Φ5200×4500mm Effective Size | Fully-Auto Vacuum Impregnation Equipment | Insulation Treatment System for High-Voltage Motor & Transformer Windings

1. Product Overview

This high-vacuum pressurizing impregnation system is specifically designed for insulation treatment of high-voltage motors, special explosion-proof motors, and transformer windings. Vacuum impregnation significantly enhances mechanical strength, insulation performance, moisture resistance, and anti-mold capability of windings. Featuring vertical installation, hydraulic tank cover opening/closing, resin storage and mixing system, three-stage vacuum pumps, and fully automatic PLC control, it is suitable for high-volume, high-consistency insulation treatment of large motor and transformer coils.

2. Industry Challenges & Root Cause Analysis

Inconsistent insulation treatment quality:Conventional atmospheric or low-vacuum impregnation results in uneven resin penetration – bubbles or voids remain inside windings. Root cause: insufficient vacuum level and imprecise pressurized impregnation process control.

Difficult resin temperature control and storage management:Resin viscosity varies significantly with temperature – directly affecting impregnation results. Root cause: lack of precise heating/cooling circulation systems and temperature monitoring.

Insufficient vacuum system stability:Oil mist and solvent vapors enter vacuum pumps during processing – causing pump damage and pumping speed degradation. Root cause: lack of effective buffer filtration and exhaust separation devices.

Lack of process data traceability and recording:Impregnation parameters (vacuum, pressure, liquid level, time, etc.) cannot be automatically recorded – difficult quality traceability. Root cause: control system lacks data acquisition, storage, and export functions.

High safety requirements with insufficient protection:Operation under vacuum or pressure – overpressure and misoperation risks exist. Root cause: lack of comprehensive mechanical-electrical interlock protection and alarm mechanisms.

3. Solution

3.1 High-Precision Vacuum Impregnation Tank:Tank specification Φ5200×4500mm (effective impregnation height) – working pressure 0.75MPa (controllable and adjustable) – working ultimate vacuum 100-200Pa. Tank body material 16MnR/Q345-R – equipped with over-pressure alarm and pressure safety devices. Tank cover hydraulic opening/closing and locking – opening angle ensures the vertex projects beyond inner wall for easy crane loading/unloading. Explosion-proof sight lights and observation windows on tank cover. Load-bearing bracket inside – safety interlock mechanism when cover open.

3.2 Resin Storage & Temperature Control System:Resin storage tank specification Φ4000×4200mm (effective height) – working vacuum 1000-2000Pa. Multi-layer paddle agitator (25-36rpm) for uniform resin mixing. 100mm insulation layer on outer wall – heating/cooling medium inside for precise resin temperature control. Magnetic flip level gauge, resin level alarm, continuous level display – automatic valve closure preventing backflow when tank empty. Temperature sensor for real-time resin temperature monitoring.

3.3 Three-Stage Vacuum Pump System:ZJY2500/ZJY1200/WLW300 oil-free vacuum pump units – 3-stage – maximum pumping speed 2500L/s. Vacuum buffer tank before pump unit – prevents mist from entering vacuum pumps – protects pump operation. Intelligent digital reluctance vacuum gauge and absolute pressure transmitter – high vacuum pneumatic valves. Exhaust gas passes through separation condenser before atmospheric discharge – condensed liquid manually released – environmental compliance.

3.4 Resin Supply & Return System:Vacuum differential pressure type resin return method – resin filter. Sealing components at pipeline and valve flange connections with sufficient strength and corrosion resistance – rubber sealing materials. Pneumatic valves provided by customer.

3.5 Heating & Cooling System:Heating system 48kW – electric heating circulating water – heats resin through spacer layer to set temperature – over-temperature auto shutdown. Cooling system cooling capacity 80000W/H – cold water flow 15m³/H – ethylene glycol aqueous solution working medium – parallel with heating system – automatic switching per set temperature. Cooling unit on/off and fault status displayed/controlled on computer – auto alarm on fault stop.

3.6 Fully Automatic Control System:PLC control + 21-inch LCD computer display – mouse operation – full Chinese human-machine interface – operator and administrator dual-level access. Real-time recording and printing of product numbers and process parameter curves – vacuum-time, tank pressure-time, liquid level-time. Parameters automatically collected and stored on hard disk as time-pressure curves – long-term retention – query, print, and list output available. Main electrical components – Schneider Electric – safety and reliability.

3.7 Multiple Safety Interlock Protections:Hydraulic station cannot operate for cover closing/opening when tank under vacuum or pressure. Mechanical-electrical safety interlocks – overpressure and misoperation prevention. Electric contact vacuum gauge, electric contact pressure gauge, liquid level display. Exhaust gas discharged from buffer tank via centrifugal fan – completes harmful gas emission.

4. Technical Specifications

5. Selection Guide

5.1 Recommended Scenarios

• Vacuum impregnation insulation treatment of high-voltage motors and special explosion-proof motor windings

• Insulation treatment of transformer coils

• High-volume production requiring high vacuum, pressurized impregnation, and fully automatic process control

5.2 Key Selection Considerations

1. Product dimensions: Verify maximum workpiece size fits Φ5200×4500mm effective impregnation space

2. Vacuum requirements: Working ultimate vacuum 100-200Pa – confirm process requirements match

3. Working pressure: 0.75MPa – confirm pressure range required for impregnation process

4. Resin type and temperature requirements: Confirm if resin requires heating or cooling – verify storage tank heating/cooling capacity meets requirements

5. Data management needs: Full automatic recording and printing – meets strict quality traceability requirements

6. Site conditions: Vertical installation – verify factory height and foundation conditions

6. FAQ

Q1: What vacuum level can the equipment achieve?

A: Three-stage oil-free pump units ZJY2500/ZJY1200/WLW300 – maximum pumping speed 2500L/s – working ultimate vacuum 100-200Pa – meets insulation treatment requirements for high-voltage motors and transformers.

Q2: How is resin temperature precisely controlled?

A: Resin storage tank with 100mm insulation layer – heating or cooling medium inside. Heating system 48kW – cooling system 80000W/H – parallel operation with automatic switching per set temperature – real-time feedback from temperature sensors – precise resin temperature control.

Q3: How is the vacuum pump protected?

A: Vacuum buffer tank before pump units – prevents oil mist or solvent vapors from entering pumps. Exhaust gas passes through separation condenser before discharge – condensed liquid manually released. These measures effectively protect vacuum pumps and extend service life.

Q4: What data management features does the control system have?

A: PLC + 21-inch IPC – real-time recording of vacuum-time, tank pressure-time, liquid level-time curves. Data stored long-term on hard disk – supports query, printing, and list output – complete quality traceability.

Q5: What safety protection measures are included?

A: Hydraulic station locked when tank under vacuum or pressure – over-pressure alarm and pressure safety devices – mechanical-electrical interlocks preventing overpressure and misoperation – safety interlock when cover open – exhaust gas discharged from buffer tank.