Stator Impregnation Plant with Dynamic Tilting and Rotation
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Solution Overview
Problem
Traditional impregnation methods for electric motor stators, particularly those with 'hair pin' technology, fail to effectively coat the compactly arranged metal bars with resin, leading to incomplete filling of cavities and potential surface contamination.
Innovation Solution
An impregnation plant and method that control the rotation direction, tilt, and speed of the stator, along with precise resin dispensing, to ensure complete coating of the metal bars, using a multi-station process with heating, impregnation, gelling, and baking steps managed by a central processing unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional trickling impregnation method is used with stator held horizontally in rotation, then the process is simple to operate, but the resin cannot effectively fill narrow and winding cavities between compactly arranged metal bars
Solution Approach 1:
The stator is made tiltable and rotatable during impregnation, transforming from a static horizontal position to a dynamic multi-position configuration. The support device allows the stator to be tilted at adjustable angles and rotated, enabling resin to access cavities from multiple directions and ensuring complete coating of compactly arranged metal bars.
Solution Approach 2:
The impregnation process transitions from a single-dimensional horizontal trickling approach to a multi-dimensional approach by tilting the stator at various angles. This allows resin to penetrate cavities from different spatial directions, effectively coating narrow and winding spaces between metal bars that cannot be reached by horizontal trickling alone.
2Manufacturing precision
If resin is trickled onto heads of horizontally arranged stator, then the dispensing process is simple, but the resin flow by capillarity is insufficient to fill all narrow cavities and interstices
Solution Approach 1:
The stator support device enables dynamic tilting and rotation during the impregnation process. By adjusting the tilt angle and rotation, the resin can flow into cavities from multiple angles, ensuring complete filling of narrow and winding interstices between metal bars that cannot be accessed by fixed horizontal trickling.
Solution Approach 2:
The impregnation process utilizes changes in gravitational direction by tilting the stator at various angles. This parameter change allows resin to flow into cavities from different directions, enhancing capillary action effectiveness and ensuring complete cavity filling that cannot be achieved with fixed horizontal positioning.
3Manufacturing precision
If stator is held in rotation during trickling to prevent resin loss, then resin deposition is controlled, but the rotation speed must be precisely controlled to balance coating quality and process efficiency
Solution Approach 1:
The support device allows dynamic adjustment of rotation speed and tilt angle during impregnation. By optimizing the combination of rotation speed and tilt angle, the process achieves both precise resin deposition control and improved productivity, as resin can penetrate cavities more effectively when the stator is tilted and rotated at controlled speeds.
Solution Approach 2:
The impregnation process employs periodic rotation and tilting of the stator, alternating between different positions to maximize resin penetration into cavities. This periodic action ensures complete coating while maintaining controlled deposition, balancing precision and efficiency by cycling through optimal positions during the impregnation cycle.
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
Achieves comprehensive and precise resin coating of electric motor components, enhancing mechanical strength and preventing surface contamination, suitable for both wound wire and 'hair pin' stators.
Implementation Method 1
a first heating station (22), configured to heat each component (100) to a predefined temperature
Implementation Method 2
one or more impregnating substance dispenser means (30), moved by controlled axles (32)
Implementation Method 3
This step first causes a gelation (the resin thickens or, in other words, its viscosity rises up to glass transition which determines its transition from the liquid state to the solid state)
Implementation Method 4
subsequently the baking of the resin, which polymerizes and definitively hardens
Implementation Method 5
the stator, still held in rotation, undergoes a high temperature baking step
Implementation Method 6
The resin, which is only deposited onto the heads of the cylinder which forms the stator, flows by capillarity along the wires or bars, up to penetrating and filling the cavities placed inside the wall of such cylinder
Data Source
AI summary
Impregnation plant for internally hollow cylindrical components (stators) of electric motors including working stations arranged linearly and sequentially, managed and controlled by central processing unit; and a plurality of motor-driven elements to impart rotatory motion, in both directions of rotation, and tilting motion, in both directions respective to a predefined plane, to each component mounted onto a respective support device when such support device is inserted into the plant working stations. Each support device has a spring collet in turn has blocks clamping the component onto the inner diameter of its respective cylindrical body. Each spring collet entirely crosses the component cylindrical body to rest on both of its respective circumferential ends. An impregnation method for electric motor components using the impregnation plant, wherein the component is rotatable in both directions about a support device predefined axis, and tiltable respective to a predefined plane of such support device.