Insul-Core™ Solutions LLC


Process Application

~The Insul-CoreTM Solutions #0409 Process ~ 

The Insul-CoreTM Solutions process provides a complete process that does not require the laminations to be disassembled.The Insul-Core Solutions process involves the application of a proprietary formulated solution that provides the ability to reduce core losses, core temperatures and significantly reduces shop time from the old traditional methods.

Proper application of the Insul-CoreTM Solutions process clears the interlaminar shorts between laminations in stator cores. Insul-Core Solutions converts the steel surface to form a durable core plate. The Insul-Core Solutions treatment can provide reduced static core losses by much as 38%, and improved stator core power factor by 10-12% – final results are dependent on the extent of the core plate damage.

Preparation: Based on the results of the failed core test, the following issues must be addressed: Hot Spots: The first step is to clear the hot spots by using one of 3 methods: a) Use a a bore sander to scrub the surface, b) “Wattknocking”* c) Manually spreading the laminations.

High Core Losses: The options are watt-knocking*, spreading / fanning the laminations**, and re-insulating the laminations (Insul-Core Solutions) to restore the coreplate.

Rotor / Stator Bore Contact: The shorting is most likely confined to the surface of the teeth. Use a drum sander to scrub the surface, followed with Insul-Core Solutions treatment to remove interlaminar burs. Badly shorted laminations should be separated using the procedures outlined above.

* Watt-knocking: Axial bumping of the core can break loose shorted laminations. This is most effective when surface shorting is the problem. The analogy is a break when playing billiards. By striking the core near the top of the teeth, in an axial direction, the fused laminations can be broken loose. Traditional methods include a hammer and heavy bar, or a pneumatic hammer (air hammer) with a blunt tool. The auto-body repair industry uses a flat tipped tool that resembles a piston. It is well suited for watt-knocking.

**Fanning & Spreading Laminations: When watt-knocking fails to separate the shorted laminations, use a sharp knife or thin bladed chisel to tap between the laminations and break them loose. This process is labor-intensive, so try watt-knocking first.

Next: Apply the Insul-CoreTM Solutions in the following 3 steps:

1. Scrub the stator bore with a coarse abrasive sand paper (60-100 grit). A drum sander may be used with the drum roughing the surface parallel to the laminations and completely around the entire inside diameter of the core; the ID of the core must be exposed bare metal.

2. The Insul-CoreTM Solutions and the core must be preheated to 200°F-210°F. The heated core must be continuously wetted with the lnsul Core Solutions; this wetting process of the core iron Must be maintained for 15 minutes!! (See List of Materials for application equipment.)

3. After maintaining the wetting of the core and laminations for 15 minutes, let laminations stand for 10 minutes. Then the core or laminations should be rinsed thoroughly using clean water and then baked dry above 212°F to thoroughly dry the laminations. A final core test(at room temperature) confirms the improved results using the Insul-Core Solution.

The Insul-CoreTM Solutions material adheres to the steel and becomes a integral part of lamination ( Core Plate). The complete impregnation of all areas of the shorted laminations through ADSORPTION ( the process by which an ultra thin layer of one substance forms on the surface of another substance. ) The process is relatively simple; however, each step is important to the success of the process.

Application Requirements:

a. Complete impregnation of all areas to the depth of the shorted laminations is mandatory.

b. Preheating the core to the required temperature (200-210°F as above) is critical.

c. Maintaining the Insul-CoreTM Solutions at a minimum of 180°F is critical; this enables thorough penetration of the core resulting in a capillary action which aids in the ADSORPTION PROCESS.

d. Sanding the surface ensures you have a clean and bare steel surface for the reaction. A smooth surface will not react as favorably for a successful treatment. Sanding parallel to the core laminations is required as a rough surface enhances the chemical reaction with the core laminations.

e. Exposure time is the one variable that can be adjusted. The longer the contact time between the impregnation and the steel being treated, the more aggressive the coating results will be.

f. After the core iron continues to be thoroughly wetted throughout the laminations for a period of 15 minutes, the core iron must be thoroughly rinsed with clean water as the Insul-Core Solutions will leave some residual material which needs to be rinsed off the core iron with clean water.