New ViSCO.mag: Leak-free dosing and reliable process monitoring in trickle impregnation

Increased process reliability when processing impregnation resins

Trickle impregnation is a proven and established manufacturing process in the production of electric drives. By applying resin specifically to the windings of stators for electric motors and to other electrical components, they are electrically insulated, mechanically stabilised and protected against environmental influences. After curing, a durable structure is formed within the insulation that mechanically stabilises the windings, permanently maintains the electrical properties of the insulation layer, reliably protects the components against thermal and mechanical stresses, reduces vibrations and increases the robustness of the windings, thereby making a significant contribution to the performance and service life of modern electric motors. As requirements for energy efficiency, product quality and traceability continue to increase, the importance of precise and reproducible dosing technology is also growing, as the quality of the impregnation is largely determined by the accuracy with which the resin is applied.

Precise dosing as the basis for reproducible results

To ensure that trickle and impregnation resins perform their function reliably, they must be applied with a high degree of accuracy and consistent quality. The components can be heated, for example, by induction or in special industrial ovens. The aim is to achieve optimum flow and penetration of the resin between the windings. The progressive cavity pumps of the ViSCO.series® enable continuous, low-pulsation delivery of a wide range of media, from low-viscosity to very high-viscosity 1K and 2K resin systems. The flow rate and dosing speed can be precisely adjusted and controlled to meet the respective process requirements. This results in uniform wetting and reproducible impregnation quality. Particularly in automated production processes, this repeatability is a decisive factor in maintaining stable manufacturing quality and reducing rejects.

Magnetic coupling instead of a rotating seal

A key difference compared with many conventional progressive cavity pumps lies in the sealing technology. While mechanical seals or shaft seals are frequently used, these pump systems are equipped with a permanent magnetic coupling from affiliated company DST Dauermagnet-SystemTechnik GmbH, which develops and manufactures the permanent magnetic couplings. The magnetic coupling provides hermetic separation between the drive and the fluid section. No rotating seal is required. This creates a completely leak-free system that offers significant advantages, particularly when handling demanding media. Due to their composition, trickle and impregnation resins can cause deposits, encrustation or increased wear on conventional sealing systems. This can result in increased maintenance requirements, unplanned downtime and potential quality risks. By eliminating dynamic seals, these potential weak points are consistently avoided with this solution. The wear-free transmission of torque therefore also increases system availability and significantly reduces maintenance requirements. Depending on the application, options for flushing or temperature control of the sealing area are also available, allowing even demanding process conditions to be managed reliably over the long term. The advantages of the magnetic coupling are by no means limited to the processing of trickle and impregnation resins. The ViSCO.mag was developed for applications where the highest requirements are placed on leak tightness and operational reliability. Particularly when handling toxic, hazardous, aggressive or otherwise critical media, as well as in applications where conventional rotating sealing systems reach their limits due to wear, emissions or increased maintenance requirements, the magnetically coupled design offers decisive advantages. It enables permanently leak-free delivery and makes a significant contribution to the safety of people, the environment and the process.

Real-time flow measurement and consumption monitoring

In addition to precise delivery, continuous monitoring of actual material consumption is becoming increasingly important. Modern production processes require precise dosing as well as complete traceability. In conjunction with affiliated company VSE GmbH, the dosing systems can therefore be complemented by high-precision volumetric measurement technology. Depending on the medium and requirements, gear flow meters or helical screw flow meters can be used. These systems enable direct and reliable measurement of the actual volume of material delivered. The actual flow rate is continuously monitored and compared with the specified target values. Deviations can be detected and documented immediately. This makes it possible to determine the actual consumption of trickle and impregnation resin precisely and to clearly trace the quantity of material applied to each individual component.

Process quality management and traceability

The recording and documentation of dosing data make an important contribution to modern process quality management. Batch-related evaluations, consumption records and the traceability of individual production steps are becoming increasingly important, particularly in quality-critical industries. The combination of precise dosing technology and integrated volumetric measurement technology provides the basis for high process reliability and robust quality documentation. Production data can be stored, evaluated and integrated into higher-level control or quality assurance systems. This transforms a simple dosing process into a transparent and traceable production step that supports internal quality requirements as well as increasingly stringent regulatory requirements. Today, the requirements for trickle impregnation extend far beyond the simple delivery of resins. Reproducible dosing results, maximum system availability and complete documentation of material consumption are required. By combining precise dosing technology with leak-free magnetic coupling systems and integrated or optional flow measurement using gear flow meters or helical screw flow meters, a complete concept is created. It combines cost-effectiveness with high process reliability and provides the basis for modern, quality-assured production of electric drive components. Particularly where reliability, product quality and traceability are crucial, intelligent components such as pumps and flow measurement technology for dosing and measurement processes provide sustainable added value for manufacturers, processes and the products of tomorrow.