CN102586715B - New method for insulating coating of explosion proof transformer electric steel sheet - Google Patents
New method for insulating coating of explosion proof transformer electric steel sheet Download PDFInfo
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- CN102586715B CN102586715B CN201110384151.8A CN201110384151A CN102586715B CN 102586715 B CN102586715 B CN 102586715B CN 201110384151 A CN201110384151 A CN 201110384151A CN 102586715 B CN102586715 B CN 102586715B
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Abstract
The invention relates to a new method for insulating coating of an explosion proof transformer electric steel sheet. The method comprises the steps of performing sand blasting enhancement, laser shock shot blasting and plasma high temperature spraying. Plasma high temperature spraying equipment comprises a conveying belt, a plasma spraying machine, an ultrasonic generator, a position motor, a guide rail, an image sensor and a drive motor. By the process, the problems that the insulating layer on the surface of the traditional electric steel sheet is easy to damage at high temperature and the coating is non-uniform and thick are solved. A nano ceramic material serves as the insulating coating and the plasma high temperature spraying technology is adopted, so that the insulating coating has high temperature resistance, high insulating property and aging resistance and can guarantee safety operation of the high capacity explosion proof transformer under the full load operation condition.
Description
Technical field
The present invention relates to insulating coating field, relate in particular to a kind of method that forms insulating coating on the electric steel disc of transformer.
Background technology
During the logical upper alternating-current of transformer, on electric steel disc, can produce alternating magnetic field, this alternating magnetic field can produce alternating electric field around at electric steel disc, and the electric field of this alternation can be at inner exchange current, the namely eddy current of producing of electric steel disc.For fear of or reduce eddy current, aborning, electrical sheet very thin and mutual insulating is superimposed, forms the electric steel disc of an intensive insulation, like this, the eddy current in large loop is just difficult to form, and in every a slice electricity steel disc, due to very thin, eddy current is also difficult to form, even if having also extremely faintly, can ignore.
But, when using, transformer arrives certain time limit, and the insulation layer on electric steel disc surface can be aging gradually, insulativity between electricity steel disc can decline gradually, if the insulation on electric steel disc surface is completely destroyed, being equivalent to iron core is to have adopted a monoblock, it is very large that eddy-current loss can become, and occurs larger eddy current in iron core, not only can cause eddy-current loss waste electric power, and cause that iron core generates heat, serious may burning is red, even melts, and the consequent is, the electric current of coil increases, so that burns.Whole transformer temperature rises, and transformer causes blast because of above-mentioned overtemperature fault.
Adopt traditional insulating material to also have a disadvantage, a large amount of individual workships reclaims and processes damage the transformer of scrapping because of insulation layer, and they often use the mode of burning that electric steel disc is taken apart, and electric steel disc is badly damaged in this process.This transformer inferior declines the permeability of electricity consumption steel disc greatly, and this badly influences much Power Consumption of Industrial Enterprises safety, has also therefore buried hidden danger, and this hidden danger, chases after the low consequence causing of its root or transformer core insulating property.
Up to the present, on transformer core electricity steel disc, form the technology of a layer insulating and the formula of coating has had many.Wherein main use is chromic salt and phosphatic inorganic materials, uses in addition the mixed coating material of organic and inorganic two main ingredients.Although the thermotolerance of these material marks can reach the temperature rise requirement of transformer, but transformer is for a long time under full-load conditions in operation or of short duration overload operation, transformer working current can reach rated value or overrate, thereby make coil at high temperature operation always, in iron core, the insulation layer of electric steel disc is subject to temperatures involved, slowly aging, its insulating property reduce gradually, thereby superheating phenomenon occurs even causes permeability decline to make the electric current of transformer sharply increase, accelerated the rising of temperature, and finally burnt.If it is high temperature resistant that insulation layer adopts, high stable, ultra-thin insulating material, even if transformer moves for a long time or has of short duration overload operation under full-load conditions so, transformer can not cause because of high temperature aging yet, burns even.
Therefore transformer industry urgent need is a kind of high temperature resistant, and the new coating of good insulation preformance replaces existing insulating coating.
Summary of the invention
Technical problem to be solved by this invention is to provide a kind of novel process of novel transformer electricity steel disc insulating coating, it is fragile that this technique has overcome traditional electrical steel disc surface insulation layer high temperature, coating is inhomogeneous, the problems such as coating is thicker, adopt a kind of nano ceramic material as the material of insulating coating, and adopt plasma pyrolytic coating technology, thereby reach high temperature resistant, good insulation preformance, ageing-resistant ability, guarantees that high-capacity non-explosive transformer is in the safe operation of oepration at full load situation.
This flow process mainly comprises following step: stress peening, laser shock peening and plasma pyrolytic coating.
The corresponding equipment of processing step of the present invention is as follows: sand-blast device, and laser shock peening equipment, plasma pyrolytic coating equipment three parts form.
