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Bonding Machines

Thermal bonding of windings and coils of any type

We implement your individually designed automatic thermal bonding machines according to your specifications. We offer manual individual or multiple workstations as well as fully automatic systems for line production or rotary switching tables.

SCHLEICH bonding systems allow for up to eight simultaneous, autonomous bonding processes.

Product consultant

You need a personal product advice?
Please use our direct contact:
+49 2372 901 25 40
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Key-Facts

Reliable. Easily configurable. Reproducible. Highest precision.

  • Current heating systems
  • Electrical heating of coils
  • DC-bonding machine
  • AC-bonding machine for interconnected 3-phase windings
  • Up to 100 kW
  • Up to 2.500 A
  • Up to 1.000 V
  • Up to 250 A/mm and more – depending on the load capacity of the winding connector
  • Different heating methods
    • constant voltage
    • constant current
    • constant temperature
    • temperature profil
  • Bonding or impregnation of numerous coils in series- and parallel connection
  • Standard- and high speed bonding with current densities up to 200 A/mm2
  • Monitoring of temperature course during the bonding process
  • Kelvin-resistance measurement (4W technology)
  • Online temperature-monitoring
  • Online connection clamps monitoring
  • Dynamic over-current sensor and quick switch off
  • Ground fault oberserver and quick switch off
  • Monitoring of integrated sensors like temperature sensors…
  • May also be combined with numerous other tests
    • Surge test
    • Partial discharge test
    • HiPot test
    • Field rotation test
    • Insulaton test
  • Integration into test systems- the bonding process is performed as additional test step
  • Integration in automatic production lines

Description

Excellent quality for your product.

SCHLEICH-bonding machines make it possible to bond and test self-bonding wired coils directly after the winding process.  They allow the bonding and curing of coils for single- and three phase motors and all kinds of armatures and coils like speaker coils, magnet coils etc.

The bonding process is monitored by a PC and is performed by means of the controlled, electrical heating of the coils. Depending on the current density, different heating times result. Different current densities lead to bonding processes which may last from only a few seconds up to several minutes. After the heating phase it is also possible to constantly keep the reached temperature for a certain time. The result is a uniform temperature distribution within the winding and thus the best possible, homogeneous bonding in all parts of the winding.

Besides the use at single working stations our bonding machines are also perfectly suitable for the integration into fully-automatic production lines. Pallet control in a production line or the exchange of data with a PLC can also be easily realized. The machine´s design is intended to control up to eight independently running bonding processes and to display them on the screen.

As system supplier we are able, in addition to the electric bonding machine itself, to also provide the entire mechanics which may consist of single bonding stations, a rotary indexing table or even an entire production line. Only the combination of these perfectly-matched components assures you the best possible production result.

Of course, also overhang forming tools and expanding mandrels belong to our range of products.

Furthermore our bonding machines may be extended by our MTC3- stator testers which make it possible to get detailed information about your product´s quality before and after the bonding process.

Bonding variant: Constant voltage method

A constant voltage is supplied to the winding. With increasing temperature also the winding´s resistance increases and thus the current decreases. Consequently, with rising temperature less power/energy is transferred into the winding.

The advantage of this method is, that the temperature rises rather slow which results in a good and even stator heating. Thus, the temperature deviation between overhang and slot is ideally low when reaching the bonding temperature.

However, as the densest current in the wire can only be reached at the beginning of the bonding process, no short bonding time is possible.

Bonding variant: Constant current method


This method keeps a constant current level during the bonding process. To be able to keep the decreasing current level constant while the resistance increases, the bonding machine automatically increases the voltage during the bonding process. That is why the final temperature is reached in shorter time compared to the bonding method with constant voltage. However, at this, the temperature may be unevenly distributed in the winding.

The advantage of this method is the achievement of short bonding times. However, in most cases an uneven temperature distribution occurs.

 

Bonding variant: Constant temperature method 


During the constant-voltage or constant-current method the bonding process is stopped, as soon as the bonding temperature is reached.

The time, in which the self bonding coat melts at the wire´s surface and coalescenses with the neighbouring strands is relatively short at both methods. Due to this, it may happen, that the slot´s wires stay a bit cooler then the ones in the overhang, due to the surrounding laminated core. This could lead to a poorer quality.

With the constant-temperature method, as soon as the targeted temperature is reached, it is kept for a certain time. By this, the  time in which the self bonding coat melts at the wire´s surface and coalescenses with the neighbouring strands, is extended.

 

Bonding method: Temperature profile method


Bonding with a temperature profile basically corresponds to bonding with constant temperature, but, however, at this method, several temperature levels are reached one after another.

At this, the temperature difference between hangover and slot may aready be adapted during lower pre-temperatures before the actual melting process.

