Modular Motor Component Impregnation to Minimize Handling Shocks
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Solution Overview
Problem
Existing impregnation plants for electric motor components suffer from handling shocks during transitions between work stations, leading to suboptimal results, and are inflexible in accommodating changes in production volume.
Innovation Solution
A modular impregnation plant with movable modules and central control for axial symmetrical components, minimizing component movement and allowing easy adaptation to production volume changes and process modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If components are moved between separate work stations for pre-heating, impregnation, and gelling, then the process can be completed in sequence, but handling shocks occur during transitions leading to suboptimal impregnation results
Solution Approach 1:
The patent combines pre-heating, impregnation, and gelling operations into a single integrated work station. The heating element, resin injection system, and rotation mechanism coexist in one stationary workspace, eliminating the need to move components between separate stations. This merging prevents handling shocks while maintaining sequential process steps, directly resolving the contradiction between process completion and shock avoidance.
Solution Approach 2:
Instead of moving the component through multiple stationary work stations, the patent inverts the approach by bringing all necessary processing functions to a single stationary work station where the component remains throughout the entire process. The heating element, resin injection system, and control mechanisms are positioned around the stationary component, reversing the traditional flow and eliminating transport-related shocks.
2Adaptability or versatility
If traditional impregnation plants use fixed work stations for each process step, then the process flow is stable, but the plant cannot easily adapt to changes in production volume
Solution Approach 1:
The patent introduces dynamic adjustability to the work station configuration. The heating element, resin injection system, and other processing components can be repositioned or reconfigured within the workspace to accommodate different production volumes and component types. This dynamic capability allows the same plant to adapt from low-volume custom production to high-volume standard production without requiring complete reconfiguration.
Solution Approach 2:
The single work station is designed with universal functionality to perform multiple operations (pre-heating, impregnation, gelling) and accommodate different component types and production volumes. The integrated design allows the same equipment to serve various manufacturing needs, making the plant versatile and adaptable to changing production requirements while maintaining a relatively simple overall structure.
3Adaptability or versatility
If multiple separate work stations are used for each impregnation step, then each process can be optimized independently, but the plant requires complex management and cannot easily modify processes
Solution Approach 1:
By merging pre-heating, impregnation, and gelling functions into a single integrated work station, the patent reduces the number of separate systems that need to be managed. The centralized control architecture allows process modifications to be implemented in one location rather than coordinating changes across multiple independent stations, significantly easing process adaptation while maintaining the ability to optimize each step independently through coordinated control.
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
Reduces handling shocks, ensures better impregnation quality, and allows flexible production adjustments without stopping the process, enhancing productivity and product customization.
Implementation Method 1
a heating element, which is arranged to heat each component (100) to a predefined temperature
Implementation Method 2
The resin penetrates the interstices between the individual filaments or the individual bars by capillarity
Implementation Method 3
each support device (16) is configured to impart a rotary movement around a predefined rotation axis
Implementation Method 4
arranged to impart a tilting movement, with respect to a predefined plane, to each component (100) mounted on its respective support device (16)
Implementation Method 5
The impregnation plant (10) is managed by a central processing unit, which is arranged to control a sequence of operations
Implementation Method 6
In this gelling step, the temperature of the component is raised, so as to trigger a resin reticulation process
Implementation Method 7
Once the baking step is over, the component undergoes a final cooling step
Data Source
AI summary
Impregnation plant for electric motors axial symmetrical components including: a fixed support frame; a fixed heating station to heat each component to a predefined temperature, each fixed heating station has one or more motorized support devices to support the components and a rotary movement, in both directions of rotation around a predefined rotation axis, and a tilting movement, with respect to a predefined plane are provided on each component mounted on its respective support device; an impregnation module to cover at least part of each component with an impregnating substance; and a transport and loading/unloading module to transfer components from and toward the fixed heating stations. The support frame has a handling and guiding apparatus, having movably mounted thereon impregnation modules and the transport and loading/unloading modules and, removably selectively receive a further movable work module of the impregnation plant.