TECHNOLOGY
TECHNOLOGY Whether trickling, roll dipping, hot dipping, vertical dipping or potting our solutions ensure a reliable process to guarantee a high quality and continuous impregnation result. The bdtronic trickling and dipping equipment is particularly used to impregnate and cure electro-technical wounded objects. Our large product portfolio goes from small standalone to high-volume machines.
APPLICATIONS All winded objects Solenoids & transformers Electrical motors Coils Stators Rotors
PRINCIPLES 1. Trickling 2. Roll dipping 3. Hot dipping 4. Vertical dipping 5. Potting (vacuum)
WHY IMPREGNATING? To glue the coils and provide mechanical strength To provide thermal and environmental resistance To improve the heat transfer To replace the air in the insulating system (PD) To reinforce the electrical insulation
1. TRICKLING How it works - The object (rotor or stator) is placed on rotating tools - The resin is trickled with the correct amount onto the rotating and pre-heated windings of the object - The treated unit travels into an oven and is cured while still rotating Advantages - Lowest resin consumption - High percentage of filling grade - Clean and automatic process - Complete process monitoring possible - High reactive or 2 components resins should be used - Perfect resin distribution and selection of the resin application zones - Possibility to access narrowed zones (with inclination options)
2. ROLL DIPPING How it works - The object (rotor or stator) is placed on rotating tools - The resin is sucked by the pre-heated windings of the object through the slot during the surface dipping into the resin bath - The treated unit travels into an oven and is cured while still rotating Advantages - Low resin consumption - High percentage of filling grad - Clean and automatic process - Process monitoring possible - Perfect resin distribution and selection of the resin application - Simple machine set up
3. HOT DIPPING How it works - The object is pre-heated - The component is dipped into the resin - The object is drained over the dip tank or dropping tank and placed/transferred into an oven to cure Advantages - Low tooling and machine cost - Simple process (no rotation) - Low resin loss (compared to normal dipping) - High productivity (high density of parts in volume) - Versatile (simple set up of parameters)
4. VERTICAL DIPPING How it works - The object is pre-heated using joule effect on wires and SWIR on external side - The component is dipped into the resin - The object is drained over the dip tank with a defined angle, then scraped to clean - The rotation is started and the current flows into the wires to cure and the SWIR cures the external resin Advantages - High percentage of filling grad - Low resin consumption - Clean and automatic process - Process monitoring possible - Fast heating system - Small surface occupied (no ovens)
5. POTTING (VACUUM) How it works - The object should be pre-heated after mold or base preparation - The resin is potted into the component, a mold is pressed into the bore or with mold in place the resin is injected from the bottom by using vacuum - The object is placed/transferred in an oven to cure - The mold is pulled out Advantages - Highest quality of the parts (heat transfer and environmental protection) - 2 components material usage - No void in the potting mass - Low temperature curing
TEMPERATURE MANAGEMENT Impregnation material status changes from liquid application to solid functional cure! (In general 1 or 2 components need to add external energy) Heating up Gelling Curing Cooling down
GELLING & CURING Gelling Time in which the resin starts to polymerize at a given temperature (the resin is not fully cured at this stage) Curing Time needed by the resin to be fully cured at a given temperature. The resin is fully cured when there is no more polymer evolution during this time. The end glass transition temperature of the resin has been reached. The resin needs to be fully cured at the end of this process in order to: - Avoid chemical evaporation (smell ) when the motor runs - Avoid weight loss (air gaps and ageing problems) and resin shrinkage - Obtain the best mechanical and chemical resistance properties - If polymer is not stabilized, the ageing properties will certainly change
CURING METHODS Impregnation resin and varnish needs to be cured by external energy supplying (from 80 up to 200 C) in function to the resin type 1. Hot air 2. SWIR (Infrared) 3. Joule effect
