Applications of Fully Automatic Glue Potting Machines in the Power Supply Industry?
Fully automatic dispensing machines have a wide and crucial application in the power supply industry, significantly improving the reliability, consistency, and production efficiency of power supply products. Below, I will elaborate on its application scenarios, core advantages, and future development trends
1.Main Application Scenarios of Fully Automatic Potting Machines in the Power Supply Industry
Potting technology is mainly used to protect power modules, circuit boards, and components. Specific applications include the following types of power supply products:
a.Switching Power Supplies
Industrial Power Supplies: Power supplies used in industrial control equipment, machinery, etc., operating in environments that may be dusty, oily, and vibrating. Potting provides dustproof, moisture-proof, and corrosion-proof protection.
Communication Power Supplies: Base station power supplies, server power supplies, etc., require extremely high reliability. Potting enhances their weather resistance, prevents condensation caused by drastic temperature changes, and improves shock resistance.
b.Modular Power Supplies
Including AC-DC and DC-DC converter modules. These modules are typically compact with densely packed components. Potting cures all components into a single unit, effectively resisting vibration and impact, preventing pin breakage due to external forces, and improving heat dissipation.
Communication Power Supplies: Base station power supplies, server power supplies, etc., require extremely high reliability. Potting enhances their weather resistance, prevents condensation caused by drastic temperature changes, and improves shock resistance.
c.LED Driver Power Supply
LED driver power supplies are commonly used in outdoor lighting (such as streetlights and landscape lights), facing harsh environments including sun, rain, high temperature, and high humidity. Potting provides comprehensive waterproofing, moisture protection, and insulation, ensuring long-term stable operation.
d.New Energy Vehicle Power Supplies
On-board chargers, DC-DC converters, motor controllers, etc. These components operate in locations such as the vehicle chassis, facing challenges such as severe vibration, temperature differences, moisture, and salt spray. Potting is a necessary process to meet automotive-grade reliability and safety standards.
Fully Automatic 3-Axis Potting Machine SEC-S3030B & SEC-S3030C
The work of the glue potting machine mainly depends on air pressure control. Through the air pressure device, the glue is pressed out by pressure, and the size of the glue is controlled by the pump body. At the same time, the robotic arm is responsible for controlling the moving position of the glue discharge to achieve fully automated operation. This automated operation not only solves the problem of low labor efficiency, but also greatly improves the quality of production.
e.Photovoltaic/Energy Storage Inverter Power Supplies
Power modules (such as IGBTs) in inverters generate a lot of heat and need to be tightly coupled to heat sinks. Using highly thermally conductive adhesives for potting provides both insulation and efficient heat transfer to the heat sink.
f.Specialty Power Supplies
Such as military power supplies and medical equipment power supplies, which have extreme requirements for safety and reliability. Potting provides the highest level of insulation and physical protection.
2.The Specific Role of Potting in the Power Supply Industry
a.Enhanced Heat Dissipation
Power devices (such as MOSFETs and diodes) in a power supply are the primary heat sources. By filling with a highly thermally conductive insulating adhesive (such as thermally conductive silicone), heat from the point heat source can be conducted to the entire adhesive and casing, significantly reducing the operating temperature of the components and extending their lifespan.
b.Improved Insulation Performance and Safety
The potting compound fills the gaps between high-voltage components (such as the primary side) and low-voltage components (such as the secondary side), eliminating the problem of unstable air dielectric constant and providing stable and extremely high insulation strength. This prevents high-voltage breakdown and short circuits, ensuring safe use.
c.Superior Physical Protection
Shock and Shock Resistance: Solidifies loose components into a robust whole, effectively withstanding vibrations and impacts during transportation and use, preventing cold solder joints and wire breakage.
Moisture and Dust Protection: Completely seals the PCB board and components, resisting the corrosive effects of moisture, salt spray, dust, mold, and other environmental factors, improving the product’s adaptability to harsh environments.
Chemical Corrosion Resistance: Protects circuitry and components from corrosion by acids, alkalis, and other chemicals.
d.Achieving Miniaturization and Lightweight Design
Through the protection provided by potting compound, designers can reduce the size and thickness of the power supply casing (or even use a plastic casing instead of a metal casing), as the protective function is partially provided by the compound, thus achieving product miniaturization and lightweighting.
3.Key Considerations for Selecting and Applying a Fully Automatic Potting Machine
a.Adhesive Type: The power supply industry commonly uses epoxy resin (high hardness, strong adhesion, good temperature resistance), polyurethane (good elasticity, resistance to thermal shock), and silicone (best elasticity, resistance to high and low temperatures, good electrical properties). The appropriate adhesive must be selected based on product requirements.
b.Mixing and Metering System: For two-component adhesives, a high-precision metering pump and dynamic mixing valve are required to ensure accurate and uniform mixing of components A and B.
c.Motion Control System: A multi-axis robotic arm or a three-axis platform ensures the accuracy and repeatability of the dispensing path.
d.Vacuum Degassing Function: For products with extremely high requirements, vacuum degassing treatment of the adhesive is necessary before dispensing to prevent air bubbles from affecting insulation and thermal conductivity.
e.Ease of Cleaning and Maintenance: The equipment should be easy to clean to prevent adhesive from hardening and clogging the system.
Summary:
Fully automatic mixing potting filling machines have become an indispensable key piece of equipment in modern power supply manufacturing, especially in the production of mid-to-high-end power supply products. By automating and intelligently maximizing the value of the protective dispensing process, it directly empowers power supply products, giving them higher reliability, longer lifespan, and superior performance, thereby meeting the increasingly stringent technical requirements of cutting-edge fields such as automotive, industrial, communications, and new energy. For power supply manufacturers, investing in fully automated dispensing machines is a strategic choice to enhance core competitiveness and move towards high-quality manufacturing.
Second Intelligent has played an important role in theresearch, development, manufacturing, pre-sales and after-sales services of fluid dispensing robot, potting and coating solutions which range from various types of automatic fluid dispensing, potting, two-component potting machines and coating machines with desktop, free-standing, inline or cobot combined systems, and widely used in global electrical, electronics, home appliances, automobile, telecom, pharmaceutical, automotive electronics, semiconductor, aerospace, LED and more.
