Dreisilker Electric Motors can now offer a patented insulation process called the Ultra-Sealed Winding™. The process was developed to create total protection against moisture, prevent corrosion, improve heat transfer from the coils to the frame and enhance winding rigidity. The Ultra-Sealed Winding™ procedure involves insulating and sealing the winding through a mechanical and pressure process using a patented resin.
An Ultra-Sealed Winding™ should not be confused with an encapsulated winding. Encapsulation only involves coating the coil ends, but when Ultra-Sealed, the coils are completely impregnated and sealed within high molecular weight thermoset polymer resin. There are two major advantages over traditional insulation methods. One is total protection against moisture. During in-house tests, windings have been completely submerged in synthetic cutting fluid for as much as 2 months without faulting to ground. The second advantage is more efficient cooling. The high molecular weight thermoset polymer resin is approximately 40 times more efficient at heat transfer than air.
Ultra-Sealed vs. Conventional
The Ultra-Sealed motor windings on the left compared to conventionally varnished windings illustrate the dramatic difference in the process.
Benefits of Ultra-Sealed Winding™
Windings are completely sealed and void free.
Resin penetrates any voids in laminations.
Resin penetrates between slot insulation and laminations. Adds ground wall insulation and prevents failure to ground if moisture seeps into laminations.
Prevents shorting of ground of coils where they come out of the slots. A very common area of failures due to pressure points and grounding from contaminants.
Encapsulation of winding heads act as surge rings. This prevents movement and loosening of coils and individual wires when motor starts or cycles.
Windings are firm in the slots. Windings and individual wires will not vibrate and loosen up.
Frequency drives can cause vibrations and harmonics in windings. This can be prevented by Ultra-Sealed Winding.
Resin is elastic to allow for expansion and contraction of the windings in the slots.
Ultra-Sealed solidifies windings and laminations, therefore helps dampen noise and vibrations in high speed and spindle applications.
An Ultra-Sealed Winding on a motor tested under 100% load, ran 15% cooler in the slot and 25% cooler at 125% load.
Heat transfer is 40 times better than air. More mass is in contact with laminations and housings.
Leads are sealed.
Leads used are non-wicking.
Winding can not easily be damaged from bumping or nicking when assembling rotors and spindle components.
Greatly reduces winding failures.
Eliminated static failures due to contamination from: Water, Oil, Coolant, Metal Chips, Chemical Attack, Air-born particles such as graphite, carbon black and etc.