Method for producing a high-quality insulation for electric conductors or conductor bundles of rotating electrical machines by means of thermal spraying

A process for producing a high-quality insulation for conductors or conductor bundles, comprising the steps of:

• (S1) mounting a conductor or conductor bundle which is to be coated on a rotation and holding device,
• (S2) heating the conductor or conductor bundle to a predetermined substrate temperature,
• (S3) orienting the conductor or conductor bundle position with a flat side perpendicular with respect to a spray gun,
• (S4) spraying a liquid or plastic internal corona-discharge protection onto the heated substrate, the application layer thickness being approximately 0.05 to 0.2 mm,
• (S5) rotating the conductor or conductor bundle, so that a further flat side of the conductor or conductor bundle is oriented perpendicular to the spray gun, and then repeating steps S3 and S4 and repeating this step S5 until all the sides of the conductor or conductor bundle have been coated,
• (S6) changing the coating powder into an insulant-filled powder,
• (S7) coating the conductor or conductor bundle with the insulant-filled powder in at least one pass on all sides of the conductor or conductor bundle as described in steps S3 to S5,
• (S8) carrying out steps S6 and S7 using a coating powder for an external corona-discharge protection, for example a conductively filled powder, and
• (S9) allowing the coated conductor or conductor bundle to cool and removing it from the rotation and holding device.