Stages of production

Engineers of technical department of REM & Coil LLC prepare technical documentation necessary for the manufacture of a set of stator sections: coil drawing, material specification, composition of the repair kit. Having agreed on the technical documentation with the customer (client), terms of reference for production is issued with detailed information on the manufacture of a set of stator sections for each operation of the process.

Winding of blanks is performed on specialized winding machines in accordance with the technological assignment. All machines are equipped with a wire tension control system, which allows getting a smooth and dense column of conductors event at the first stage of manufacture. It is also possible to apply additional insulation to each turn during the winding process. The maximum length of the blank is 3,500 mm. The maximum number of conductors wound at a time is 12.

Application of frame insulation is performed using automated insulating machines. The operator of the isolating machine enters basic information on the geometric dimensions of the coil, as well as the number of layers of electrical insulating and protective coatings, the percentage of overlapping tapes in individual sections of the coil and the speed of insulating into the isolating program. Rollers with material are installed in the insulating head, the tension level is adjusted depending on the type of tape used and the isolating process is started. The insulating machine operator continuously monitors the belt application process. The maximum length of the blank is 3,500 mm, the maximum cross-section of the coil in the groove part is 35.0x70.0 mm

Pre-molding is performed to prepare the blank for molding operation. During this operation, the blank takes the form of a trapezoid.

Molding of coils in the end shape is carried out using automated molding machines. The molding machine operator enters data on the coil geometry into the molding machine program, installs the blank in the working area and then the machine stretches the blank into the end shape in accordance with the program. After molding, each coil is installed in the stator dummy to verify conformance of geometric parameters with the drawing.

All coils manufactured using Resin Rich technology are exposed to pressing. The pressing process is performed on specialized computer-controlled presses that ensure uniform heating of the insulation and the exact size of groove parts.

Upon the readiness of all kit sections, geometric parameters of the sections are monitored by the engineers of the quality control department, and electrical tests are performed in the scope agreed with the customer (client).

Upon completion of inspections and tests, the kit of coils is delivered to packaging. Products are packed in containers that ensure preservation of the geometry and integrity of coils insulation. Together with the coils, stator kit coils data sheet and test reports are placed in the container.