In high-end manufacturing, behind every precision component lies the support of advanced technology and cutting-edge equipment. Recently, the high-end fully automatic vacuum impregnation furnace customized by our company for a leading enterprise in the domestic power electronics field has completed all debugging and acceptance, and has been officially delivered for production.
Customer Challenge: The "Invisible" Barrier of Precision Manufacturing
The customer is facing severe challenges in the production of its core product - the specific component of high-voltage power capacitors:
The insulation reliability requirement is extremely high: Even the tiniest pores may cause breakdown under high-voltage and high-frequency operating conditions, leading to product failure.
The consistency of the process is hard to guarantee: The traditional impregnation method has dead corners, making it difficult to ensure that every product meets a uniform quality standard.
Production efficiency needs to be improved: there are many manual intervention links and the production cycle is long, which cannot meet the growing market order demands.
The customer urgently needs an automated, high-precision and highly reliable vacuum impregnation solution to break through the bottleneck and consolidate its leading position in the market.
Our solution: Tailor-made fully automatic vacuum impregnation system
Facing the client's strict requirements, the project team delved into the client's production frontline and conducted multiple rounds of in-depth exchanges with technical experts. Eventually, they provided a solution that integrates "intelligence, efficiency, and stability"
Core equipment: Fully automatic vacuum impregnation furnace
Highlights of the vacuum impregnation furnace system
High-precision programmable control system: It adopts PLC+ human-machine interface intelligent control. The entire impregnation process (vacuuming, glue injection, pressure holding, exhaust, and glue dripping) is automatically completed. Process parameters can be precisely stored and called up, completely eliminating human operation errors.
Outstanding vacuum and sealing performance: With a multi-stage vacuum system, it can achieve a high vacuum degree in an extremely short time and ensure that the furnace body maintains extremely high sealing performance during long-term operation, providing a perfect environment for the deep penetration of the impregnating agent.
Efficient recycling and cleaning design: Integrated impregnating agent recycling system, significantly reducing consumable costs; The interior of the furnace is coated with a special anti-stick coating and designed for cleaning, which is convenient for maintenance and reduces downtime.
Comprehensive safety protection: Equipped with multiple safety interlock protections (such as overpressure, over-temperature, and power-off protection, etc.) to ensure the safety of the equipment and operators.
Project outcomes and customer value: What is delivered is not just equipment, but competitiveness
Since the equipment was put into production, its outstanding performance has brought immediate benefits to customers
Quality leap: The impregnation and filling rate of the product has been increased to over 99.8%, and the insulation performance fully meets the most stringent industry standards, significantly enhancing the product's yield rate.
Efficiency doubling: The fully automated process has reduced the processing time of a single batch by approximately 40%, enabling 24-hour uninterrupted production and significantly boosting production capacity.
Cost optimization: Precise consumable control and an efficient recycling system effectively reduce the comprehensive production cost per unit of product.
Intelligent upgrade: It has achieved digital management and traceability of production processes, laying a solid foundation for customers to move towards "Industry 4.0" intelligent factories.
The successful completion of this project not only marks a crucial step for the client in enhancing product reliability and production efficiency, but also once again demonstrates our company's strong R&D capabilities and outstanding project delivery skills in the field of special heat treatment equipment.