As a key component for the stable operation of the motor, the manufacturing process and quality control of ac motor capacitors are directly related to the performance and service life of the motor.
First, the selection and preparation of electrode materials are the basic links. Common electrode materials include aluminum foil. High-quality aluminum foil has high purity, smooth surface and no obvious defects, which can ensure good conductivity and charge storage capacity. During the preparation process, the thickness tolerance of the aluminum foil is controlled by a precise rolling process, which generally needs to be controlled within a very small range, such as ±0.005mm, to ensure the consistency of electrode performance and lay a solid foundation for subsequent capacitor manufacturing.
Secondly, dielectric materials are crucial. For ac motor capacitors, materials such as polypropylene film are often used, which have the advantages of high insulation and low dielectric loss. The film production needs to strictly control the thickness uniformity, and use advanced stretching technology to make the film thickness deviation not exceed the specified value, avoid the risk of electrical breakdown caused by local weakness, and ensure the voltage resistance performance of the capacitor.
In addition, the winding process is delicate and critical. The electrodes and dielectrics are precisely wound according to a specific structure. The winding tension should be stable and moderate. If it is too large, it is easy to cause film tearing and electrode damage. If it is too small, the winding will be loose and affect the accuracy of the capacitance value. For example, a closed-loop tension control system is used to monitor and adjust the winding tension in real time to ensure that each layer is tightly and neatly wound, to ensure the stability of the internal structure of the capacitor, and to achieve accurate capacitance parameters.
Impregnation treatment cannot be ignored. The wound capacitor core is impregnated in a special impregnant. The impregnant must be fully penetrated and filled to enhance the insulation performance and heat dissipation capacity, while stabilizing the capacitance parameters. Strictly control the parameters such as impregnation temperature and time to prevent incomplete or excessive impregnation, and ensure that the capacitor can operate reliably under different working conditions.
In the packaging link of ac motor capacitors, on the one hand, an insulating, heat-resistant, and mechanically strong plastic shell is selected to ensure external protection; on the other hand, the sealing process must be rigorous, and advanced technologies such as ultrasonic welding are used to prevent external water vapor and dust from invading, avoid internal short circuits and other faults, and extend the life of the capacitor.
Quality inspection runs through the entire process. From random inspection of raw materials entering the factory, to capacitance and withstand voltage tests of semi-finished products, to comprehensive performance evaluation of finished products, such as high-temperature aging tests and vibration tests, professional instruments and equipment are used to strictly control the quality. Only when all indicators meet the standards can we ensure that AC motor capacitors can work stably and efficiently in complex motor operating environments, providing solid protection for AC motors.
