Products Manufactured

Continuous Wire Drawing

Continuous wire drawing is a process in which metal wires are elongated by pulling them through diamond dies with small trumpet-shaped holes. A slightly thinner wire than the mother wire is threaded through a hole, and by pulling it at a constant reduction ratio, a finer metal wire is produced. Multiple diamond dies are set on a single wire drawing machine, allowing the metal wire to continuously pass through them, gradually refining its thickness.

In the production of resistance wires, this becomes one of the most fundamental and essential operations. Tokyo Resistance Wire employs 20 continuous wire drawing machines, customizing the manufacturing process based on customer applications, steel types, and specifications.

Wire drawing machine models	The number of units in possession
Wire drawing machine for thick to medium wires	10 units
Wire drawing machine for thin to ultra-fine wires	10 units
Vertical drum-type wire drawing machine	1 unit

To create resistance wires that pass through dies of different sizes without imposing stress and achieve uniformity, an exceptional level of technical expertise is required. Therefore, adjustments are made to consider the torque applied within the wire drawing machine and the varying distances resulting from the extension of the winding wire.
Wires are wound on spools of different sizes, and with careful consideration to maintain uniform tension, resistance wires are manufactured.

Rolling Process

Rolling processing involves passing metal wires between upper and lower sets of carbide rolls to flatten and shape them into a strip. This process is repeated multiple times, gradually reducing the thickness of the strip and adjusting its width and thickness, as well as the conductor resistance.

Rolling mill	The number of units in possession
A rolling mill larger than 120 φ in diameter	4 units
A rolling mill larger than 95 φ in diameter	1 unit

The mother wire is also processed with greater precision by using materials elongated in-house to the 1/1,000mm level. It finds applications in various uses 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℃.re.

Electric furnace	The number of units in possession
Phase-controlled traverse Kantal system	7 units
Blue Line Use	1 unit

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.

The winding and unwinding devices are dancer controlled in an electric furnace at a constant wire speed and tension to ensure stable operation from the beginning to the end of the winding.

Heat Treatment Winding Process

Winding machine	The number of units in possession
Annealing Ultra-Fine Wire Size 6-Unit Bobbin Traverse	1 unit
Annealing for Thin Wire Size 10-Units	1 unit
Annealing Intermediate Size 5-Units + 3-Units Bobbin Traverse	1 unit
Annealing for Intermediate Size with 6-Units Bobbin Travers	1 unit
Annealing for Intermediate Size with 8-Units	1 unit
Annealing for Thick Wire Size with 4-Units Bobbin Traverse	1 unit

Cleaning Process

Cleaning Equipment	The number of units in possession
Ultrasonic Cleaning Machine	4 units

Finishing Winding Process

The bobbins are winded according to the specifications specified by each customers such as bobbin type, winding volume, etc.
Meter winding control is also available with a precise meter counter.

Winding machine	The number of units in possession
Ultra-fine to Fine Wire Size Bobbin Traverse Winding	5 units
Fine to Intermediate Size Winding	9 units
Intermediate Size Bobbin Traverse Winding	1 unit
Intermediate Size Winding	1 unit
Intermediate to Thick Wire Size Winding	2 units
Fine Wire Size 5-Unit Winding	1 unit
Strip Winding	3 units
Coil Master Supply	1 unit

For fine wires and ultra-fine wires, we utilize a bobbin traverse winding device. The equipment records and manages constant wire speed, constant tension, and winding pitch, ensuring consistent winding conditions for each steel type and wire diameter.

Spiral Processing

In spiral processing, we primarily engage in manufacturing products used for "electric heaters." We undertake the production of various materials such as Kanthal wire, iron-chromium electric heating wires, nickel-chromium electric heating wires, etc., catering to different applications based on a rich variety of material types and wire diameters. We propose the most suitable processed products by taking into account specified requirements such as arbitrary outer diameter dimensions, voltage (V), power (W), characteristics, lead length, twisting, and more.

Spiral processing machine	The number of units in possession
Fully automatic winding machine	2 units
Manual winding machine	3 units

Spiral processing carried out by skilled artisans allows us to accommodate small-batch manufacturing that cannot be achieved by machines alone. Additionally, we can accommodate various shapes for leads, including length, orientation, centering, and more.

Diamond Dies Polishing

Diamond dies polishing is a process of grinding and polishing diamond dies used to shape metal wires into fine lines during wire drawing. The precision of the holes in the polished diamond dies is extremely high, reaching as fine as 1/1,000 to 5/10,000 millimeters.

Polishing machine models	The number of units in possession
Diamond dies polishing machine	5 units

Polishing allows for meticulous control over wire diameter and conductor resistance, enabling the production of more precise resistance wires.

In diamond dies polishing, metal wires passed through the holes are adjusted vertically over time using a polishing agent containing diamond particles, achieving the desired size. Furthermore, the die itself is rotated to perform uniform polishing with a perfect circular and tapered shape.

Product Inspection

We conduct a comprehensive inspection management for each bobbin using our in-house developed computer resistance inspection system. Special specifications unique to each customer are recorded in the computer, allowing data to be read from measuring instruments and automatically determining compliance with the set conditions.

Testing and Measurement Equipment	The number of units in possession
Resistance Wire Automatic Management System	1 unit
Resistance Meter	9 units
Tensile Testing Machine	2 units
Weight Scale	18 units
Low-Temperature Constant Temperature Bath	1 unit
Digital Micrometer	22 units
Laser Outer Diameter Measurement Device	1 unit
Electron Microscope	1 unit
Optical Microscope	1 unit

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, meter count, 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.
In cases where a small quantity of resistance wire is needed for prototypes or similar purposes, we provide it in increments of 10 meters if it is available in stock.

Finished Products

Products created with our in-house proprietary technology are used in a wide range of applications, including automotive components, smartphones, and various other products.