One Factor at a Time Analysis to Modify Potting Technique for Manufacturing of Bubble-Free High-Voltage Polyester Insulated Automotive Coils

The current study focuses on minimising the bubbles in polyester-insulated ignition coils, which were produced with a defect level of ~21–25% or 210–250 coils per 1000 batch size by using potting method. This high-level rejection makes substantial financial impact increasing waste material, manufacturing, and after-sales costs. Hence, to control bubbled problem without expensive maintenance-heavy techniques, process parameters method alternated investigated one factor at time, played vital role formation/reduction coil insulation. Process parameters, including pre/process heating, appropriate MEKP/cobalt naphthenate ratio, pouring amount/increments, stirring speeds, reduced bubble formation lot from 205 ± 30 146 25, 108 21, 61 17, 10 2 accordingly. In addition, comparative was conducted terms performance life cycle endurance, Japanese Indian standards. Furthermore, an after-sale warranty claim also supports proposed changes technique. modification may reduce within two years approximately ~85%. technique is extremely cost-effective comparison processes, i.e., vacuum-pressure impregnation vacuum impregnation, require extensive labour maintenance.