This method is mainly used in cases, where the laminated core is rather long (compared to a relatively short hangover) and/ or if the laminated core´s dimensions are rather large.


Technology

Impressions

SCHLEICH_bonding machine
Bonding machine with production line

 

SCHLEICH_dual station with expanding mandrel
Dual station with expanding mandrel

 

SCHLEICH_contacting tool with expanding mandrel
Contacting tool with expanding mandrel

 

SCHELICH_forming tool
Forming tool

 

SCHLEICH expanding mandrel with forming tool
Expanding mandrel with forming tool

 

SCHLEICH_forming tool open  SCHLEICH_forming tool closed

Forming tools opened and closed

 

SCHLEICH form shaper

Form shaper for forming with pressing power


Applications

Impressions

SCHLEICH_bonding machine
Bonding machine with production line

 

SCHLEICH_dual station with expanding mandrel
Dual station with expanding mandrel

 

SCHLEICH_contacting tool with expanding mandrel
Contacting tool with expanding mandrel

 

SCHELICH_forming tool
Forming tool

 

SCHLEICH expanding mandrel with forming tool
Expanding mandrel with forming tool

 

SCHLEICH_forming tool open  SCHLEICH_forming tool closed

Forming tools opened and closed

 

SCHLEICH form shaper

Form shaper for forming with pressing power


Accessories

Terminal blocks

Modular terminal blocks to contact loose lead ends
  • stackable 4-wire clamps
  • modular design
  • different designs and sizes

read more

Kelvin Clamps

High-precision resistance measurement even for smallest resistances
  • condition for high-precise resistance measurements
  • solid industrial quality
  • 3 different sizes

read more

Motor Terminal Plugs

Test plugs for contacting motor terminal boards
  • induction motor test plugs
  • motor terminal board plugs
  • quick contact for 6, 9 or 12 bolts
  • for different motor terminal board sizes
  • with replaceable wear plate
  • without or with 2 motor housing contacts
  • the HIGHLIGHT >> with 4-wire technology

read more

Special contactings

Customized solutions based on the modular SCHLEICH building kit
  • individual solutions
  • for perfect 4-wire measurement
  • float-mounted collets

read more

analyzer

PC-Software for statistical analysis of test results
  • in-depth test result analysis
  • production online monitoring
  • informative statistics-report printout

read more

For further information please do not hesitate to contact our technical sales under:


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Product comparison

 
 
 
 
type of tester
surge test
resistance
PE/GB
insulation
polarization index
high voltage AC
high voltage DC
partial discharge
function AC 1-phase
function AC 3-phase
sense of rotation
test terminals
test cover
automation
database
test plans
test results
communication
test report print-out
label print-out
scanner port
password protection
user management
operating system
display
battery mode
delivery
 
 
 
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MotorAnalyzer1
 
MotorAnalyzer2 R2
 
MTC2
 
MTC3
 
VoltageAnalyzer
 
GLP3-M
 
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Dynamic MotorAnalyzer
 
Bonding Machines
 
Current-UV Impregnation Systems
 
PortaTest
 
Winding Machines
 

motor Service · repairs · troubleshooting · maintenance · servicing · battery operation · PC software …

multitool · 15 test methods · surge voltage 3 kV · resistance · inductance · capacitance · motor service · repair · fault detection · maintenance · battery mode · PC software …

THE surge tester – up to 50 kV – plus normative partial discharge – resistance – 4-wire measurement – Windows10® – test protocol – PDF printing – network …

Uncompromising ALL-IN-1 winding test for production · for all standard and special motors · for automotive drives · for coils of all kinds · automation · in-line partial discharge testing – worldwide networking · central data storage …

high-precision test probe – direct surge voltage measurement at the winding – partial discharge – passive / active microwave antenna – up to 6 kV …

modular ALL-IN-1 engine test system · no limits · customer specific · VDE/EN/UL/IEC … · production · automation · global networking · databases · statistics · data import/export · Windows® · complex systems …

encoder and resolver testing/adjustment · encoder signal analysis · encoder power supply: 3 – 30 V · interface: HIPERFACE – EnDat – SSI – BiSS · BEMF measurement · repair · motor service · encoder production · servo motor production …

online monitoring · fault analysis on the running motor · for mains and frequency converters · over 100 measured values · speed · torque · efficiency · unique oscilloscope · data recorder · trend analysis · battery operation · outdoor …

bandable enamelled wire electrically heated · ≤ 2.500 A · ≤ 1.000 V · online temperature monitoring · ≤ 250 A/mm² · voltage, current or temperature controlled · earth fault detector <10 μs off time · compatible with tests …

heating with current · curing with UV light · ≤ 2500 A – ≤ 1.000 V · online temperature monitoring · ≤ 250 A/mm² · voltage, current or temperature controlled · can be combined with tests …

