A fully automatic dipping machine and its dipping method

Abstract

The present invention discloses a fully automatic dipping machine and its dipping method. The dipping machine includes a housing body component, a working component, and a control component. The working component includes a vacuum chamber, a lifting component, a wedge clamping component, and a stainless steel cover plate component. A wire basket and a paint storage barrel are arranged in the vacuum chamber. The wire basket is controlled by the lifting component to enter and leave the paint storage barrel. A sealing ring is arranged at the contact position between the stainless steel cover plate component and the vacuum chamber to form a seal with the vacuum chamber to prevent air leakage. The wedge clamping component is used to form a clamping connection with the wedge-shaped buckle of the stainless steel cover plate component. The control component is used to control the gas circuit and the circuit. The dipping method of the dipping machine mainly includes processes such as preparation, vacuum dipping, positive pressure dipping, pressure relief and material taking. Through the technical solution of the present invention, it is ensured that the air in the product is completely pumped out before the product is immersed in the insulating paint, and after the product is immersed in the insulating paint, air is filled and pressurized to ensure that the insulating paint completely penetrates into the gaps of the product, ensuring good dipping of the product.

Description

Technical Field

[0001] The present invention belongs to the technical field of dipping machines, and particularly relates to a fully automatic dipping machine and a dipping method thereof, which are used for dipping and insulating wire-wound products such as motor stators and rotors. Background Art

[0002] Due to the continuous expansion of the application scope of electronic device products such as motors and transformers, higher requirements are put forward for their insulation performance, and the dipping process is an important link to ensure insulation performance.

[0003] As Figure 1 shown, the working mode of the dipping machine in the prior art is as follows: First, the product is placed in the insulating paint in the dipping machine barrel, the lid is covered, and then the inside of the dipping machine is evacuated to let all the air in the product gaps run out and be pumped away. Finally, the product is taken out of the dipping machine and placed in an oven for heating to cure the insulating paint.

[0004] The existing dipping machine process has the following technical defects: 1. Using this dipping process, it is very easy to generate bubbles in the product gaps after the insulating paint is cured, which affects the appearance and insulation performance of the product after dipping. Because the product is completely wrapped by the insulating paint when placed in the insulating paint and then evacuated, there will be some air in the gaps that cannot be pumped out. When heated and cured at high temperature, the air expands and bubbles or pores will be formed in the insulating paint in the gaps; 2. For some products with small gaps, the insulating paint simply cannot enter, resulting in no insulating paint adhering to some positions of the product. Summary of the Invention

[0005] In view of the above problems, the present invention provides a fully automatic dipping machine and a dipping method thereof, which solve the technical problems of bubbles, pores in the product after dipping and the inability of the insulating paint to enter the tiny gaps of the product in the existing dipping process.

[0006] In order to achieve the above object, the technical solution adopted by the present invention is as follows:

[0007] A fully automatic dipping machine includes a housing body assembly, a working assembly and a control assembly. The working assembly includes a vacuum chamber, a lifting assembly, a wedge clamping assembly and a stainless steel cover plate assembly. A wire basket and a paint storage barrel are arranged in the vacuum chamber. The lifting assembly is used to control the wire basket to enter and leave the inside of the paint storage barrel. A sealing ring is arranged at the contact position between the stainless steel cover plate assembly and the vacuum chamber to form a seal with the vacuum chamber to prevent air leakage. The wedge clamping assembly is used to form a clamping connection with the wedge-shaped buckle on the stainless steel cover plate assembly, and the control assembly is used to control the air circuit and the circuit.

[0008] Further, the housing body assembly includes a welded frame, a rear door assembly and casters, which are used to fix and support the working assembly and the control assembly.

[0009] Further, the control component includes a button board component and a pipeline component. The button board component is arranged on the upper end face of the housing body component and is used for operating and controlling the dipping machine. The pipeline component includes a gas circuit component and an electric circuit component, which are respectively fixed on the vacuum chamber and the electrical installation board.

[0010] Further, the gas circuit component includes a vacuum pump, an electromagnetic valve, a pressure gauge and a safety valve which are connected to the vacuum pump through pipelines. The electromagnetic valve includes an exhaust electromagnetic valve and a pressurizing electromagnetic valve, and the control switching is carried out through the control component.

