TU-TESL

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With the growing market demand for cars and electric vehicles, a new generation of more efficient, higher performance, more reliable and environmentally friendly motors will continue to emerge. As the world's leading liquid and powder coating enterprise headquartered in Philadelphia, USA, with more than 70 years of experience in R & D and production of high-quality insulating materials, Ashtar coating system can provide the world's leading solutions for high-quality and high-performance insulating systems, which can help the design of a new generation of electric machines, making the coated motors smaller, larger output and longer driving mileage. "We work closely with our customers to fully understand the needs of auto parts manufacturers and always follow the industry trend to predict the development trend of the industry demand." Dr Christoph lomoschitz, global product manager, energy solutions division, Astor. "Based on our in-depth research on motors and related industries, we have launched insulation system solutions for future requirements to help build a new generation of motors." Aiside insulation coating can provide effective insulation protection for conductor, electrical steel, transformer, generator and motor. At present, aiside is the only supplier in the world who can provide a comprehensive and innovative combination of environmental friendly insulating liquid coating. The main purpose of the new motor design is to meet two major needs, namely, increasing power and reducing volume. In order to help achieve the above goals, Ashtar launched four kinds of unique insulation products to the market - silicon steel sheet paint, enameled wire paint, impregnating resin and pouring resin. These four types of products respectively meet specific challenges to support the manufacturing of existing and future new energy vehicles (NEVs). New type and its components need to be mass produced, which must be considered in the initial design stage of insulation products. "In developing new insulation products, we need to minimize the curing, coating and impregnation time, so as to achieve large-scale production of engines and other components." Dr. lomoschitz said. Electrical insulation products (including coatings and resins) have four main uses in the field of electrical machinery, and Ashtar has corresponding solutions for each use. The core of an engine is usually made up of a thin sheet punch to limit the negative effects of eddy currents. When the iron core is connected by welding, screw fixing or interlocking, even if it is coated with silicon steel sheet paint, it may still have thin weakness. At the same time, a conductive bridge is formed at the traditional connection. Due to the increase of eddy current loss caused by short circuit at the metal connection, the conductive bridge may reduce the engine efficiency. In order to solve the above problems, aiside self-adhesive silicon steel sheet paint can glue the punching sheets together. Because welding, interlocking, clamps, rivets and screws can only provide local connection between a single interlayer, self-adhesive can also improve the hardness of the core, and the whole laminate will be stuck together. In addition, this form of bonding can also reduce the noise caused by the inevitable vibration of the engine during operation. Higher voltage, silicon carbide (SIC) technology and inverter can cause partial discharge, that is to say, the small sparks constantly striking at the same point will cause local damage to the insulating material. Local discharge will gradually destroy the impregnating resin, thus significantly reducing its protection on the enameled wire paint, and eventually lead to the enameled wire paint also exposed to local discharge. With the decrease of the effectiveness of the main insulation, electrical faults will occur. Based on its corona resistant enamels voltatex ® 7740 and voltatex ® 8534, and voltatex ® 8536, the company has launched a new type of enameled wire paint that can resist the effects of partial discharge and enhance the durability and reliability of motors. These three enamelled wire paints are part of the Aston voltron ® system, which has the first dielectric patent based on nanotechnology to improve corona resistance. Nanoparticles are the main mechanism to reduce electrical aging. Frank saborowski, product manager, enamelled wire paint, energy solutions division, Ashtar, said, "it is essential that the impregnating resin covering the entire equipment be adapted to the enamelled wire paint for optimum wettability and compatibility. We do this through a special design of the surface of the Aston ® series of enameled wire paints. " New engines usually aim to increase production and efficiency. Therefore, one of the solutions is to increase the operating voltage of the motor, and the other is to use the hairpin flat wire design instead of the scattered round wire design. The gap left by the circular line design is large, while the flat line design can largely eliminate the gap, improve the slot full rate of the engine, and thus improve its efficiency. However, in order to achieve the same permeability as the circular line design, while reducing the gap, the development and use process of impregnating resin also needs to be more advanced. The permeability of the impregnated resin mainly depends on the viscosity of the resin, the surface tension of the system, the fluidity of the resin and the size of the gap. The insulating high thermal conductivity impregnation corona resistant resin voltatex ® 4224, which recently won the International Innovation Award, is a pioneering impregnation resin with significantly enhanced thermal conductivity and local discharge resistance. Thanks to the extremely low viscosity and excellent fluidity, voltatex 4224 can effectively reduce the operating temperature without affecting the machinability. It can be used in the standard impregnation process to ensure excellent heat transfer from copper winding to iron core, so that the thermal stress in engine components is smaller and the performance is better. In the application of some high performance motors, the advantages of castable resin are greater than that of impregnated resin. This kind of secondary insulating material is more complex to use, but the casting resin can provide better thermal conductivity and high stability. Ashtar has built many castables in the voltacast collection. These casting resins are polyurethane or two-component epoxy systems, which are composed of one resin and corresponding curing agent. According to the different component materials, the addition polymerization during chemical curing will produce different grades of hard plastic materials, each of which has the terminal characteristics of a specific system. The purpose of castable resin is to protect all fixed electrical equipment, including transformers and ballasts, from vibration, contamination, liquids, as well as thermal and mechanical stresses. Increasing the application of new energy in the field of traditional internal combustion engine technology has become a global trend. To do this, lighter, cleaner, more efficient hybrids and. The insulation products under the brands of Astor voltatex ®, voltaprem, voltacast, voltabas and voltron ®. "Thanks to Ashtar's rich experience in providing first-class surface and insulating coatings to leading automotive manufacturers, Ashtar is committed to introducing more pioneering technologies in this field. For Astor's energy solutions, the future is at hand. " Dr. lomoschitz concluded.