Baking systems are used to securely connect all components of an electrical winding to each other and to the laminated core.

Heat is always the basis of the process. It is needed to bond the enameled wires together or to bond the insulating resins to the winding. To heat the winding, electricity is passed through it. This causes electrical losses in the winding resistances, causing the winding to heat up. We call this principle the "electricity-heat process." By precisely measuring and regulating the flowing current, the heating process can be controlled accurately and reproducibly.

With SCHLEICH, up to 8 baking processes can run simultaneously and independently of each other.

With our baking systems, coils manufactured with baking enamel wire can thermal bonding immediately after winding. If necessary, thermal bonding can run before and after thermal bonding .

The windings made with baking enamel wire are heated to the melting temperature of the baking enamel using electric heat with temperature control. Once the desired target temperature has been reached and the windings have cooled down, the winding wires bond together. The entire winding then forms a solid unit.

The process-reliable procedure is controlled and monitored by computer.

Depending on the current density, stator winding size, different heating times result. By varying the current density, heating times between 1 and 300 seconds can be achieved. The aim is to achieve a very even temperature distribution within the winding and thus very good, homogeneous bonding in all parts of the winding.

The bonding systems are suitable for all types of windings. Provided that the winding contacts allow a significantly higher current flow than during normal operation, single coils as well as single-phase and three-phase stators andarmature can thermal bonding armature thermal bonding .

Manual baking systems

In manual baking systems, the winding ends are connected by the operator. A wide range of different manual connection options are available for this purpose. These are specialized designed specialized high temperatures and high currents.

The contact devices can also be equipped with an automatic opening function. This saves working time, as the operator thermal bonding longer has to remove the winding ends individually from the contact after thermal bonding .

Automatic baking systems 

In automatic baking systems designed as continuous production lines, the entire process runs fully automatically. The workpiece carriers with the coiled goods to be bonded are automatically stopped and separated by the bonding system the line control system. They are then lifted into the bonding position. The subsequent shaping by forming tools and the contacting of the free coil ends or a plug is also fully automatic.

Even unwrapped winding ends can be contacted. Special contacting tools ensure that the wire is contacted through the insulation.

The SCHLEICH considers thermal bonding one step in a chain of test steps.

It does not make economic sense to thermal bonding a faulty winding. For this reason, additional tests are often carried out on the winding before electrical heating. It may also be advisable to carry out a final test after the heating process.

Depending on the scope of the desired tests, the MTC3 winding test system or the GLP3 function test system is used as the base device. The software functionality is identical for both test devices. Compared to the GLP3, the MTC3 has the additional advantage that run also run surge voltage and partial discharge tests. The configuration is custom so that the test methods and the type of current heat required are precisely tailored to your application.

We consistently rely on the integration of an industrial PC for testing, process control of electrical heat, and storage of heating/test plans and results. A simple and clear user interface makes it operator for operator to control the system.

The displays during testing and current heating are clear, showing only the important data and graphics.

Numerous statistical evaluations support quality assurance. A wide range of different print protocols serves as proof of the quality delivered to your customers.

To generate heat, direct or alternating current flows through the winding. The power loss that occurs at the winding resistance is converted into heat.

A high current density is desired in order to achieve a short heating time. This is limited by the wire cross-section and, if applicable, by the type of contact. To avoid damage, the wire and contact must not be overloaded.

A power module in the heating system is responsible for generating electricity. It is controlled and regulated by the system's software.

The system's extremely fast and highly accurate measurement technology delivers hundreds of thousands of current and voltage readings per second. The software uses these readings to continuously calculate the winding temperature, among other things. Based on the process values determined, the software regulates the power module according to different heating methods.

Constant voltage method 

This is the simplest method. The voltage kept constant throughout the entire heating process. The initial current flow decreases as the copper resistance of the winding increases with rising temperature. The heat energy supplied to the winding decreases.

The advantage of this method is that the temperature rises relatively slowly, ensuring that the winding is heated thoroughly and evenly. The temperature difference between the winding in the winding head and the winding in the slot therefore usually small when the baking temperature is reached. However, since the maximum current density is only reached at the beginning of the heating process, the desired final temperature is only reached after a relatively long time.

Constant current method 

In this process, the current is kept constant throughout the entire heating process. Since the copper resistance of the winding increases with rising temperature, this is only possible by means of a voltage increase controlled by the regulator.

Compared to constant voltage , the desired final temperature voltage reached much faster.

Procedure for elevated initial temperatures 

This procedure can be used, for example, during repair work. In such cases, the winding is often still very warm. The heating system detects this elevated winding temperature and starts the heating process with this initial value.

Additionally constant final temperature 

The time during which the baking varnish layer on the wire surface softens and can bond with the adjacent wires may be too short if the machine is switched off immediately upon reaching the melting temperature. As a result, the wires in the slot may remain laminated core cooler than in the winding head slot the surrounding laminated core . This can lead to a loss of quality.

The constant voltage or constant current method can therefore also be configured so that, if necessary, the device is not switched off immediately after reaching the desired melting temperature, but the temperature is kept constant for some time.

This extends the time during which the baking varnish layer on the wire surface can melt homogeneously and form a secure bond with the adjacent wires.

Process with temperature profile 

To do this, the operator specifies operator desired heating profile in different time zones. In the event that the integrated power module voltage supply the current or voltage , this is checked in an upstream plausibility check and corrected if necessary.

This procedure is the standard procedure for an impregnation plant, which is also thermal bonding in thermal bonding .