[0011] Further, the lifting component is fixed on the vacuum chamber and includes a servo motor, a linear guide rail, a connecting plate and a fork arm. The servo motor drives the ball screw to rotate forward and backward to realize the lifting and lowering of the fork arm.

[0012] Further, the wedge clamping component is arranged on the vacuum chamber and includes a cylinder and two wedge clamping parts controlled by the cylinder. A wedge-shaped buckle is arranged at the end of the stainless steel cover plate component. The two wedge clamping parts of the wedge clamping component are clamped with the wedge-shaped buckle to form a clamping connection. The angle between the wedge-shaped buckle and the inclined surface of the wedge is less than the friction self-locking angle. When the tangent of the friction angle is less than the static friction factor, self-locking can be achieved.

[0013] Further, nitrogen springs are also arranged on both sides of the stainless steel cover plate component to support the stainless steel cover plate component.

[0014] The present invention also provides a dipping method for a full-automatic dipping machine, which is carried out by using the full-automatic dipping machine as described above and includes the following technological steps:

[0015] (1) Preparation: First, place the product and the insulating paint in the wire basket and the paint storage barrel, close the stainless steel cover plate component, adjust the technological parameters of the dipping machine during operation through the control component, and then press the start button;

[0016] (2) Dipping: The dipping machine starts to operate. The cylinder of the wedge clamping component pushes the wedge clamping part to clamp the wedge-shaped buckle on the stainless steel cover plate component, and then the vacuum pump starts to work. When the set vacuum pressure is reached in the vacuum chamber, after maintaining the vacuum degree for a period of time, the lifting component starts to lower the wire basket into the paint storage barrel, and the product also enters the insulating paint accordingly;

[0017] (3) Pressurization: When the product is completely immersed in the insulating paint, the control component makes the pressurizing electromagnetic valve get powered on to connect the external compressed air, and starts to inject compressed air into the vacuum chamber. After the set air pressure is reached in the vacuum chamber, the pressurizing electromagnetic valve automatically disconnects, and then maintains the positive pressure in the vacuum chamber for a certain period of time;

[0018] (4) Pressure relief and material extraction: After the pressurization is completed, the control component energizes the exhaust solenoid valve to connect the vacuum chamber to the external atmosphere. After the air pressure in the vacuum chamber returns to normal atmospheric pressure, the lifting component lifts and separates the wire basket from the paint storage bucket. The cylinder of the wedge clamping component operates to release the wedge-shaped buckle on the stainless steel cover component. After the product is immersed in paint, the product after immersion in paint is taken out and dried.

[0019] Further, the vacuum pressure set in step (2) is -100 to -80 kPa, and the vacuum state holding time is 1 to 30 min; the pressure set for pressurization in step (3) is 0.1 to 0.5 Mpa, and the positive pressure state holding time is 1 to 30 min.

[0020] Compared with the prior art, the technical solution of the present invention has the following beneficial effects:

[0021] (1) The paint immersion method of the present invention adopts the process of vacuum paint immersion. First, the paint immersion machine is evacuated, and then the product is immersed in the insulating paint. Compared with the traditional paint immersion process, the evacuation process in the paint immersion machine is advanced, ensuring that the air in the product is completely evacuated before the product is immersed in the insulating paint;

[0022] (2) The present invention adopts the process of positive pressure paint immersion: Pressurized paint immersion is to fill compressed air into the paint immersion machine to pressurize after the product is completely immersed in the insulating paint, indirectly pressurizing the insulating paint that wraps the product, so that the insulating paint can completely penetrate into the gaps of the product, ensuring good paint immersion of the product;

[0023] (3) The paint immersion machine of the present invention uses a lifting component to lift and lower the wire basket, increasing the degree of automation of the product, and making it convenient for the product and the insulating paint to be combined and separated;

[0024] (4) The paint immersion machine of the present invention adopts a wedge locking structure between the wedge clamping part of the wedge clamping component and the wedge-shaped buckle of the stainless steel cover component. While ensuring the sealing performance of the vacuum chamber, it can effectively ensure that the stainless steel cover component will not be suddenly pushed open by the air pressure during the pressurized air filling stage, ensuring safety. Description of the Drawings

[0025] Figure 1 It is a schematic structural diagram of a paint immersion machine in the prior art;

