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TECHNOLOGY
IMPREGNATION
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TECHNOLOGY
Whether trickling, roll dipping, hot dipping, vertical dipping or
potting – our solutions ensure a reliable process to
guarantee a high quality and continuous impregnation result.
The bdtronic trickling and dipping equipment is particularly
used to impregnate and cure electro-technical wounded
objects. Our large product portfolio goes from small stand-
alone to high-volume machines.
IMPREGNATION
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IMPREGNATION
APPLICATIONS
All winded
objects
Coils
Solenoids &
transformers
Stators
Electrical motors
Rotors
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IMPREGNATION
PRINCIPLES
1. Trickling 2. Roll dipping 3. Hot dipping 4. Vertical dipping 5. Potting (vacuum)
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IMPREGNATION
• To glue the coils and provide mechanical strength
• To provide thermal and environmental resistance
• To improve the heat transfer
• To replace the air in the insulating system (PD)
• To reinforce the electrical insulation
WHY IMPREGNATING?
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IMPREGNATION
How it works
- The object (rotor or stator) is placed on rotating tools
- The resin is trickled with the correct amount onto the rotating and
pre-heated windings of the object
- The treated unit travels into an oven and is cured while still rotating
Advantages
- Lowest resin consumption
- High percentage of filling grade
- Clean and automatic process
- Complete process monitoring possible
- High reactive or 2 components resins should be used
- Perfect resin distribution and selection of the resin application zones
- Possibility to access narrowed zones (with inclination options)
1. TRICKLING
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IMPREGNATION
How it works
- The object (rotor or stator) is placed on rotating tools
- The resin is sucked by the pre-heated windings of the object
through the slot during the surface dipping into the resin bath
- The treated unit travels into an oven and is cured while still rotating
Advantages
- Low resin consumption
- High percentage of filling grad
- Clean and automatic process
- Process monitoring possible
- Perfect resin distribution and selection of the resin application
- Simple machine set up
2. ROLL DIPPING
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IMPREGNATION
How it works
- The object is pre-heated
- The component is dipped into the resin
- The object is drained over the dip tank or dropping tank and
placed/transferred into an oven to cure
Advantages
- Low tooling and machine cost
- Simple process (no rotation)
- Low resin loss (compared to normal dipping)
- High productivity (high density of parts in volume)
- Versatile (simple set up of parameters)
3. HOT DIPPING
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IMPREGNATION
How it works
- The object is pre-heated using joule effect on wires and SWIR on
external side
- The component is dipped into the resin
- The object is drained over the dip tank with a defined angle, then
scraped to clean
- The rotation is started and the current flows into the wires to cure
and the SWIR cures the external resin
Advantages
- High percentage of filling grad
- Low resin consumption
- Clean and automatic process
- Process monitoring possible
- Fast heating system
- Small surface occupied (no ovens)
4. VERTICAL DIPPING
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IMPREGNATION
5. POTTING (VACUUM)
How it works
- The object should be pre-heated after mold or base preparation
- The resin is potted into the component, a mold is pressed into the
bore or with mold in place the resin is injected from the bottom by
using vacuum
- The object is placed/transferred in an oven to cure
- The mold is pulled out
Advantages
- Highest quality of the parts (heat transfer and environmental
protection)
- 2 components material usage
- No void in the potting mass
- Low temperature curing
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IMPREGNATION
TEMPERATURE MANAGEMENT
Heating up
Curing
Gelling
Cooling down
Impregnation material status changes from liquid application to solid functional cure!
(In general 1 or 2 components need to add external energy)
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IMPREGNATION
GELLING & CURING
Gelling
Time in which the resin starts to polymerize at a
given temperature (the resin is not fully cured at
this stage)
Curing
Time needed by the resin to be fully cured at a
given temperature. The resin is fully cured when
there is no more polymer evolution during this
time. The end glass transition temperature of
the resin has been reached.
