Inductive Heating for Stator Impregnation
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Solution Overview
Problem
Current methods for impregnating the stator or armature of electric machines with synthetic resin are inefficient, requiring extended production time and increased energy costs due to indirect heating and temperature regulation challenges, particularly when using electrical heating currents through windings.
Innovation Solution
The method employs inductive heating using a high-frequency or medium-frequency alternating magnetic field generated by an electromagnetic inductor to rapidly and uniformly heat all electrically conductive components of the stator or armature, including the synthetic resin, allowing for simultaneous and efficient temperature control across all components.
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 heating function is achieved, but the temperature control becomes complex and time-consuming
Solution Approach 1:
The patent replaces the electrical heating current method (mechanical/electrical system) with infrared radiation heating (electromagnetic radiation system). The infrared heater directly radiates thermal energy to the stator or armature and synthetic resin, eliminating the need to pass current through windings and the associated temperature control complexity. This substitution significantly reduces heating time while simplifying the control system.
Solution Approach 2:
The patent employs periodic heating cycles with distinct phases: a first heating period to reach trickle temperature for resin impregnation, followed by a second heating period to reach curing temperature. This periodic action optimizes the heating process by applying heat in controlled stages, reducing total heating time while ensuring proper resin penetration and curing.
2Temperature
If electrical heating current is used to heat the windings, then heating is achieved, but energy consumption increases
Solution Approach 1:
The patent substitutes the energy-intensive electrical heating current method with infrared radiation heating. The infrared heater directly transfers thermal energy to the stator or armature and synthetic resin through electromagnetic radiation, eliminating energy losses associated with resistive heating of windings. This results in significantly reduced energy consumption while achieving the required curing temperature.
3Temperature
If heating current is passed through windings, then temperature control is possible, but the complexity of feeding current into rotating stator or armature increases
Solution Approach 1:
The patent replaces the complex electrical heating system requiring current feed into rotating components with a stationary infrared radiation heating system. The infrared heater can be positioned externally and radiates heat through space, eliminating the need for sliding contacts, rotary joints, or other complex current feeding mechanisms for rotating stators or armatures. This dramatically simplifies the heating device while maintaining effective temperature control.
4Temperature
If heating is performed indirectly through windings, then heating is achieved, but the heating time extends significantly
Solution Approach 1:
The patent substitutes indirect heating through windings with direct infrared radiation heating. The infrared heater directly irradiates the stator or armature and synthetic resin, providing immediate and uniform heating throughout the components. This direct heating approach eliminates the thermal lag associated with indirect heating through windings, significantly reducing the heating duration required to reach curing temperature.
Solution Approach 2:
The patent implements optimized periodic heating cycles with a first period to reach trickle temperature and a second period to reach curing temperature. This staged heating approach ensures efficient heat transfer and proper resin impregnation followed by complete curing, minimizing total heating time while maintaining quality standards.
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
This approach significantly reduces heating time and energy consumption, enabling faster and more cost-efficient impregnation processes while ensuring uniform heating and preventing overheating of non-metallic components.
Implementation Method 1
heating the stator or armature inductively
Implementation Method 2
high-frequency or medium-frequency alternating magnetic field generated by an electromagnetic inductor
Implementation Method 3
When the stator or armature is subsequently heated to a curing temperature of the synthetic resin, it solidifies and becomes a duroplast
Data Source
AI summary
A method for trickle impregnation of a stator or armature of an electric machine with a synthetic resin curing under temperature increase comprises heating the stator or the armature from an initial temperature to a trickle temperature range of the synthetic resin; keeping constant the temperature in the trickle temperature range and introducing the synthetic resin into the stator or the armature; heating the stator or the armature to a curing temperature range; keeping constant the temperature of the stator or the armature in the curing temperature range and setting and curing the synthetic resin to a duroplast; and cooling down the stator or the armature. The trickle temperature range has lower temperatures than the curing temperature range. The method includes inductively heating the stator or the armature. The stator or the armature may be disposed in an impregnation device.