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    Resin Impregnation

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    pc gamer
    Resin impregnation seals porosity in parts made through processes like casting or sintering. It forces polymer resin into pores using vacuum or pressure, then cures the resin. This improves insulation, prevents vibration, increases heat and stress resistance, and reduces short circuits. Different resins like epoxy are used. Impregnation reinforces primary insulation on copper windings. Methods include trickling, roll dipping, hot dipping, vertical dipping, and full stator impregnation. Trickling and roll dipping maximize filling and quality but use more resin. Choice of material depends on required mechanical, thermal, and electrical properties.

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    Resin Impregnation

    Uploaded by

    pc gamer
    54 views15 pages
    Resin impregnation seals porosity in parts made through processes like casting or sintering. It forces polymer resin into pores using vacuum or pressure, then cures the resin. This improves insulation, prevents vibration, increases heat and stress resistance, and reduces short circuits. Different resins like epoxy are used. Impregnation reinforces primary insulation on copper windings. Methods include trickling, roll dipping, hot dipping, vertical dipping, and full stator impregnation. Trickling and roll dipping maximize filling and quality but use more resin. Choice of material depends on required mechanical, thermal, and electrical properties.

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    Resin impregnation seals porosity in parts made through processes like casting or sintering. It forces polymer resin into pores using vacuum or pressure, then cures the resin. This improves insulation, prevents vibration, increases heat and stress resistance, and reduces short circuits. Different resins like epoxy are used. Impregnation reinforces primary insulation on copper windings. Methods include trickling, roll dipping, hot dipping, vertical dipping, and full stator impregnation. Trickling and roll dipping maximize filling and quality but use more resin. Choice of material depends on required mechanical, thermal, and electrical properties.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    54 views15 pages

    Resin Impregnation

    Uploaded by

    pc gamer
    Resin impregnation seals porosity in parts made through processes like casting or sintering. It forces polymer resin into pores using vacuum or pressure, then cures the resin. This improves insulation, prevents vibration, increases heat and stress resistance, and reduces short circuits. Different resins like epoxy are used. Impregnation reinforces primary insulation on copper windings. Methods include trickling, roll dipping, hot dipping, vertical dipping, and full stator impregnation. Trickling and roll dipping maximize filling and quality but use more resin. Choice of material depends on required mechanical, thermal, and electrical properties.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 15

    Resin Impregnation

    What is Resin Impregnation?


    • Resin impregnation refers to the sealing of porosity which occurs in
    manufacturing processes such as casting and sintering. Through
    vacuum and/or pressure methods, polymer resin is forced into the
    porosity and then cured to form a pressure tight part.
    • For example: Impregnation is the process of closing and sealing
    • Resin impregnation of windings and
    copper wires
    • provides better insulation
    • prevents vibration.
    • It also increases resistance to stresses and
    temperature loads and heat exchange
    during normal operation,
    • reduces the risk of short circuits in the
    windings.
    Thus, the impregnation process increases
    thermal conductivity and contributes to a
    better environmental balance.
    Types of impregnating resins
    • There are different impregnating resins on the market based on Epoxy
    resins (EP), unsaturated Polyester and polyesterimides or silicones
    with different characteristics.
    Impregnation as secondary insulation
    • Impregnation is also known as secondary insulation because it
    reinforces the copper enamel that is defined as the first insulation. It
    is a chemical procedure that uses coating substances, such as resins
    and varnishes, plus heat, through a variety of methods, necessary to
    fix and improve the mechanical performance and stability, and
    improve the thermal and electrical performances of the copper
    winding parts.
    How to choice the correct matrial?
    • By using impregnation systems, manufacturers of automotive and electrical components are able to
    achieve improvements in the production and the repairs of these components. The choice of the
    correct material influences significantly the quality of the product and the final performances of the
    motor.
    • The choice is based on several factors that depend on the requirements of the product:
    1) Mechanical strength at high temperatures
    2) Heat transfer
    3) Replacement of the air in the insulating system
    4) Electrical insulation
    5) Thermal and environmental resistance
    6) Motor performance
    7) Resistance to mechanical shock and vibration
    8) Reduction of noise
    Impregnation methods
    • There are different processes for impregnating wire-wound
    components such as rotors or stators.
    • To achieve the best results, a different impregnation method may be
    considered depending on the component. The shape and size of the
    stator or rotor are among the special features that are taken into
    account. Whether trickling, roll dipping, hot dipping, vertical dipping
    or full stator impregnation.
    Trickling

