Optimized Electrical Insulation Systems under Technological and Commercial Aspects

Transcription

1 Optimized Electrical Insulation Systems under Technological and Commercial Aspects Dr. Andreas Levermann Schwering & HasseElektrodraht GmbH Jörg Nelges Pucaro Elektro-Isolierstoffe GmbH Thomas Haeusler Stockmeier Urethanes GmbH & Co. KG Member of ZVEI Division Electrical Winding & Insulation Systems

2 Part one: The New Efficiency-enhancing Magnet Wire Generation Schwering und Hasse Elektrodraht GmbH Berlin, 24. June 2014, Dr. Andreas Levermann Innovative partner of the winding industry Synflex / SH booth in Hall 4.2

3 The most important components of the EIS Designing technically and commercially ideal systems: Electrical adhesive tapes Cables and sleevings Connection technology Flexible insulating materials Stamped/punched parts Winding wires Impregnants Special Press litz Winding wire manufacturing is the art of producing hundreds of thousands of miles of wire reliably at the same highest quality level and prove it! Folie 3

4 The New Generation: SH Therm 210 Glide The product is in the market and is increasing power of density and winding speed A common requirement of the market is an improved glide characteristic So far there is no solution without using external lubricants. Description The gliding property is put into the outermost enamel layer. Sample Advantages Improved product properties (power of density, height of winding heads etc.) Improved winding speed and machine efficiency No contamination Folie 4

5 Highest process stability for high-quality-wire Managed by the unique SH production control system with inline insulation control Continuous monitoring of all relevant process parameters Advance to direct process control / correction Description In case of deviations the system automatically blocks the reel Documentation, perfect traceability and transparency of decisions Data processing / analysis in real time Continuous further development Sample Advantages Reliable 100% inline quantitative measuring results Full documentation and tracebility Highest process stability realisation Folie 5

6 Part two: Requirements on combined flexible Insulation materials Pucaro Elektro-Isolierstoffe GmbH Berlin, 24. June 2014, Jörg Nelges Booth 1.1 / B39

7 Requirements on combined flexible Insulation materials Main properties of laminated insulation materials are standardized in the IEC : Mechanical requirement Electrical requirements Thermal requirements Folie 7

8 Differentiation of combined flexible insulation materials Differentiation of the materials is only coming from additional features like: Prepreg topcoat used in combination with B-stage wires to cut down impregnation in small motors Improved heat conductivity optimization of the connection between stator and insulation material Extra slippery coating improved converting properties increased filling factor of the slot Folie 8

9 PUCARO Triflexil - ESA Development objective: Significant reduction of the coefficient of friction of NMN and DMD insulation materials Reduction of friction with Triflexil -ESA surface treatment COF 100% 80% - 40% - 60% 60% 40% Standard Material ESA Modification 20% 0% Triflexil NMN Triflexil M/VL Folie 9

10 Pucaro Triflexil - ESA Advantages within the automated winding process 1. Easy slot insulation The extra slippery surface is abrasionresistant and reduces dust The high smoothness guarantees an excellent machinability of the product Folie 10

11 Pucaro Triflexil - ESA Advantages within the automated winding process 2. Simplified winding The extra slippery coating supports an easy inserting of the winding and the slot closure into the slot According to the response from first customers the filling factor of the slots can be increased by 3-5% depending on the frame size Folie 11

12 Pucaro Triflexil - ESA Advantages within the automated winding process 3. Good impregnation properties Due to the necessity of heating during the impregnation/trickling process the surface tension of the coating will increase. This leads to a good compound between the impregnation resin and the insulation material. Folie 12

13 PUCARO Triflexil - ESA Product Portfolio Product Name Composition Available Thickness Triflexil M/VL-ESA Typical Application DMD coated 0,13-0,46 mm Slot insulation, slot closure Insulation Class F (155 C) Triflexil NMN-ESA NMN coated 0,13 0,63 mm Slot insulation, Slot closure H (180 C) Folie 13

14 Part three: Magic Triangle Stockmeier Urethanes GmbH Berlin, 24. June 2014, Thomas Haeusler Booth 1.1 / E29

15 Magic Triangle Resin Machine Processor A Guideline for Developing, Project planning, Processing Folie 15

16 Magic Triangle Folie 16

17 Resins Different Raw Materials Different Curing Profiles Different Properties : Epoxi; Polyurethane; Silicone : Cold-Curing ; Hot-Curing : From Soft to Hard Chemical reaction : Change of Consistency and Properties during processing Consumption Material Folie 17

18 Machine Different Metering Technologies Different Mixing Technologies : Gear-Pumps; Piston-Pumps : Static-Mixer, Dynamic-Mixer Taylor-Made for Specific Process Investment Folie 18

19 Processor Developer => Cured properties Producer => Raw Material Properties Application Resin Core Properties High Medium Low Resin Amount High Medium Low Interfering Materials Application Low Medium High Insulators Bushings Transformer Electronics Driver / Sensors Design Construction Part Construction Part / Housing Housing Folie 19

20 Never Change a Running Process Risks: Process-Modification Adaptions Not only in case of doubt : Contact the Resin- / Machine-Supplier in advance, not after running a modification. Folie 20

21 Scientific Background Temperature Increasing Temperature => Increasing Reactivity (Arrhenius Plot) => Decreasing Viscosity Folie 21

22 Scientific Background Pressure (Hydrodynamic Effects) Function of Viscosity : Increasing of Viscosity => Increasing Pressure Constant Pressure => Recommended for optimized Metering + Mixing Quality Albert Einstein : Economic Aspect : What cost s nothing is worth nothing? Pay attention and Invest in the Project phase => Saving money + resources in production Folie 22

23 Resume Sharing information is important at any stage of project Close contact and direct communication between all parties involved Testing and Trials in advance before finalizing the layout Changing process parameters can cause side effects It s more efficient to talk in advance instead of doing firefighting afterwards Folie 23

24 Thank you for your Attention Optimized Electrical Insulation Systems under Technological and Commercial Aspects Dr. Andreas Levermann Schwering & HasseElektrodraht GmbH Jörg Nelges Pucaro Elektro-Isolierstoffe GmbH Thomas Haeusler Stockmeier Urethanes GmbH & Co. KG Booth 4.2 / B75 Booth 1.1 / B39 Booth 1.1 / E29 Member of ZVEI Division Electrical Winding & Insulation Systems