SCHLEICH impregnation systems enable the curing of manufactured stators with insulating resin using the UV radiation process. This process is suitable for all types of winding systems. It essentially consists of computer-controlled heating and the subsequent application and curing of the impregnating resin.

The impregnation systems are designed such that several independent impregnation processes are optimally controlled and displayed on screen in a user-friendly manner.

The windings, manufactured from conventional enameled copper wire, are electrically heated to the desired temperature and then immersed in impregnating resin. During this, 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 the individual phases, which run 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 mechanics, the handling of the impregnating resin, as well as electrical heating and UV curing. The impregnation systems are custom tailored to your needs. Only the combination of these optimally coordinated components ensures the best possible production result for you.

In addition to the impregnation process, tests can also be built-in into the process flow. Here, the high voltage test and the surge test are particularly noteworthy. Fundamentally, all tests of the MTC3 winding test system can be built-in into the process.

In addition to use as a standalone workstation, our impregnation systems are also naturally suitable for integration into fully automatic rotary indexing tables or production lines. The control of workpiece carriers in a line and data exchange with a PLC are easily possible.

Method with constant voltage 

This is the simplest method. The voltage is kept constant throughout the entire heating process. The initially flowing current continuously decreases because the copper resistance of the winding increases with rising temperature. The thermal energy supplied to the winding decreases.

The advantage of this method is that the temperature rises relatively slowly, resulting in good and uniform through-heating of the winding. The temperature difference between the winding in the winding head and the winding in the slot is therefore usually small when the curing temperature is reached. However, since the maximum current density is only achieved at the beginning of heating, the desired final temperature is only reached after a relatively long time.

Method with constant current 

In this method, 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 through a voltage increase controlled by the regulator.

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

Method with elevated initial temperatures 

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

Additionally, constant final temperature 

The time during which the bondable enamel layer on the wire surface can soften and form a connection with adjacent wires may be too short if switched off immediately upon reaching the softening temperature. As a result, the wires in the slot may remain somewhat cooler than in the winding head due to 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 required, it does not switch off immediately upon reaching the desired softening temperature, but rather maintains the temperature constantly for some time.

This extends the time during which the bondable enamel layer on the wire surface can soften homogeneously and form a secure connection with adjacent wires.

Method with temperature profile 

To do this, the setter specifies the desired heating profile in different time zones. In the event that the integrated power module supplies the current or the voltage cannot deliver, this is checked in a preliminary plausibility check and corrected if necessary.

This procedure is the standard approach for an impregnation system, which is also used for thermal bonding.

The software is based on the Microsoft Windows® operating system. The optimized operator interface enables operator-friendly execution of

• Heating with current
• Test
• Creation of heating/test plans
• Printing of test protocols
• Statistical Evaluation of Results

All heating processes and, if applicable, tests are carried out fully automatically. The measurement results are continuously displayed and evaluated during the processes. The clear GO/NO-GO display visualizes the automatic evaluation.

The process sequence is edited by simply adding or removing heating and test steps. This allows the sequence to be optimally adapted to different requirements. Each individual step can be quickly edited by double-clicking.

The extensive built-in operator management ensures that only authorized personnel 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 safety and optimal data exchange between various test systems.

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

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

The heating systems can also be ideally networked with ERP, PPS, and CAQ systems. For all requirements, we provide extensively proven and customer-optimized standard solutions.

The Windows^®-based heating systems can be operated in arbitrarily complex network topologies. You can install any number of test devices at various company locations worldwide, all of which work with a central server memory for test plans and test results. Our extensive experience in the global networking of our test devices provides you with the safety to provide the same product quality regardless of the production location.

Naturally, all test plan, printing, labeling, and statistics tasks can also be run on the individual testing devices. However, to avoid disrupting the production process, it is advisable for networked systems to use separate workstations for these tasks. These workstations operate with the same software as the testing devices to achieve the highest possible ease of use.

The label templates 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 the test. The labels can also be designed according to your specifications.

In the event of remote maintenance (via Remote Access), we can temporarily dial into your network if required and switch directly to the individual testing device. We then see the screen content of your testing device directly at our location. With your permission, we also have access to the mouse and keyboard. These operations are, of course, only carried out in consultation with you and require your separate access authorization.

The heating systems are ideally suited for integration into automation systems. For this purpose, it provides an enormous variety of different interfaces for communication with various automation systems.

Typical requirements are:

• Control of complete sequences and components
  – Processing of inputs, signal generators, scanners, RFID readers…
  – Setting of outputs e.g. for cylinders …
  – Control of Motors and drives …
• Exchanging Start, Stop, and result signals
• Direct communication with a PLC control
• Bidirectional communication
  – Receiving test plans and test parameters
  – Sending qualitative and quantitative test results
  – Sending raw data
• Communication with robots, cameras …

These tasks are fulfilled by our configurable standard software modules, which reduce the effort for integrating the MTC3 into automation systems to a minimum.

Data exchange between heating systems and other IT systems is carried out via proven solutions.

Typical applications:

• Importing production orders from ERP systems
• Automatic dynamic generation of heating and test plans from production orders and bills of material
• Automatic generation of serial numbers from production order data
• Reporting of results to ERP systems
• Receiving label data for label printing
• Communication with specialized systems in the automotive industry

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

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

We provide responses 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 built into the end product?
• When, where, and by whom were which parts processed in the manufacturing process?
• Who manufactured or supplied the assemblies and components?
• Which test results are available for the individual assemblies and the end product?

A prerequisite for the response to these questions is the unique identification of each component, assembly, and final product with a number or code. Additional information such as customer number, supplier number, batch number, etc., may be required for improved traceability and search functionality.

The heating systems are able to capture these markings and additional information, e.g., via barcode input, and save them together with the test results, test date, and operator name in the memory of the test device or in the network. Based on this information, it can later be traced 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 current heating control
• Temperature-controlled heating
• Temperature graph during heating
• Built-in four-wire resistance measurement
• DC impregnation systems
• AC impregnation systems for interconnected 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 Terminal Point Monitoring (optional)
• Dynamic Excess Current Monitor
• Earth Fault Monitoring (optional)
• Monitoring of built-in sensors/temperature probes

• Combinable 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 integrator's system
  • Communication with PLC control based on all common bus systems
  • Communication with product carriers, e.g., via RFID
  • Communication/data exchange with ERP or MES systems