insulation oil testing ⋅ fully automatic ⋅ dielectric strength ⋅ mobile ⋅ portable ⋅ on-site testing ⋅ laboratory testing ⋅ test voltages: 60 kV – 80 kV – 100 kV ⋅ various electrodes ⋅ integrated international test standards …

coil winding machines for electric motors · for repair · for motor production · standard machines · special solutions …

read more   read more   read more   read more   read more   read more   read more   read more   read more   read more   read more   read more  
winding testers
motor & winding testers ALL-IN-1
surge testers
winding testers
motor & winding testers ALL-IN-1
surge testers
winding testers
surge testers
winding testers
electric motor testers ALL-IN-1 encoder/resolver testers electric motor testers ALL-IN-1 thermal-bonding machines current-UV impregnation machines insulating oil testers winding machines
0–3 kV 0–6 kV
0–12 kV
0–15 kV
0–25 kV
0–30 kV
0–40 kV
0–50 kV
0–6 kV
0–15 kV
0–6 kV 0–6 kV
4-wire measurement 4-wire measurement 4-wire measurement 4-wire measurement 4-wire measurement
1–10 A˜       6/12 Veff
1–30 A˜       6/12 Veff
1–10 A˜       6/12 Veff
1–30 A˜       6/12 Veff
custom
0–3 kV ˭ 0–6 kV ˭ Vmax like surge test Vmax like surge test 0–1 kV ˭       max. 250 GΩ
custom
Vmax like insulation test Vmax like insulation test Vmax like surge test Vmax like surge test
0–6 kV˜       max. 100 mA 0–3 kV˜       max. 100 mA
0–6 kV˜       max. 100 mA
0–6 kV˜       max. 200 mA
0–6 kV˜       max. 1 A
custom
0–3 kV˜       max. 100 mA
0–6 kV˜       max. 100 mA
0–6 kV˜       max. 200 mA
custom
0–4 kV ˭ 0–6 kV ˭ custom
in case of surge test in case of surge test
in case of high voltage test AC
in case of surge voltage and high voltage
in case of surge test in case of surge test
in case of high voltage test AC
in case of surge voltage and high voltage
according to your requirements
according to your requirements according to your requirements
yes yes yes yes yes
T1, T2, T3, frame T1, T2, T3, frame T1, T2, T3, frame
T1, T2, T3, Y, frame
K1, K2, frame
T1, T2, T3, frame
T1, T2, T3, Y, frame
3, 6, 9, 12, 15, 18, ..., frame
T1, T2, T3 L1, L2, L3, N, PE
made to your specifications
possible possible possible
with digital I/O
with RS232 via SCHLEICH communication protocol
with LAN via SCHLEICH communication protocol
with digital I/O
with RS232 via SCHLEICH communication protocol
with LAN via SCHLEICH communication protocol
with LAN via TCP/IP Socket Communication
with PROFIBUS
with PROFINET
with EtherCAT
with DeviceNet
made to your specifications
with digital I/O
with RS232 via SCHLEICH communication protocol
with LAN via SCHLEICH communication protocol
with LAN via SCPI commands
with PROFIBUS
with PROFINET
with EtherCAT
with CANopen
with CAN Automotive
with DeviceNet
made to your specifications
ACCESS
SQL
ACCESS
SQL
ACCESS
SQL
ORACLE
stored in the tester
stored in the tester and network
import from PC, PLC, MES, ...
stored in the tester
stored in the tester and network
import from PC, PLC, MES, ...
stored in the tester
stored in the tester and network
import from PC, PLC, MES, ...
cached in the tester cached in the tester cached in the tester or network
transfer to PC, PLC, MES, ...
cached in the tester or network
transfer to PC, PLC, MES, ...
cached in the tester
cached in the tester or network
transfer to PC, PLC, MES, ...
with ERP, MES, PLC, CAQ, ...
via LAN, WWW, OPC, ...
with ERP, MES, PLC, CAQ, ...
via LAN, WWW, OPC, ...
with ERP, MES, PLC, CAQ, ...
via LAN, WWW, OPC, ...
yes - via PC-Software yes - via PC-Software yes yes yes yes
yes yes yes
yes yes yes
yes yes yes yes yes
yes yes yes yes
SCHLEICH embedded SCHLEICH embedded Windows 10®-PC in the tester Windows 10®-19"-Industrial PC integrated Windows 10®-19"-Industrial PC integrated Windows 10®-PC in the tester
LCD 120 x 80 touch color LCD 480 x 272 PC monitor of any size PC monitor of any size PC monitor of any size
yes yes yes
on stock on stock on stock order-related manufacturing order-related manufacturing order-related manufacturing order-related manufacturing order-related manufacturing order-related manufacturing order-related manufacturing order-related manufacturing order-related manufacturing