In-house Stator Coil Manufacturing

IPS single-source capabilities include in-house coil manufacturing, for complete control of QA and delivery. IPS PennCoil (Certified to ISO 9001:2008 With Design) manufactures a wide range of AC stator coils, B-stage hard coils, and rotor, armature and field coils. We also manufacture Roebel bars in-house for turbine generators. In-house coil manufacturing means shorter lead times for breakdowns and emergency repairs. Combining control of coil manufacturing with the rewind process ensures superior quality and performance with minimal downtime.

We have extensive engineering and manufacturing experience with all major OEM coil designs for Global VPI and sealed insulation systems, plus an engineering coil database with over 100,000 design configurations, including all Allis Chalmers designs. IPS maintains an extensive inventory of high voltage coils for motors and generators made by the leading OEMs. These are available for emergency delivery on a 24/7 basis.

Additional resources include:

• Dedicated environmentally-controlled clean room for
  coil manufacturing
• 200,000 lb. inventory of magnetic wire plus a wire insulating mill for quick turns on glass, mica and Kapton strand insulation
• Automated CNC taping and spreading equipment for consistent coil geometry

IPS offers the precision and repeatability of the industry’s fastest taping process, using programmed coil data to produce uniform tape applications with electronically controlled tension, layering and overlap. We electronically store the data for your high-voltage coils, to ensure that future replacements are a precise match.

We use an inside pressing operation to consolidate our B-stage hard coils before moving to the automated CNC spreader. After our manufacturing specialists complete final hand-taping operations, the coils move to an outside press to complete consolidation of the slot region, ensuring a proper fit in the stator. This improves reliability, mechanical stress resistance and dielectric performance.

IPS PennCoil B-stage high-voltage coils feature the use of a shrink Mylar taping over the resin-rich B-stage mica tape and are then placed in a temperature controlled oven to completely cure the insulation system (the oven curing drives resin through the coil structure and ground wall, to prevent corona and partial discharge).

Every IntegraSeal™ B-stage hard coil meets or exceeds independent third-party standards, including the IEEE 1043 voltage endurance life test, IEEE Standards 533 and 286, ANSI Standards 522 and 286, ANSI Standards C-50-10 to C-50-26 and is certified by ISO Standard 9001:2008 with Design.