SCHLEICH impregnation systems SCHLEICH the cured stator to be hardened with insulating resin using a UV radiation process. The process is suitable for all types of winding systems. It essentially consists of computer-controlled heating and the subsequent application and hardening of the impregnating resin.

The impregnation systems are designed so that several independently running impregnation processes can be optimally controlled and the processes are displayed on the screen in a user-friendly manner.

The windings, made from conventional copper enamel wire, are heated electrically to the desired temperature and then dipped in impregnating resin. The impregnating resin gels on the heated winding. After this process, the remaining impregnating resin drips off. The final curing process is accelerated with the aid of UV light.

The impregnation process is divided into four phases. During each phase, which runs automatically, the winding is continuously energized. The computer-controlled process ensures that the required different temperatures and temperature profiles are reliably maintained.

As a system supplier, we deliver the complete impregnation system. This includes all mechanical components, handling of the impregnating resin, electrical heating, and UV curing. The impregnation systems are custom your needs. Only the combination of these optimally coordinated components ensures you the best possible production results.

In addition to the impregnation process, tests can also built-in into the process sequence. The high voltage test the surge test are particularly surge test here. In principle, all tests of the MTC3 winding test system can built-in into the process.

In addition to their use as individual workstations, our impregnation systems are of course also suitable for integration into fully automatic rotary indexing tables or production lines. The workpiece carriers PLC easily controlled in a line and data exchanged with a PLC .

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. The optimized user interface enables user-friendly execution of

• Heating with electricity
• examination
• Preparation of heating/test plans
• 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 is edited by simply adding or removing heating and testing steps. This allows the process to be optimally adapted to different requirements. Each individual step can be quickly edited by double-clicking.

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

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, etc.
  – Setting outputs, e.g., for cylinders, etc.
  – Control of motors and drives, etc.
• 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, etc.

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 input, 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.

• Heating with direct current and low-frequency alternating current 
• Current densities up to 200 A/mm²
• Five different methods for regulating electricity and heat
• Temperature-controlled heating
• Temperature graph during heating
• Integrated four-wire resistance measurement
• DC impregnation systems
• AC impregnation systems for interlocked three-phase windings
• Up to 100 kW
• Up to 1,000 A
• Up to 1,000 V
• Five heating strategies
  • constant voltage
  • constant current
  • constant temperature
  • temperature profile

• 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