The principle of work of each step process flow process of the present invention is as follows:
One, stress peening is carried out in airtight sand-blast device, is mainly used in removing or clearing up electric steel disc outside surface oxide compound, improves electric steel disc surface tissue, is strengthened in electric steel disc surface, improves the bonding strength of electric steel disc and coating.
The effect of sandblast and principle:
Sandblast is to adopt pressurized air as power, to form high-velocity jet bundle, material spray high-velocity jet is arrived and needs electric steel disc to be processed surface, state or the shape of electric steel disc outside surface are changed, due to impact and the shear action of material spray to electric steel disc surface, make the surface of electric steel disc obtain certain degree of cleaning and different roughness, the mechanical property on electric steel disc surface is improved, therefore improved the planeness of electric steel disc, increase the sticking power between it and coating, extended the weather resistance of coating.We know that excessive surging force has certain influence to electric steel disc crystalline network, but grasp certain sandblast dynamics through repeated multiple times experiment, and through microscopic inspection, the crystalline network of electric steel disc sheet is without any change; Owing to adopting, quartz sand size is less, and after treatment, its surperficial microcosmic hollow structure reduces electric steel disc in a large number, and surface is more smooth.
Wherein, sandblast process completes in sand blasting room, and sand blasting room is provided with intake pressure, blasting pressure demonstration etc., realizes automatic blasting completely, used material spray mechanize the automatic recovery.
Preferred purity quartzite (the SiO of material spray
2>=88-99.8%, Fe
2o
3≤ 0.1-0.005%), refractoriness 1450-1800 ℃, outward appearance uniform particles, conventional granularity is 0.1-0.3mm, granularity 270-325 order.The pressure fixing of sandblast required air is at 0.4MPa.
Two, laser shock peening carries out after blasting craft is processed, and in airtight laser shock peening equipment, carries out, and to supplementing of blasting craft, electric steel disc is hardened especially, makes electric steel disc obtain further careful strengthening.
Laser shock peening does not substitute previous blasting craft, and this is in general blasting craft after treatment, re-uses laser shock peening electric steel disc is processed, and makes electric steel disc surface further smooth.
Wherein, the model that the preferred Beijing of laser apparatus Lei Bao photoelectricity technology corporation, Ltd. produces is SGR-Extra-25 macro-energy high-peak power solid statelaser, output energy region 10J-25J, repetition 1-10Hz.High light beam quality, super-Gaussian is uniformly distributed, 10ns pulsewidth, high-peak power, high-energy, 1064nm output energy can reach 25J, and 532nm energy can reach 10J, Engineering Design, vibrator adopts indium steel construction, ultrastability and reliability.
Above two steps are that explosion proof transformer electric steel sheet is done to preliminary treatment in early stage, through processing the planeness on the micro-surface of electric steel disc afterwards, are greatly improved, and effectively improve the corrosion resistance nature of material, and material at high temperature oxidation susceptibility.Following part is, in plasma spraying equipment, plasma spraying operation is carried out in electric steel disc surface.
Three, plasma pyrolytic coating, is the topmost part of the present invention, mainly completes the spraying of electric steel disc surface ceramic coating.
Pyrolytic coating chamber equipment comprises following a few part, and they are respectively conveying belt 1, plasma spraying machine 2, ultrasonic generator 3, position motors 4, guide rail 5, image sensor 6, driving motor 7.Wherein, plasma spraying machine uniformly sprays the surface at electric steel disc by nano ceramic coat; Ultrasonic generator is launched ul-trasonic irradiation in electric steel disc, makes it to produce vibration, contributes to pottery to penetrate in the micropore of electric steel disc surface microscopic state; Carry motor, position motors, three components work, adjust the transfer rate of conveying belt, and ultrasonic generator, and the position of plasma spraying machine makes the ceramic coating can be accurate, and evenly spraying, is attached to electric steel disc surface.
1, the operation mechanism of plasma spraying is as follows:
Plasma spraying is a kind of in thermospray, and it is relatively flexible aspect deposition parameter and raw material.Plasma spraying can adopt solid, powder raw material, solid, the powder raw material dispersion in liquid carrier, or Liquid precursor.Due to the diversity of available flame pattern, speed and flame temperature, therefore plasma spray is coated in the composition aspect high flexible of raw material, thereby make the composition of the material that produces varied.
Plasma spraying is that a kind of to adopt rigidity non-transfer type plasma arc be thermal source, take dusty spray material as main heat spraying method.The temperature of plasma flame flow is higher, and flame Flow Velocity can reach hundreds of m/s at nozzle exit, but the distance of nozzle increases plasma flame flow temperature and speed decays rapidly along with leaving.Dusty spray is sent into after plasma flame flow under powder feeding gas promotes, by rapid heat fused, formed molten drop, simultaneously also accelerated, with very high speed, constantly collide matrix surface, there is flattening, and quick cooled and solidified, the drop bundle of melting is constantly deposited on the stacked swaging in particle upper strata of previously having solidified and becomes coating.
