Inductive Heating Stator Impregnation Device
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Solution Overview
Problem
Existing methods for impregnating stators or armatures of electric machines with synthetic resin are inefficient due to complex temperature control and indirect heating, leading to prolonged production times and increased energy costs.
Innovation Solution
An impregnation device utilizing an electromagnetic inductor for inductive heating, which generates eddy currents to rapidly and uniformly heat all electrically conductive components, including the synthetic resin, thereby reducing heating time and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electrical heating current is passed through the windings to heat the stator or armature, then the windings can be heated to the required temperature, but the heating process becomes time-consuming and energy-intensive due to indirect heating and temperature control deviations
Solution Approach 1:
The patent replaces the conventional electrical resistance heating system with an electromagnetic induction heating system. Instead of passing heating current through the windings, an electromagnetic inductor generates a time-varying magnetic field that induces eddy currents in the stator or armature, producing heat directly within the workpiece. This substitution of heating mechanism dramatically reduces heating time and eliminates temperature control deviations associated with resistance heating.
Solution Approach 2:
The electromagnetic inductor acts as an intermediary between the power source and the stator/armature. Rather than directly heating the windings through electrical contact, the inductor mediates the energy transfer by generating a magnetic field that penetrates the stator or armature and induces internal eddy currents. This intermediary approach enables rapid, uniform, and contactless heating.
2Temperature
If conventional electrical heating is used, then the windings can be heated, but all components surrounding the windings do not reach the required temperature uniformly, requiring extended heating time
Solution Approach 1:
The electromagnetic induction heating system applies local quality by generating heat directly within each component that the magnetic field penetrates. The time-varying magnetic field induces eddy currents locally in the stator core, windings, and surrounding components, causing each to heat uniformly from the inside out. This localized heating approach ensures all components reach the required temperature simultaneously and uniformly, eliminating the temperature gradients and extended heating times associated with conventional methods.
3Measurement precision
If heating current is regulated based on winding temperature alone, then the winding temperature can be controlled, but the temperature of other components and the synthetic resin remains uncertain, requiring safety margins that extend process time
Solution Approach 1:
The patent implements a feedback control system using temperature sensors that directly measure the temperature of the stator or armature and the synthetic resin. This real-time temperature feedback is fed to a control unit that automatically regulates the electromagnetic inductor's power output and the trickle device's resin application rate. This closed-loop feedback ensures all components reach and maintain the required temperatures with precision, eliminating the need for safety margins and extending production efficiency.
Solution Approach 2:
The patent replaces indirect temperature inference (based on winding resistance) with direct temperature measurement using temperature sensors. This substitution provides accurate, real-time temperature data from all critical components including the synthetic resin, enabling precise control without safety margins and dramatically improving productivity.
4Temperature
If indirect heating through windings is used, then the windings can be heated, but the synthetic resin heats slowly through heat transfer, prolonging the impregnation process
Solution Approach 1:
The electromagnetic inductor serves as an intermediary that directly transfers energy to the synthetic resin through the time-varying magnetic field. The magnetic field penetrates the stator or armature and induces eddy currents that generate heat directly within the resin, bypassing the slow heat transfer process from the windings. This direct electromagnetic heating of the resin dramatically reduces the heating duration and accelerates the impregnation process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device enables faster and more energy-efficient impregnation, reducing manufacturing costs and production time by simultaneously heating all components, including the resin, while ensuring uniform temperature distribution.
Implementation Method 1
utilizing an electromagnetic inductor for inductive heating, which generates eddy currents to rapidly and uniformly heat all electrically conductive components
Implementation Method 2
electromagnetic inductor for inductive heating
Data Source
AI summary
The invention relates to an impregnation device (1) for trickle impregnation of a stator (2) or armature of an electric machine with a synthetic resin (5) curing under temperature increase, comprising a holding device (32) which can be tilted vertically relative to the horizontal (16) and to which a drive motor (12) is attached as a rotary drive for the stator (2) or the armature, a drive shaft (58) operatively connected to the drive motor (12), a clamping device (34) which is non-rotatably connected to the drive shaft (58) and capable of detachably connecting the stator (2) or the armature to the drive shaft (58), a trickle device (24) capable of applying a synthetic resin (5) onto at least one axial end of the windings (4) of the stator (2) or the armature, and a heating device capable of heating the windings (4) of the stator (2) or the armature to a trickle temperature and to a comparatively higher curing temperature. The heating device according to the invention comprises an electromagnetic inductor (6) which is arranged coaxially or axially parallel to the stator (2) or the armature. The invention also relates to a production plant (40) for the trickle impregnation of a stator (2) or armature, in which this impregnation device (1) is integrated.