Two-Component Vacuum Potting Machine HY-SAV600
Bubbles trapped in potted electronics cause insulation failure, partial discharge and field returns. The HY-SAV600 potting under a deep vacuum of up to −98 kPa cuts residual voids from the 2–5% typical of atmospheric potting to below 0.1% — bubble-free encapsulation for BMS, ECU and power modules, in one compact machine.
−98 kPa Deep Vacuum | ±2% Mixing Ratio Accuracy | 1:1–10:1 Adjustable Ratio
Product Introduction
The HY-SAV600 is a two component potting machine built for automotive Tier 1 electronics suppliers who cannot afford bubble defects. It meters, mixes and dispenses two-component epoxy, polyurethane or silicone under vacuum, so the compound reaches deep cavities, dense coil windings and undercuts without trapping air. Independent servo drives for the A and B components hold the mixing ratio in closed loop, while multi-stage vacuum degassing treats both the raw material and the workpiece. As a programmable AB glue dispensing machine, the SAV600 stores hundreds of potting programs for fast changeover between products — one cabinet covers the vacuum sealing work that used to need several offline machines. Bench and in-line vacuum potting machine conveyor versions are available, and every shot’s ratio, vacuum level and volume is logged to your MES for full batch traceability.
Specification
| Item | HY-SAV600 |
|---|---|
| Type | Two-component vacuum potting machine (bench / inline conveyor versions) |
| Mixing ratio | 1:1 – 10:1, adjustable, closed-loop servo control |
| Ratio accuracy | ±2% |
| Dispensing accuracy | ±3% |
| Metering pumps | Gear / screw / piston (material-dependent), independent A/B servo drives |
| Working travel (X/Y/Z) | Customisable per workpiece — contact us for the range for your part size |
| Running speed | 0–500 mm/s |
| Dispensing rate | 1–9 g/s or 5–30 g/s (pump configuration) |
| Vacuum level | Up to −98 kPa, multi-stage graded degassing |
| Material tanks | 15L / 30L / 55L optional, heating + stirring + degassing |
| Multi-head metering | 1–4 sets (optional) |
| Compatible materials | Epoxy, polyurethane, silicone, AB adhesives; viscosity up to 500,000 cps |
| Mixing method | Dynamic / static |
| Control system | Windows 10 PC + touchscreen, recipe storage, MES/ERP link via Ethernet |
| Monitoring | Pressure, flow, weighing, liquid level, stirring; glue-shortage and vacuum-leak alarms |
| Power supply | AC 220V, 50Hz |
| Air supply | 0.5–0.7 MPa |
Specifications can be customised to your workpiece and material.
Features
- Independent closed-loop servo metering — separate servo motors drive A and B components with real-time pressure feedback; ratio adjusts in software, no gear change.
- Multi-stage vacuum degassing — raw material and workpiece cavities are degassed synchronously, clearing micro-bubbles in deep, dense windings.
- Automatic cleaning & anti-curing — auto-clean cycle with 0–300s adjustable anti-curing timer keeps the mixing tube clear between shifts.
- Full process monitoring — pressure, flow, weighing, tank level and stirring monitored continuously; anomalies trigger alarm and stop before a bad part is made.
- Quick-change programs — hundreds of stored trajectories and recipes; changeover by program recall plus fixture swap.
- Detachable cleaning modules — daily maintenance without full disassembly.
- MES-ready data — per-tray records (ratio, vacuum, temperature, volume) export to daily reports and ERP/MES systems.
- Safety package — leak detection, air-pressure alarm, emergency stop and light curtain.
Optional Configuration
| Option | What it does |
|---|---|
| Metering pump type (gear / screw / piston) | Matches metering to your material’s viscosity and filler content |
| 15L / 30L / 55L heated stirring tanks | Capacity for your daily consumption; heating stabilises viscosity |
| 1–4 multi-head metering sets | Parallel potting for higher throughput or multi-material stations |
| CCD vision positioning | Automatic workpiece location for irregular housings |
| Inline track conveyor | Connects the machine into an automated production line |
| Plasma cleaning module | Surface pre-treatment for better adhesion on difficult substrates |
| Pipeline heating | Keeps high-viscosity material flowing in cold workshops |
Comparison
| Vacuum potting (HY-SAV600) | Atmospheric potting | |
|---|---|---|
| Residual voids | Below 0.1% | Typically 2–5% |
| Complex geometries / undercuts | Fills reliably | Air traps likely |
| Insulation reliability | High — no void-related partial discharge | Voids can lower dielectric strength |
| Suitable parts | HV modules, dense coils, safety-critical electronics | Simple geometries, non-critical parts |
| Equipment cost | Higher | Lower |
Typical property ranges from published material guides; check your compound’s TDS for exact figures.