    • The trickle impregnation method offers numerous advantages: lowest


    resin consumption at a high filling level, a clean, automatic process
    without dripping and post-cleaning of the components, which is
    completely monitored, and perfect resin distribution even in narrow
    areas in the windings. Since trickling is technically complex, it takes a
    lot of experience and process knowledge to turn a laboratory system
    into a high-volume machine with a cycle time of less than 120
    seconds per component and an availability of more than 95 percent.
    • Some advantages of the impregnation method trickling are the
    following points:

    1) Highest quality thanks to precise impregnation


    2) No time-consuming rework necessary
    3) The grooves are filled to the maximum in the windings
    4) Minimal process handling
    5) Maximum productivity
    6) Resins can be used with or without monomers
    Roll dipping

    • The roll dipping impregnation process can be used for both rotors and
    stators. In this process, the components are only partially immersed
    and rotated in a controlled manner until the desired depth is reached.
    • Roll dipping is a further development of the dipping process in which
    the complete component is not immersed in a basin filled with
    impregnating resin. The rotors or stators are mounted on special
    grippers that move with constant rotation around the center axis. In
    this way, the components are only partially immersed and rotated in a
    controlled manner until the desired depth is reached. After the
    component is moved out of the bath, excess material drips back into a
    collection tray.
    • Some advantages of the roll diving method are the following:
    1) High quality impregnation
    2) The grooves are filled to the maximum in the windings
    3) Particularly short process handling
    4) Maximum productivity for the individual plants
    5) Perfect coverage and distribution of the resin
    6) Resins can be used with or without monomers
    Other impregnation methods

    • The traditionally used impregnation process is dipping. It is generally used for electric motors,
    generators and in the production of transformers. In this process, the parts are immersed in the
    dipping tanks filled with suitable impregnating resin. After a certain dripping period, the parts
    are placed in an oven for drying. This allows the wire winding and the center to become one
    solid and mechanically stable unit.

    • These methods have in common a relatively :


    1) High resin consumption and the need for subsequent cleaning of the components.
    2) The dip tanks filled with several hundred liters of epoxy or polyester resin have to be emptied
    and cleaned regularly.
    3) These methods are not compatible with the current requirements for a sustainable and
    "green" production environment,
    4) Also entail high operating costs.
    • Hot Dipping
    • This method applies impregnation by preheating the components in order to
    handle viscous impregnation media. Viscosity of resin and other sealing
    products may be reduced with preheated components, which allows higher
    levels of penetration. Low or none process monitoring achieved.

    • Vertical Dipping
    • The component is preheated and then fully dipped into the resin; the
    component is drained with a specific angle and then follows the rest of the
    process until the resin or varnish is sealed. Partial process monitoring
    achieved.
    • Stator full potting
    • A mold or base is prepared and receives a preheated component.
    After pouring the sealing product into the component, the mold is
    pressed; it is also possible to set the mold first and then inject the
    sealing product from below using a vacuum.
    1. This process ensures high quality of the final product
    2. and very high heat dissipation of the engine.
    3. Due to its complexity, this process has low productivity. Complete
    process control is achieved.
    Impregnation machines
    • The fastest
    The B8300 impregnating machine is designed for series production and
    is ideally suited to the requirements of the automotive industry.
    • Modular & serial
    The modular machine concept of this fully automatic series production
    line allows full product variability.
    • Small and medium production volumes
    bdtronic also offers systems for laboratories and prototypes as well as
    small and medium production volumes.

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