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| Stator Manufacturing - |
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| STACK WELDING PROCESS BY ARGON ARC WELDING MACHINES (SPM) |
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| Gas tungsten arc welding, also known as Tungsten Inert Gas (TIG) welding, is an arc welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by a shielding gas (usually an inert gas such as argon), and a filler metal is normally used, though some welds, known as autogenously welds, do not require it. A constant-current welding power supply produces energy, which is conducted across the arc through a column of highly ionized gas and metal vapors known as plasma. GTAW is most commonly used to weld thin sections of stainless steel and light metals such
as aluminum, magnesium, and copper alloys. The process grants the operator greater control over the weld than competing procedures such as shielded metal arc welding and gas metal arc welding, allowing for stronger, higher quality welds. However, GTAW is comparatively more complex and difficult to master, and furthermore
it is significantly slower than most other welding techniques. |
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| Coil Winding : |
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| Magnet wire of the specified type and size is wound on custom precision chucks to produce coils of the correct diameter. When possible, coils are wound in series to eliminate interconnections. In some special applications magnet wire is wound in-place over the insulated lamination stack. |
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| INSULATION FILM SLITTING MACHINE |
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| Slitting widht 12mm. |
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| INSULATION CUTTING & FOLDING MACHINES |
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| As per required size & folds |
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| Coil Placement/Stator Winding : |
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| The wound coils are inserted into the insulated slots of the stack. Specialized techniques are used to minimize coil size and thereby attain lower resistance values, and shorter end turns. When specified, insulation is also placed between coil phases within the slots |
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| Stator Ultrasonic Cleaning |
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| Ultrasonic cleaners use high frequency sound waves to create bubbles within a bath, which expand and rapidly collapse. This cavitation creates a scrubbing action on the immersed parts for loosening and removal of dirt, scale, and other impurities. Ultrasonic cleaners are used to remove grease, soil, oil, abrasive dust, blast debris, swarf, paint, corrosion or other contamination from the surfaces of components coming off a production line. Industrial ultrasonic cleaners include degreasing cleaners, sterilizer washers and ultrasonic parts washers. |
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| Stator Varnish Impregnation – |
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| Dip & Bake or Vacuum & Bake. The stators are baked in continuous Rotary Roller Hearth Furnace having precise temperature control. Furnace Temperatures are mapped periodically. The present invention provides a method for manufacturing a dynamoelectric stator enabling coil ends to be impregnated with varnish simply and to a high fill factor by adjusting varnish viscosity at a temperature of a stator during varnish application to a predetermined range. The configuration includes a varnish treatment process including: a preheating process in which the stator is preheated; a varnish application process in which a varnish adjusted so as to have a viscosity of 16 to 105 mPas at a temperature of the stator during varnish application is dripped onto a coil end from radially outside the stator while rotating the preheated stator around a central axis; and a varnish heat hardening process in which the varnish is hardened by heating the stator to which the varnish has been applied. In this manner, a stator can be manufactured in which coil ends are impregnated with varnish to a high fill factor, improving the electrical insulation properties and the galvanic corrosion resistance of the stator winding, and also increasing the overall rigidity of the stator. |
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| Electrical Testing and Final Inspection : |
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| Every unit undergoes a Quality Assurance review. High potential voltage, surge, resistance, inductance, Insulation resistance (Megger) and other electrical tests are performed as necessary to assure conformance to Customer specifications. Test results are electronically recorded and stored for future analysis. If requested, test results may accompany product shipments. |
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| SEALED-AIR, INSTA-PAK PACKAGING M/C |
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| For export packaging as per EU norms. |
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