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Processes
Each application has unique peculiarities. Thanks to our experience in a wide range of core processes, we are able to offer a comprehensive and proven solution that can meet even the most demanding requirements.
Copper wire winding is our core business. We specialize in winding coils, solenoids and electric motors with concentrated poles. Our high-end machines enable us to achieve layers and fills that meet performance requirements.
Each wire is wound using the correct tension for each step in the process. This ensures control and repeatability of the winding cycle.
Tecpool can wind a wide range of wires with diameters ranging from 0.04 mm to 2.5 mm to date. We also process various Litz wires used for high-frequency application.
The Marsilli Omnibus for special applications is a state-of-the-art 16-axis system that allows complex windings to be made with precision and versatility. Every different type and concept of winding can be realized quickly and with consolidated results.
Rotary spindle machines enable high-precision, high-speed winding of coils, solenoids, and single-tooth motors.
External Needle winding consists of winding magnetic laminations through a wire guide acting from outside the motor. This provides an excellent compromise between hollow filling and ease of assembly.
Internal Needle winding involves winding magnetic laminations through a wire guide acting from inside the motor. The hollow filling is less than other technologies, but subsequent assembly steps are reduced.
The soldering of the copper wire is the key process that enables the correct contacting of the winding with the system that feeds the component. It is essential to ensure its quality by monitoring all process parameters and validating the result with trials and tests.
Resistance Welding is a welding process that uses heat generated by electric current passing through highly resistive electrodes to sublimate the copper wire insulation and join the wire with the terminal.
Insulation Displacement Connection is a technology that involves contacting the wire with the terminal by enamel etching. This technology is used when currents are relatively low and cost and cycle time are important targets to meet.
Tin Welding involves the addition of material (tin alloys) to ensure the electrical and mechanical connection between the two interfaces to be joined. Various alloys are used depending on operating temperatures.
Arc welding is a welding process that uses an electric arc to fuse materials. It ensures strong and precise joints, ideal for industrial applications.
The injection molding process is a manufacturing technique in which a molten material is injected into a mold to obtain a specific shape.
The molding process, on the other hand, involves applying a layer of plastic over a pre-existing component, which may be metal, plastic, or other.
Materials processed
- PPS
- PA6-PA66
- PPA
- PBT
- POM
Filler
- Glass fiber or granules
- Ceramic fiber
- Mineral
- Carbon fiber
Tecpool has 16 Arburg presses, a reference in the plastic molding industry. Horizontal presses are used to mold plastic components such as spools, reels, motor insulators. Vertical presses allow overmolding and molding finished parts such as stators, connectors, ECU covers with integrated pins.
Tecpool boasts a team of experienced operators who manage the complex process operations. With their training and expertise, they ensure precision and quality in maintenance, tooling, production, and quality control.
Magnetic platens on each Tecpool press enable fast and accurate mold changes, reducing downtime and increasing production efficiency. This advanced technology provides greater flexibility in production and facilitates equipment maintenance.
Tecpool S.r.l. handles a wide range of technical polymers with a variety of fillers to ensure mechanical, thermal and electrical performance according to the needs of our customers.
With our R&D department and laboratory equipment, we are able to make rapid prototyping components to test and validate design choices quickly and verify design FEA calculations.
The Marsilli Omnibus for special windings is a state-of-the-art 16-axis system that enables complex windings to be made with precision and versatility. Every different type and concept of winding can be realized quickly and with consolidated results.
Vacuum potting is a process that relies on filling the component with a resin that increases its mechanical, thermal, and electrical characteristics. At Tecpool, we use a dedicated resin machine for prototypes that allows vacuum dosing to optimize filling and, through the use of dedicated tools, to ensure the required shape and functionality.
Among the many component validations of great importance are electrical and electromagnetic tests. We use state-of-the-art equipment for low and high voltage electrical testing including Partial Discharge testing to predict the reliability of the component over the product life.
We use tensile and compression machines both for testing the mechanical strength of components and for characterizations of solenoids and actuators.
We have 3 brake bench systems for mechanical and electrical characterization of motors of our own design and production.
Through Magtrol brakes and Yokogawa Power Analyzer, we are able to provide customers with validation reports of actual engine performance.
The Vacuum Potting process involves encapsulating the component in a resin by vacuum casting. This increases its mechanical, thermal and electrical properties and, in general, increases its reliability. Through the use of dedicated tools, multiple geometries can be obtained to reduce weight and ensure the functionality of the finished product.
Prototypes, pre-series, and small batches can be handled at our Laboratory through the use of a dedicated resin dosing machine. Both the resin and the dispensing environment are maintained under vacuum to ensure optimal results.
When volumes are high, automatic assembly lines can be investigated for a fully automated and controlled process to ensure cycle time and part quality.
Our experience on different projects and products allows us to identify from the outset what is the best strategy to achieve the result while meeting all requirements.
The study and design of the resin tool is a service we offer to our customers.
Our metrology room and laboratories are equipped with advanced instruments for precision measurements and process controls.
CMM measuring machines, microscopes, automatic optical measuring machines and many others enable us to check compliance with tolerances and ensure product quality.
Instruments for plastic materials analysis and machinery for metallography enable us to offer a complete package.
Tests and controls
- Dimensional checks
- Electrical testing
- Thermal Shock
- Tensile and compression testing
- Metallographs
- Tear test
- Leak and flux testing
- Vacuum tightness test
- Testing of seals
- Verification of plastic material characteristics (Melt Flow, DSC)
- Potting impregnation checks
- Root Cause Analysis
- 100% End of Line Controls
At Tecpool, we use Zeiss coordinate measuring machines (CMMs) to ensure excellence in quality control. Our metrology room performs precise measurements on components and products, intercepting any defects and ensuring adherence to the most stringent tolerances.
Our Falcon Measuring System allows us to integrate the flexibility and speed of the optical system with the accuracy of the touch-trigger system. Through the creation of automatic measurement programs, we can handle a high number of acceptance and pre-shipment checks.
Each product goes through thorough inspections either by our extremely skilled workers or through automatic inspections with cameras or vision sensors.
Our quality control personnel are extremely qualified and trained to investigate all process steps and product characteristics to ensure quality in all aspects.
Training and continuous improvement enable us to improve and refine skills to fully meet our customers’ demands.
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