1. HOT AIR Electrical heaters heat up the air that due to a close loop recirculation will exchange energy with the parts that will be heated up Advantages - High drying effect during the pre-heating for laminations pack and windings - Temperature uniformity in whole parts mass - No wires connection needed - Allows automatic work flow and similitude in new parts processing - The continuous mix of the air allows works in safe mode also with solvent presence - No over temperature possible (safe for production) - Simply machine set up - No influence on the quality due the process interruptions - Perfect curing of the resin also on plastic parts and laminations - High efficiency and precision temperature regulation on bdtronic machines
2. SWIR (INFRARED) The parts are exposed to a SWIR light that due to the irradiation energy transfer the parts will be heated up Advantages - High speed of the surface heating - Simply adjusting of the emission power - No wires connection needed - Allows automatic work flow and similitude in new parts processing - Low temperature tooling needed (only the parts are heated up) - Normally the best is to use that technology in combination with joule effect or hot air technology - Machine size - Highest efficiency and precision temperature regulation on bdtronic machines
3. JOULE EFFECT The parts wires are connected with a power supply systems (DC or AC) that will circulate the electrical current trough the parts wires that will be heated up Advantages - High speed of windings heating - High temperature accuracy on the windings - Low temperature tooling needed (only the parts are heated up) - Possibility to achieve an high filling grade due to a fast resin gelling process - Machine size - Highest efficiency and precision temperature regulation on bdtronic machines
Ahornweg 4 97990 Weikersheim Germany www.bdtronic.com sales@bdtronic.com RESINS CHEMISTRY Polyester - Usually diluted in monomer (unsaturated polyester UP) or solvent (saturated polyester PE) - Highly reactive & easy to use - Medium adhesion & mechanical (brittleness) thermal class F-H Epoxy - With our without solvent (e.g. for high voltage) - Relatively high viscosity - Good adhesion, mechanical & chemical resistance properties - Usually lower ageing properties at high temperature than good polyesterimide Silicone - High temperature resistance - Class C application for traction motors - Some mechanical and chemical resistance weakness
PROCESS CONTROL Temperature monitoring/ temperature control Trickling nozzle control Dipping tank level control Rotation speed control
STANDARD MACHINES B7200 Impregnation machine for single or double spindle production with joule effect B8100 Fully automated impregnation machine for small parts production B8300 Fully automated impregnation machine for small parts and high production volume B8400-8500 Impregnation machine for large parts production B8600 Impregnation lab machine for single part processing B8700 Fully automated and modular impregnation machine for large parts production
QUESTIONNAIRE Object to be impregnated Dimensional drawings For joule heating: resistance and wiring details Special requirements (i.e. maximum resin thickness, temperature limit) Resin Datasheets and MSDS Local contact of resin supplier Impregnation process Preferred impregnation method/s Production capacity (a year/shift or parts/h) Operation mode (manual/semi automatic/automatic) Varies Lab trials required /needed for Any special request? Budget/place of installation/forecast of production start
REFERENCE PROJECT Product description & usage/function/information: Work piece material/ product composition: Project description: Machine description: Process: Material description: Impregnating and curing of stators and armature (rotor) using polyester resin in mix flow More than 1000 variants max. Ø 490 mm, shaft max. 1.050 mm, weight = 250 kg Roll dipping in 1 phase with automatic recipe selection, manual load/unload Hot air ovens with continuous transportation chain and parts rotation Load/unload 1 or 2 equal parts, barcode recipes load, pre-heat, roll dipping, gelling, curing, cooling Polyester (FT 1040/120E)
REFERENCE PROJECT Product description & usage/function/information: Work piece material/ product composition: Project description: Machine description: Process: Material description: Impregnating and curing, with a high and constant filling grade, the stators coils using a silicone keeping cleaned all the metal surfaces (inside and outside) for the automotive industry Stator max. Ø 400 mm, length max. 160 mm, weight = 35 kg; 21 stators/h, 170 s/pieces (6 parallel) Trickling in 1 phase with automatic recipe selection, inclination 10, 6 gear pumps + MPS Hot air ovens with continuous transportation chain and parts rotation Load/unload 6 equal parts, barcode recipes load, pre-heat, trickling in inclination, gelling, curing, cooling Silicone Silres H62 C 1 component
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