[0026] Figure 2 It is a schematic assembly diagram - 1 of the full-automatic paint immersion machine of the present invention;

[0027] Figure 3 It is a schematic assembly diagram - 2 of the full-automatic paint immersion machine of the present invention;

[0028] Figure 4 It is a schematic structural diagram of the outer shell body component of the present invention;

[0029] Figure 5 Schematic diagram - 1 of the working component structure of the present invention;

[0030] Figure 6 Schematic diagram - 2 of the working component structure of the present invention;

[0031] Figure 7 Schematic diagram of the control component structure of the present invention;

[0032] Figure 8 Schematic diagram of the air circuit component structure of the present invention;

[0033] Figure 9 Schematic diagram of the lifting component structure of the present invention;

[0034] Figure 10 Schematic diagram of the wedge clamping component and its opening and locking structure of the present invention;

[0035] In the figure: 1. Outer shell body component; 2. Working component; 3. Control component; 4. Welding frame; 5. Rear door component; 6. Caster; 7. Vacuum chamber; 8. Lifting component; 9. Wedge clamping component; 10. Stainless steel cover plate component; 11. Mesh basket; 12. Paint storage bucket; 13. Wedge-shaped buckle; 14. Nitrogen spring; 15. Button board component; 16. Pipeline component; 17. Air circuit component; 18. Sealing ring; 19. Electrical installation board; 20. Vacuum pump; 21. Wedge clamping part; 22. Servo motor; 23. Linear guide rail; 24. Ball screw; 25. Connecting plate; 26. Fork arm. Detailed implementation manners

[0036] The technical solutions in the embodiments of the present invention will be described clearly and completely below. Apparently, the described embodiments are only a part of the embodiments of the present invention, rather than all of them. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0037] As Figures 2 - 3 shown, a full-automatic dipping machine of the present invention can be divided into three components, including an outer shell body component 1, a working component 2, and a control component 3.

[0038] As Figure 4 shown, the outer shell body component 1 is composed of a welding frame 4, four casters 6, and a rear door component 5, and is mainly used to fix and support the working component 2 and the control component 3.

[0039] As Figures 5 - 6As shown in the figure, the working component 2 consists of a vacuum chamber 7, a lifting component 8, a wedge clamping component 9, and a stainless steel cover plate component 10. Among them, the vacuum chamber 7 is the main working area of the dipping machine. The outside of the vacuum chamber 7 is welded with reinforcing ribs to ensure that the vacuum chamber 7 has sufficient strength and rigidity. The product and the insulating paint are respectively placed in the wire basket 11 and the paint storage bucket 12, and the contact and separation of the product and the insulating paint are realized through the lifting component 8. There is a circle of sealing rings 18 at the contact position between the stainless steel cover plate component 10 and the vacuum chamber 7 to prevent air leakage during air extraction and pressurization.

[0040] As Figure 10 shown in the figure, the wedge clamping component 9 is arranged on the vacuum chamber 7 and includes a cylinder and two wedge clamping parts 21 controlled by the cylinder. A wedge-shaped buckle 13 is arranged at the end of the stainless steel cover plate component 10, and the two wedge clamping parts 21 of the wedge clamping component 9 are clamped with the wedge-shaped buckle 13.

[0041] As Figure 7 shown in the figure, the control component 3 mainly consists of a button board component 15 and a pipeline component 16. Among them, the button board component 15 is the operation panel for the user to directly control the dipping machine, including emergency stop, start, and stop buttons, a digital display pressure gauge, and a touch screen. The pipeline component 16 can be further divided into an air circuit component 17 and an electrical circuit part, which are respectively fixed on the vacuum chamber 7 and the electrical installation board 19.

[0042] As Figure 8 shown in the figure, the air circuit component 17 includes a vacuum pump 20 and solenoid valves, pressure gauges, and safety valves connected to the vacuum pump through pipelines. The solenoid valves include an exhaust solenoid valve and a pressurization solenoid valve, and the control switching is carried out through the control component 3.

[0043] The dipping method of the full-automatic dipping machine of the present invention mainly includes the following processes:

[0044] Before the dipping machine works, first place the product and the insulating paint in the wire basket 11 and the paint storage bucket 12. Then close the stainless steel cover plate component 10, and then adjust the process parameters such as the dipping times of the product during the operation of the dipping machine, whether to pressurize, and the pressurization value through the touch screen. After confirmation, press the start button.