| Property | Epoxy | Polyurethane (PU) | Silicone |
|---|---|---|---|
| Cured hardness | Shore D 70–95 (rigid) | Shore A 30 – D 60 (flexible–semi-rigid) | Shore A 20–70 (elastomeric) |
| Continuous temperature | Up to 150–180°C | −40 to 120–130°C | −55 to 200°C |
| Adhesion | Excellent | Good–excellent on plastics | Moderate (primer recommended) |
| Thermal shock resistance | Fair (can crack) | Good | Excellent |
| Reworkability | Poor | Poor | Excellent (cuttable) |
| Relative cost | Medium | Low–medium | High |
| Typical automotive use | Power modules, coils needing structure | Sensors, connectors needing flex | High-temperature / high-vibration electronics |
| On the HY-SAV600 | ✔ | ✔ (vacuum recommended — PU traps bubbles easily) | ✔ |
Packaging & Delivery
The HY-SAV600 is packed in a fumigation-free export wooden case with moisture protection, fixed for sea freight. Standard machines ship in 30–45 days; customised configurations in 60–120 days depending on complexity (final schedule in contract). HY engineers provide installation, commissioning and operator training on site or by video, with process parameters set against your own parts before handover. Warranty and after-sales terms follow the sales contract; remote troubleshooting is available for overseas customers, and every machine’s potting programs and calibration data are archived by HY for lifetime support.
Core Advantages
Multi-stage −98 kPa vacuum degassing reduces residual voids to below 0.1%, protecting insulation strength on high-voltage parts.
Hundreds of stored programs and 1:1–10:1 ratio adjustment without gear changes; program switch in minutes, not hours.
Constant-temperature stirring tanks stop viscosity drift and settling, so the first part and the ten-thousandth part pot identically.
Integrated cabinet design saves over 2㎡ of workshop space versus a separate degassing + dispensing setup.
Ratio, vacuum, tank temperature and volume recorded per tray and bound to a QR code; PPAP-ready reports for IATF 16949 audits.
One-pass bubble-free potting removes rework and scrap from insulation failure, cutting warranty exposure.
Applications
EV BMS & High-Voltage Power Modules — bubble-free potting of BMS boards, OBC chargers and power modules to IATF 16949 audit standards. New energy & lithium battery industry
Automotive ECU & Sensors — deep-cavity controller and radar sensor sealing for Tier 1 suppliers. Auto parts industry
Inverters, Transformers & Motor Coils — vacuum impregnation of dense windings with high-viscosity epoxy. Auto parts industry
E-Bus & Light Commercial Power Assemblies — wide-travel inline version for large power modules, two-shift duty. New energy & lithium battery industry
R&D Labs & Small Batches — bench pilot version for prototype validation and PPAP test reports. Contact us
FAQ
Vacuum machines pot under up to −98 kPa, removing air from both the compound and the workpiece, so deep cavities and dense windings fill without bubbles. Standard machines are cheaper and fine for simple geometries where voids are not critical.
Two-component epoxy, polyurethane and silicone, including filled grades up to 500,000 cps. Tell us your material and ratio — we match the pump type (gear, screw or piston) to it before delivery.
Closed-loop servo metering holds ratio accuracy to ±2% and dispensing accuracy to ±3%, with adjustable ratios from 1:1 to 10:1 set in software — no gear changes.
Yes. Hundreds of programs can be stored, 1–4 metering heads can be fitted, and changeover is a program recall plus fixture swap — designed for high-mix Tier 1 production.
Run the automatic cleaning cycle after each shift, replace filters weekly, and lubricate guides and screws monthly. The anti-curing timer (0–300s) protects the mixing tube during stops.
Standard configurations ship in 30–45 days; customised machines in 60–120 days depending on options, confirmed in the contract.
Get a Quote for the HY-SAV600 Vacuum Potting Machine
Send us your workpiece drawing and potting material — our engineers will reply with a configuration and quotation.
Email: vip@huayuautoline.com | WhatsApp: +86 18158897969
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