VARNISHING OVEN And ITS HANDLING SYSTEM

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.

In situation 2, the varnish tank don't move and don't need transmission, no drive needed.