[0045] The dipping machine starts to operate. The cylinder of the wedge clamping component 9 will push the two wedge clamping parts 21 to clamp the wedge-shaped buckle 13 on the stainless steel cover plate component 10. Then the vacuum pump 20 starts to work and pumps air out of the dipping machine. When the set vacuum pressure is reached in the vacuum chamber 7 (the set value is -100~-80 kPa), it is maintained for 10 minutes, and the lifting component 8 starts to lower the wire basket 11 into the paint storage bucket 12, and the product is also immersed in the insulating paint. As Figure 9As shown in the figure, the lifting assembly 8 is composed of a servo motor 22 fixed on the vacuum chamber 7, a linear guide 23, a ball screw 24, a connecting plate 25 and a fork arm 26. The servo motor 22 drives the ball screw 24 to rotate forward and backward, realizing the lifting and lowering of the fork arm 26.

[0046] When the product is completely immersed in the insulating paint, the control assembly 3 energizes the pressure - adding solenoid valve to connect to the external compressed air, and starts to inject compressed air into the vacuum chamber 7. After the pressure in the vacuum chamber 7 reaches the set pressure (the set value is 0.1 - 0.5 MPa), the pressure - adding solenoid valve automatically disconnects, and then maintains a positive pressure in the vacuum chamber 7 for 15 minutes.

[0047] When the pressure gauge fails, when the inflation pressure exceeds the set pressure of the safety valve, the compressed air will be discharged from the safety valve, which can prevent danger caused by excessive internal pressure.

[0048] Since the angle between the wedge - shaped buckle 13 and the inclined surface of the wedge block of the wedge - block clamping assembly 9 is less than the friction self - locking angle, even if the air supply is suddenly cut off after the cylinder clamps, the wedge - shaped buckle 13 will not slide out from the middle of the wedge block, which can effectively ensure that during the inflation stage, the stainless - steel cover assembly will not be suddenly pushed open by the air pressure, ensuring safety.

[0049] After the pressurization is completed, the control assembly 3 energizes the exhaust solenoid valve to connect, connecting the vacuum chamber 7 to the external atmosphere. After the pressure in the vacuum chamber 7 returns to normal atmospheric pressure, the lifting assembly 8 lifts and separates the wire basket 11 from the paint storage barrel 12. The cylinder of the wedge - block clamping assembly 9 acts to loosen the wedge - shaped buckle 13 on the stainless - steel cover assembly 10, and the product dipping process ends.

[0050] After the wedge - block clamping assembly 9 loosens the wedge - shaped buckle 13, the nitrogen springs 14 on both sides of the stainless - steel cover assembly 10 will slightly bounce up the cover, which can better open the cover; when the cover is fully opened, the nitrogen springs 14 can well maintain the open state of the cover, avoiding the cover falling when taking out the product. The taken - out product is dried to obtain the finished product.

[0051] The technical idea of the present invention is as follows: 1. Replace the dipping process, advance the vacuum - pumping process in the dipping machine, and ensure that the air in the product is completely pumped out before immersing the product in the insulating paint; 2. Improve the dipping process, and add a process after the product is immersed in the insulating paint: pressure - adding dipping. Pressure - adding dipping is to inject compressed air into the dipping machine to pressurize after the product is completely immersed in the insulating paint, indirectly pressurizing the insulating paint wrapping the product, so that the insulating paint can penetrate into the gaps of the product, ensuring good dipping of the product.