The resin needs to be fully cured at the end of
this process in order to:
- Avoid chemical evaporation (smell…) when the motor
runs
- Avoid weight loss (air gaps and ageing problems) and
resin shrinkage
- Obtain the best mechanical and chemical resistance
properties
- If polymer is not stabilized, the ageing properties will
certainly change
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IMPREGNATION
Impregnation resin and varnish needs to be cured by external energy supplying (from 80 up to 200°C)
in function to the resin type
CURING METHODS
1. Hot air 2. SWIR (Infrared) 3. Joule effect
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IMPREGNATION
Electrical heaters heat up the air that due to a close loop recirculation will
exchange energy with the parts that will be heated up
Advantages
- High drying effect during the pre-heating for laminations pack and windings
- Temperature uniformity in whole parts mass
- No wires connection needed
- Allows automatic work flow and similitude in new parts processing
- The continuous mix of the air allows works in safe mode also with solvent presence
- No over temperature possible (safe for production)
- Simply machine set up
- No influence on the quality due the process interruptions
- Perfect curing of the resin also on plastic parts and laminations
- High efficiency and precision temperature regulation on bdtronic machines
1. HOT AIR
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IMPREGNATION
The parts are exposed to a SWIR light that due to the irradiation energy
transfer the parts will be heated up
Advantages
- High speed of the surface heating
- Simply adjusting of the emission power
- No wires connection needed
- Allows automatic work flow and similitude in new parts processing
- Low temperature tooling needed (only the parts are heated up)
- Normally the best is to use that technology in combination with joule effect or hot air technology
- Machine size
- Highest efficiency and precision temperature regulation on bdtronic machines
2. SWIR (INFRARED)
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IMPREGNATION
The parts wires are connected with a power supply systems (DC or AC) that
will circulate the electrical current trough the parts wires that will be heated up
Advantages
- High speed of windings heating
- High temperature accuracy on the windings
- Low temperature tooling needed (only the parts are heated up)
- Possibility to achieve an high filling grade due to a fast resin gelling process
- Machine size
- Highest efficiency and precision temperature regulation on bdtronic machines
3. JOULE EFFECT
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IMPREGNATION
Polyester
- Usually diluted in monomer (unsaturated polyester UP) or solvent (saturated polyester PE)
- Highly reactive & easy to use
- Medium adhesion & mechanical (brittleness) thermal class F-H
Epoxy
- With our without solvent (e.g. for high voltage)
- Relatively high viscosity
- Good adhesion, mechanical & chemical resistance properties
- Usually lower ageing properties at high temperature than good polyesterimide
Silicone
- High temperature resistance
- Class C application for traction motors
- Some mechanical and chemical resistance weakness
RESINS CHEMISTRY
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IMPREGNATION
PROCESS CONTROL
Temperature monitoring/
temperature control
Dipping tank level control
Trickling nozzle control
Rotation speed control
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IMPREGNATION
STANDARD MACHINES
B7200
Impregnation machine
for single or double
spindle production
with joule effect
B8400-8500
Impregnation
machine for large
parts production
B8100
Fully automated
impregnation machine
for small parts
production
B8600
Impregnation lab
machine for single
part processing
B8300
Fully automated
impregnation machine
for small parts and
high production
volume
B8700
Fully automated and
modular impregnation
machine for large
parts production
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IMPREGNATION
QUESTIONNAIRE
Object to be impregnated
Dimensional drawings
For joule heating: resistance and wiring details
Special requirements (i.e. maximum resin thickness,
temperature limit)
Impregnation process
Preferred impregnation method/s
Production capacity (a year/shift or parts/h)
Operation mode (manual/semi automatic/automatic)
Resin
Datasheets and MSDS
Local contact of resin supplier
Varies
Lab trials required /needed for
Any special request?
Budget/place of installation/forecast of production start
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IMPREGNATION
REFERENCE PROJECT
Product description &
usage/function/information:
Impregnating and curing of stators and
armature (rotor) using polyester resin in
mix flow
Work piece material/
product composition:
More than 1000 variants – max. Ø 490
mm, shaft max. 1.050 mm, weight = 250
kg
Project description: Roll dipping in 1 phase with automatic
recipe selection, manual load/unload
Machine description: Hot air ovens with continuous
transportation chain and parts rotation
Process: Load/unload 1 or 2 equal parts, barcode
recipes load, pre-heat, roll dipping, gelling,
curing, cooling
Material description: Polyester (FT 1040/120E)
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IMPREGNATION
REFERENCE PROJECT
Product description &
usage/function/information:
Impregnating and curing, with a high and
constant filling grade, the stators coils
using a silicone keeping cleaned all the
metal surfaces (inside and outside) for the
automotive industry
Work piece material/
product composition:
Stator max. Ø 400 mm, length max. 160
mm, weight = 35 kg; 21 stators/h, 170
s/pieces (6 parallel)
Project description: Trickling in 1 phase with automatic recipe
selection, inclination 10’, 6 gear pumps +
MPS
Machine description: Hot air ovens with continuous
transportation chain and parts rotation
Process: Load/unload 6 equal parts, barcode
recipes load, pre-heat, trickling in
inclination, gelling, curing, cooling
Material description: Silicone – Silres H62 C – 1 component
THANK YOU
FOR YOUR ATTENTION
