the specifications specified by each customers such as bobbin type, winding volume, etc.
Bobbin type and winding volume can be specified but we may suggest the adequate bobbin and volume.
The meter winding is also availabe using precise meter counter.
Constannt wire speed, constant tension and winding pitch are recorded into the system and provide constant condition for each tyep of alloys and wire diameter.
Final product inspection
All bobbins are inspected and managed using a computerized resistance inspection management system developed in-house.
Special specifications set by each customer are recorded in the computer, and the data from the measuring equipment is read to automatically determine the conditions.
It is possible to automatically determine the conditions.
Measured data is managed in lots, and past measurement data is also recorded and saved for retrieval.
The inspection can include dimensions (wire diameter), conductor resistance, volume resistivity, tensile strength, elongation, temperature coefficient of resistance, weight, number of meters, and other items as needed.
We also have a large inventory of products in stock, so we can provide products from stock on the same day.
If you need a small amount for prototyping or other purposes, we can provide small quantities in 10-meter increments if we have the product in stock.