The software is based on the Microsoft^Windows® operating system^.Theoptimized user interface enables user-friendly execution of 

• Heating with electricity 
• examination 
• Heating/test pan creation 
• Printing test reports 
• Statistical evaluation of the results

All heating and, if necessary, testing is performed fully automatically. The measurement results are continuously displayed and evaluated during the processes. The clear pass/fail display visualizes the automatic evaluation. 

The process can be edited by simply adding or removing heating and testing steps. This allowstheprocess to be optimally adapted to different requirements. Each individual step can be quickly edited by double-clicking on the respective step. 

The comprehensive integrated user management system ensures that only authorized persons run these changes. Additional work instructions maketheheating system the perfect ISO 9001-compliant production system.

One of SCHLEICH particular strengths SCHLEICH in the mechanical adaptation of stators and their special contacting. The heating system and mechanics are manufactured according to your specific requirements. Manually or pneumatically operated four-wire terminals are used. It is crucial that they transmit both the high currents and the measurement signals perfectly.

The design is carried out directly at the 3D CAD workstations in our company. State-of-the-art CNC machines in our mechanical production facility guarantee professional and cost-effective manufacturing of the components.

Contacts

spreading mandrels

molding tools

Heating and test plans as well as results can be stored locally or on a central server. This ensures high data security and optimal data exchange between different test systems.

The heating systems work optimally in all network infrastructures. This feature provides the ideal platform for collecting, managing, analyzing, and distributing information.

Proven and widely used technologies from^Microsoft® memory used as memory .

The heating systems can also be ideally networked with ERP, PPS, and CAQ systems. provide tried-and-tested, customer-optimized standard solutions for all requirements.

The^{Windows®-based}heating systems can be operated in network topologies of any complexity. You can install any number of testing devices at different company locations worldwide, all of which test results with a centralmemory test plans and test results . Our extensive experience in the global networking of our testing devices gives you the safety of being able to offer the same product quality regardless of the production location.

Of course, all test plan, printing, labeling, and statistics tasks can also run on the individual test devices. However, in order not to disrupt the production process, it is advisable to use separate workstations for this purpose in networked systems. These workstations use the same software as the test devices in order to achieve the highest possible level of user comfort.

The label tags can also be stored centrally on a server. The testing device loads the appropriate label according to the respective test plan and transfers the data to a thermal transfer printer after testing. The labels can also be designed according to your requirements.

In the case of remote maintenance (via remote access), we can temporarily dial into your network if necessary and connect directly to the individual test device. This allows us to see the screen content of your test device directly at our premises. With your permission, we also have access to the mouse and keyboard. Of course, this work is only carried out in consultation with you and requires separate access authorization on your part.

The heating systems are ideal for integration into automation systems. To this end, they offer an enormous variety of different interfaces for communication with a wide range of automation systems.

Typical requirements are:

• Control of complete processes and components
  – Processing of inputs, signal transmitters, scanners, RFID readers...
  – Setting outputs for e.g. cylinders...
  – Control of motors and drives...
• Exchange of start, Stop, and result signals
• Direct communication with a PLC
• Bidirectional communication
  – Receiving test plans and test parameters
  – Sending qualitative and quantitative test results
  – Sending raw data
• Communication with robots, cameras...

These tasks are performed by our configurable standard software modules, which reduce the effort required to integrate the MTC3 into automation systems to a minimum.

Data exchange between heating systems and other IT systems is carried out using tried-and-tested solutions.

Typical applications:

• Importing production orders from ERP systems
• Automatic dynamic generation of heating and test plans from production orders and parts lists
• Automatic generation of serial numbers from production order data
• Feedback of results to ERP systems
• Receiving label data for label printing
• Communication with special systems in the automotive industry

Our standard software modules reduce the effort required to integrate heating systems into an IT system to a minimum.

Traceability gives you the ability to obtain clear and complete information about the entire manufacturing process, even retrospectively. In the event of quality problems during production or after delivery, traceability allows you to respond in a targeted manner.

We provide answers to the following questions:

• Which end products, assemblies, and components are affected?
• Which customers have the end products, assemblies, and components?
• Which assemblies and components are installed in the end product?
• When, where, and by whom were which parts processed in the manufacturing process?
• Who manufactured or supplied the assemblies and components?
• What test results available for the individual assemblies and the final product?

In order to answer these questions, each component, assembly, and end product must be clearly labeled with a number or code. Additional information such as customer number, supplier number, batch number, etc. may be required for better traceability and searchability.

The heating systems are capable of recording these markings and additional information, e.g., via barcode entry, and Save together with the test results, the test date, and the tester's name in the memory testing device or in the network. This information can later be used to trace where, when, and by whom components were processed or delivered in the manufacturing process.

• electric heating systems
• Electrical heating of coils of all types
• DC baking systems
• AC baking systems for interlocked three-phase windings
• Up to 100 kW
• Up to 2,500 A
• Up to 1,000 V
• Up to 250^A/mm² and more – depending on the load capacity of the winding contact
• Five heating strategies
  • constant voltage
  • constant current
  • constant temperature
  • temperature profile
• thermal bonding coils in series or parallel connection

• Standard and flash baking technology
• Display of the temperature curve during baking for up to 8 parallel baking processes

• Integrated four-wire
• Online temperature monitoring
• Online clamping point monitoring (optional)
• Dynamic overcurrent monitor
• Ground fault monitoring (optional)
• Monitoring of integrated sensors/temperature probes

• Can be combined with the following additional tests:
  • Surge test
  • partial discharge
  • High voltage AC/DC
  • rotating field
• Integration into an existing automated production line
• Integration into an automation system
  • Communication with PLC based on all common bus systems
  • Communication with goods carriers, e.g., via RFID
  • Communication/data exchange with ERP or MES systems