Trickle Impregnation Preheating Using Winding Resistance Heating
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Solution Overview
Problem
Existing impregnation devices for electrical machine parts require lengthy heating times in ovens, increasing the overall duration of the impregnation process due to the mass and volume of the parts, which can take up to 1.5 hours to reach the necessary temperature.
Innovation Solution
An impregnation device with a preheating unit that allows for electrical heating of machine parts using a current heat unit, connected via contact means, and a control unit that adjusts power supply based on detected electrical resistance, enabling quick and energy-efficient heating, along with a dripping and curing device for uniform coating application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional oven heating is used to heat machine parts before impregnation, then the machine parts can be heated to the necessary temperature, but the heating time increases to at least 30 minutes and up to 1.5 hours
Solution Approach 1:
The patent replaces the conventional thermal convection heating system (oven) with an electrical heating system that uses current flow through the machine part windings to generate heat directly within the part. This substitution of heating mechanism dramatically reduces heating time from 30-90 minutes to a much shorter duration, as the heat is generated internally rather than being transferred from an external oven environment.
Solution Approach 2:
The patent performs the heating action before the impregnation process begins, using the machine part's own electrical windings as heating elements. By pre-heating the machine part to the required temperature (e.g., 80-100°C) before applying the coating agent, the system ensures optimal conditions for impregnation while minimizing total process time through efficient preliminary heating.
2Temperature
If conventional oven heating is used, then uniform heating can be achieved, but the energy consumption increases and production efficiency decreases
Solution Approach 1:
The patent replaces energy-intensive external oven heating with electrical resistance heating that generates heat directly within the machine part windings. This internal heat generation method is significantly more energy-efficient because it eliminates heat loss to the surrounding oven environment and directly heats the target material where it is needed, reducing overall energy consumption while maintaining temperature uniformity.
Solution Approach 2:
The machine part's own electrical windings serve as the heating element, allowing the part to heat itself without requiring an external heating system. This self-heating mechanism improves energy efficiency by eliminating the thermal inefficiencies of external heating and directly converting electrical energy into heat within the part that needs heating.
3Device complexity
If the impregnation process uses conventional heating methods, then the process can be simplified in terms of equipment, but the production time increases significantly
Solution Approach 1:
The patent makes the machine part's electrical windings serve dual functions: their primary function as electrical windings and their secondary function as heating elements during the impregnation process. This multi-functionality eliminates the need for separate heating devices, maintaining equipment simplicity while dramatically improving heating speed and overall production efficiency.
Solution Approach 2:
The patent replaces complex external heating systems with a simplified electrical heating approach that uses the existing windings. This substitution maintains device simplicity while achieving faster heating times, thereby improving productivity without increasing equipment complexity.
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 solution significantly reduces the production time for impregnated machine parts by enabling rapid heating and maintaining optimal temperatures for efficient coating application, while also being energy-efficient and allowing for flexible device configurations.
Implementation Method 1
at least one current heat unit, through which the machine part can be electrically heated to a preheating device temperature
Implementation Method 2
a sensor means, through which an electrical resistance of the machine part is determined
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to an impregnation device (2) for trickle impregnation of at least one machine part (4) intended for electrical machines, such as wound material, in particular stator or rotor, with at least one preheating device (6) comprising at least one holding means (8) to which at least one machine part (4) can be fixed, and comprising at least one electric heating unit (10) which can be manually or automatically connected or connected by at least one contact means (12) in the arrangement of the machine part (4) fixed on the holding means (8) to at least one phase connection of the machine part (4) and by which the machine part (4) can be electrically heated to a preheating device temperature, and comprising at least one trickle device (14).a machine part (4) heated to the temperature of the preheating device (6) by the electric heating unit (10) can be supplied directly or indirectly and a coating agent, such as resin, in particular synthetic resin, which hardens under temperature increase, can be applied, in particular dripped, to the machine part (4).