Claims

1. A fully automatic dipping machine, characterized in that, it includes a housing body assembly (1), a working assembly (2) and a control assembly (3). The working assembly (2) includes a vacuum chamber (7), a lifting assembly (8), a wedge clamping assembly (9) and a stainless steel cover plate assembly (10). A wire basket (11) and a paint storage barrel (12) are arranged in the vacuum chamber (7). The wire basket (11) is controlled by the lifting assembly (8) to enter and leave the interior of the paint storage barrel (12). A sealing ring (18) is arranged at the contact position between the stainless steel cover plate assembly (10) and the vacuum chamber (7) to form a seal with the vacuum chamber (7) to prevent air leakage. The wedge clamping assembly (9) is used to form a clamping connection with the wedge-shaped buckle (13) on the stainless steel cover plate assembly (10). The control assembly (3) is used to control the gas circuit and the circuit; The control assembly (3) includes a button board assembly (15) and a pipeline assembly (16). The button board assembly (15) is arranged on the upper end surface of the housing body assembly (1) for operating and controlling the dipping machine. The pipeline assembly (16) includes a gas circuit assembly (17) and a circuit assembly, which are respectively fixed on the vacuum chamber (7) and the electrical installation board (19); The gas circuit assembly (17) includes a vacuum pump (20) and solenoid valves, pressure gauges and safety valves that are connected to the vacuum pump through pipelines. The solenoid valves include an exhaust solenoid valve and a pressurizing solenoid valve, and are controlled and switched by the control assembly (3); The lifting assembly (8) is fixed on the vacuum chamber (7) and includes a servo motor (22), a linear guide rail (23), a ball screw (24), a connecting plate (25) and a fork arm (26). The servo motor (22) drives the ball screw (24) to rotate forward and backward to realize the lifting and lowering of the fork arm (26); The wedge clamping assembly (9) is arranged on the vacuum chamber (7) and includes a cylinder and two wedge clamping parts (21) controlled by the cylinder. The end of the stainless steel cover plate assembly (10) is provided with a wedge-shaped buckle (13), and the two wedge clamping parts (21) form a clamping connection with the wedge-shaped buckle (13); the angle between the inclined surfaces of the wedge-shaped buckle (13) and the wedge clamping part (21) is less than the friction self-locking angle.

2. A fully automatic dipping machine according to claim 1, characterized in that, the housing body assembly (1) includes a welded frame (4), a rear door assembly (5) and casters (6) for fixing and supporting the working assembly (2) and the control assembly (3).

3. A fully automatic dipping machine according to claim 1, characterized in that, nitrogen springs (14) are further arranged on both sides of the stainless steel cover plate assembly (10) for supporting the stainless steel cover plate assembly (10).

4. A dipping method of a fully automatic dipping machine, which is carried out by using the fully automatic dipping machine according to any one of claims 1-3, characterized in that, it includes the following technological steps: (1) Preparation: First, place the product and the insulating paint in the wire basket (11) and the paint storage barrel (12) respectively, close the stainless steel cover plate assembly (10), adjust the technological parameters during the operation of the dipping machine through the control assembly (3), and then press the start button; (2) Impregnation: The impregnation machine starts. The cylinder of the wedge clamping assembly (9) pushes the wedge clamping part (21) to clamp the wedge-shaped buckle (13) on the stainless steel cover assembly (10). Then the vacuum pump (20) starts to work. When the set vacuum pressure is reached in the vacuum chamber (7), after maintaining the vacuum for a period of time, the lifting assembly (8) starts to lower the wire basket (11) into the paint storage tank (12), and the product also enters the insulating paint accordingly. (3) Pressurization: When the product is completely immersed in the insulating paint, the control assembly (3) energizes the pressure solenoid valve to connect the external compressed air, and starts to inject compressed air into the vacuum chamber (7). After the set air pressure is reached in the vacuum chamber (7), the pressure solenoid valve automatically disconnects, and then the positive pressure in the vacuum chamber (7) is maintained for a certain period of time. (4) Pressure relief and material taking: After the pressurization is completed, the control assembly (3) energizes the exhaust solenoid valve to connect, connecting the vacuum chamber (7) to the external atmosphere. After the air pressure in the vacuum chamber (7) returns to normal atmospheric pressure, the lifting assembly (8) lifts and separates the wire basket (11) from the paint storage tank (12). The cylinder of the wedge clamping assembly (9) acts to release the wedge-shaped buckle (13) on the stainless steel cover assembly (10). The impregnation of the product ends. After taking out the impregnated product, it is dried.

5. The impregnation method of a full-automatic impregnation machine according to claim 4, characterized in that, the set vacuum pressure in step (2) is -100~-80 kPa, and the vacuum state is maintained for 1~30 min.

6. The impregnation method of a full-automatic impregnation machine according to claim 4, characterized in that, the set pressure for pressurization in step (3) is 0.1~0.5 Mpa, and the positive pressure state is maintained for 1~30 min.

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