Content area
Full Text
MATERIALS
Newer bondcoats provide improved high-temperature performance.
The use of bondable magnet wire to secure coil windings together offers a number of advantages over vacuum or trickle impregnation and dip and bake varnish securing methods in the process of manufacturing electromagnetic devices. Advantages include:
1. Less work in process (WIP) & greater throughput: Resistance bonding typically is incorporated with automated coil forming and electrical testing operations. The possibility of combining motor testing and the bonding process into a single location or manufacturing cell would speed overall workflow, thereby reducing inprocess inventory and increases throughput.
While the process of preheating stators for varnishing, varnish application, and varnish curing requires several hours, the process of bonding a stator made with self-bonding magnet wire can be accomplished in less than one minute utilizing resistance bonding. By using resistance bonding, some manufacturers accomplish the bonding process in less than ten seconds. The cost benefits, greater throughput and lower WIP realized by these manufactures, has been shown to far outweigh the initial capital equipment expenditures, increased wire cost, and the depreciation costs associated with the bonding equipment.
2. Reduced material handling: Replacing a traditional varnish process with a bondable system eliminates the need to order, store, handle, and maintain the varnish, varnish solvents, and any additives associated with the varnishing process. Consequently, raw material waste and overall waste disposal is reduced, resulting in just in time ordering practices and lean manufacturing goals more easily being met.
3. Safety issues and potential reduction of VOCs: If replacing the varnish process with a bondable system, the potential to reduce VOC emissions exists depending on the type of varnish being replaced. In addition, no ovens, open dip tanks, mixing tanks, drums of varnish or solvent are required. Cleanup time and the risk of spillage are eliminated. The bondable resin is part of the magnet wire and not on other parts of the manufactured unit or the surrounding equipment and floor of the varnish area.
Environmental Protection Agency (EPA) constraints, safety, and environmental issues and concerns are therefore reduced.
4. Bondcoat uniformity: The
distribution and uniformity of the magnet wire bond coat is more consistent and predictable compared to varnish coatings. Most products manufactured utilizing bondable magnet wire, possess greater bond...