In the production of General Purpose Electrical Motors, a
varnishing oven will be invested that will meet the production
requirements on the sheets for use in the stator varnishing
process, meeting the following minimum criterias.
- Water-based and solvent-based varnishing by cold dipping method,
- Including dipping, holding, curving and ventilation steps,
- Collection of dripping lacquers in the post-immersion stage and
recirculation to the tank, including the flue system required for
in-kiln emission collection and discharge,
- Including basket and delivery vehicle structures in suitable
structure to feed the stator to process,
- Oven tube resistance, sufficient number of circulation fans
(presentation of curing performance may be recommended by natural
gas system with recording)
- Includes oven safety covers,
- It has the Economizer,
- With movable conveyor system
- Ergonomic loading equipment, (mechanical solutions must be provided
for lifting, lifting, loading)
- It should have an integrated process control system with operator
panel which is userfriendly user-interface software program that
can follow up and control such as program loading, temperature
monitoring, alarm setting, PID & Limit temperature setting, PLC
program and computer module to follow process parameters.
Two separate requests have been made for reference to this
specification. Both demands are continuous varnishing process.
Demand-1 and Demand-2 differ only in terms of oven number and
capacity. Firms' offer suggestion may be given for only one or both
of these options.
Demand Explanation;
Small Frame Stators’ Water-Based Varnishing and Big Frame Stators’
Solvent-Based Varnishing Technical Requirements for Oven System
(Twin Production Line)
1.A) SYSTEM OPERATION STEPS in WATER-BASED PROCESS;
- First loading station: Here the stator is laid out manually. The basket is on a transfer
car. The cut-out grid is transferred onto the line conveyor with
transfer equipment.
- Transfer: The moving / driven conveyor takes the basket from the loading
station to the varnishing dip tank.
- Dipping: Slowly dip into the varnishing tank. Here, immersion level control
should be provided for the immersion level relative to the stator
heights. Dipping time should be determined by optimum varnish
impregnation. 10 minutes.
- Dripping: hanging for extraction, 20 minutes. At this time, your dripping
varnishing should be a fitting mechanism for recovery to the tank.
- Pre-oven: Slow temperature increase chamber, temperature 80-90 ° C. Here, a
slow temperature increase will be provided for evaporation and
resin gelling. Suggested time for design; 60 min.
- Firing: Curing chamber, temperature 180 ° C. 120 min.
- Ventilation: The cooling in the cooling tunnel is the ventilation compartment.
The chimney assembly for the emission discharge must be integrated.
The recommended time for the design is 30 minutes.
- Transfering the baskets to the outside of the line by conveyor and
arrival at the manual basket unloading station.
1.A.1) Technical Specifications;
- Heating: Automatic heat exchanger with natural gas exchanger
(Different suggestions can be offered).
- Maximum operating temperature: must be adjustable up to 180 ° C.
- Installed thermal power: ~ 95,000 Kcal / h (recommended)
- Installed motors: IE3 class
- Power supply: 380V / 50Hz
- Design criterias for the oven are given under heading 1.A.3.
- Check the Drawing.1.1 for placement advice.
1.A.2) Additional Specifications:
- Oven surface min. 3mm ST-37 material (to accommodate the expansion
stress) and oven air guides and inner linings must be made of ST-37
material.
- All heating areas must be insulated. For this, low thermal mass
mineral wool can be used, and different suggestions can be provided
provided that approval is given. Arçelik approval for insulation
nominal thickness should be taken.
- Inside the chain conveyor and drive group, the chains, drive wheels
and corresponding movement group, rails and bearings, electric
motor and gear reducer system must be complete.
- Varnishing tanks will be made of stainless steel material,
dipping-lifting equipment will be integrated. Pump system must be
installed for tank varnish loading.
- For water based varnish, the level controlled circulation tank will
be made of stainless steel material, the pump system will be
established for automatic varnish completion, varnish collection
and circulation according to level control. Boring should be
stainless steel, approved parts for necessary fittings, valves and
other materials should be selected.
- Heating group for water based varnish; a timed water piping system
should be set up. Temperature control and regulation group with
thermoregulator for system control, safety thermostat for hot water
line. Arçelik approval for carbon steel pipelines, fittings and
valves should be available.
- Indirect heating group; (with electric ignition, electronic safety
devices), thermostatic thermoregulator with thermometric safety
probes, flow rate adjustable automatic gas burner (with electric
ignition, electronic safety devices), combustion chamber equipped
with high temperature resistant material, tube bundle for
circulation of combustion gases,
- Arçelik approval for burner selection.
- The electrical safety equipment required for the burner system must
be provided.
- Control panel, operator panel, PLC; With process monitoring,
control and adjustment features.
- All machine parts must comply with machine approval and machine
safety regulations.
Small Frame Stator Varnish Impregnation Machine Dipping Depth Below
300mm WIND-ZCJ
Application:
Stator varnish machine composed of machine body, water cooler and
varnish supply tank. It is mainly
applied to stator winding insulation treatment for fractional
horsepower motor and industrial Y series motor
which is below frame size 132.
Automatic immersion machine is suitable for all types of industrial
motors and fractional horsepower
motorstator winding insulation treatment. Such as: industrial
electric motors, household appliances and
other motorstator, transformer coil winding insulation immersion
treatment. In addition to the entire
production processfully automated workpiece loading and unloading
outside. Workpiece at atmospheric
pressure by setting thetechnical parameters, automatic coil winding
of the preheating, varnish, gel curing
process. Automatedproduction methods, to ensure the workpiece
processed by the constant insulation
quality standards.
Insulated handle the entire process automatically immersed with the
original compared to the
traditionaldipping, the production efficiency is greatly improved,
compatible with other processes to
achieve the motorproduction line operations.
Impregnating even after the film, rub the paint process can be
saved, thus saving insulating paint,
solvents and hours of labor, and greatly reducing the labor
intensity.
The entire production process, process requirements identified,
each station of all processes, all
theconditions remain the same, the same conditions to ensure
product consistency.
Improve the quality of impregnation, immersion to achieve a stator,
the commonly used insulating paint
dryingsaves energy and raw materials, and can shorten the
production cycle at the same time greatly
improve the operator"s working environment.
Equipment, heating energy: conventional electric heating, the
conditions can be customized according to
customer energy fuel type, gas type (yao natural gas) products.
Immersion: lift, down-type; control systems: conventional control
system with human-machine interface
type(touch screen) control system.
Wind Automation produce stator varnish machine in electricity
power,diesel power or gas, It has two types mechanism
in the varnish area:
1. Varnish tank goes up and down which is driven by the screw rod
2. Varnish tank fixed and the chain goes down and up
Situation 1 is suitable for stator with dipping time requirement,
suppose the varnish dippin time is 2
minutes and pitch time is 5 minutes, stator don't need to stay
inside the varnish tank for 5 minutes
In situation 2, the varnish tank don't move and don't need
transmission, no drive needed.