Plasma spraying, is characterized in that plasma flame flow temperature is high, can spray the material of higher melt; Workpiece is not charged, and body material scope is wide; Matrix is subject to thermal damage little, and coating is finer and close, and porosity is lower, has the higher features such as bonding strength with matrix.Can be used for product manufacture, part restore; Can be used as the spraying on whole surface, to large-scale component, also can implement optionally locally sprayed simultaneously.
Although plasma aerosol spraying temperature is very high, through laboratory, great many of experiments is reached a conclusion, plasma spraying on the magnetic permeability of electric steel disc without any impact.
In numerous ceramic spraying materials, Al
2o
3, TiO
2the aboundresources and cheap of pottery, take the Al that they prepare as raw material
2o
3-TiO
2coating hardness is high, frictional coefficient is low, chemical stability is good, the most outstanding is to have good resistance to elevated temperatures and insulating property, therefore being one of stupalith being widely used in plasma spraying, is also one of emphasis of current plasma spraying nano-structured coating investigation of materials.Research shows, nanostructure Al
2o
3-TiO
2when composite ceramic coat has good insulating property, also demonstrate good resistance to elevated temperatures, resistance to wear, toughness, anti-aging and receive the ability of stress.
Ceramic spraying material is pressed 87wt.%Al
2o
3and 13wt.%TiO
2ingredient composition.
Traditional insulating coating is about 3.7um-5um as the thickness of insulation layer, and is difficult to reach uniformity.The present invention uses plasma spraying technology, and the gauge control of the ceramic coating coating of requirement is in 1.5um left and right.
The KD-80 type 80kW plasma spraying equipment that coating preparation adopts University of Science and Technology, Jiujiang thermal spraying apparatus company limited to produce.This equipment is comprised of primary source, housing, powder feeder, water power transfer box, plasma gun etc.
2, ultrasonic wave operation mechanism is as follows:
Ultrasonic wave is a kind of elastic mechanical ripple in physical medium, and electricity, magnetic, light etc. are a kind of physical energy form equally.Ultrasonic wave refers to that frequency is higher than the sound wave of 20kHZ.Ultrasonic wave has: 1, and the characteristics such as pack, orientation and reflection, transmission; 2, propagation rectilinear propagation is good, high directivity; 3, the media particles vibration that ultrasonic wave causes can produce very large speed and acceleration.
What the present invention applied is power ultrasonic.
The high-frequency electrical energy that the mechanism of ultra-sonic generator is is 28KHz by 220V, 50Hz electric energy conversion, input ultrasonic transducer, is become 28kHz mechanical vibration.
When ultrasonic vibration is added on electric steel disc, although electric steel disc is through sandblasting, electricity steel disc is gap and the hole of remaining this microeffect still, for coating is deep in these gaps and micropore, the single strength by plasma subflow is difficult to reach, electric steel disc dusty spray in ultrasonic vibration will continue to infiltrate in micropore, until fill and lead up, thereby strengthened the firmness spraying.Thereby hyperacoustic effect is only to make the spraying effect of plasma jet more perfect.Do not deposit flaw.
The invention provides a kind of method that forms insulating coating on explosion proof transformer electric steel sheet, comprise the following steps,
1) stress peening: electric steel disc is sent in airtight sand-blast device, and material spray forms high-velocity jet bundle and is ejected into and needs electric steel disc to be processed surface, makes electric steel disc surface obtain certain degree of cleaning and degree of making slightly;
2) laser shock peening: by through step 1) the electric steel disc after processing is sent in airtight laser shock peening equipment, makes electric steel disc surface further smooth;
3) the electric steel disc of plasma pyrolytic coating: by through step 2) processing is sent into plasma pyrolytic coating chamber, the mode that adopts plasma pyrolytic coating technology to combine with ultrasonic vibration, on electric steel disc surface, form the insulating coating of nano ceramic material, plasma spraying machine is evenly sprayed on electric steel disc surface by nano ceramic material, ultrasonic generator makes electric steel disc produce vibration, and nano-ceramic particle is infiltrated in the micropore on electric steel disc surface; Described step 3) in, electric steel disc is shifted into the spray gun below of plasma spraying machine, opens plasma spraying machine and sprays; After certain hour, open ultrasonic generator, move 0.2s simultaneously; Then, close plasma spraying machine, isolated operation ultrasonic generator certain hour; Open plasma spraying machine, the two moves 0.2s more simultaneously again; Close ultrasonic generator, isolated operation plasma spraying machine, iterative cycles like this, until sprayed.By regulating the flame Flow Velocity of nozzle exit to regulate coating quality, flame stream accelerates to the speed of 150m/s.
Described nano ceramic material is 87wt%Al
2o
3and 13wt%TiO
2be made into.
The gauge control of described insulating coating is at 1.5um.
The pressure fixing of sandblast required air is at 0.4MPa.
Described material spray is SiO
2the purity quartzite of>=88-99.8%, refractoriness 1450-1800 ℃, granularity is 0.1-0.3mm.
Step 3) the plasma pyrolytic coating equipment adopting in comprises, conveying belt, plasma spraying machine, ultrasonic generator, position motors, guide rail, image sensor and driving motor, driving motor is controlled the operation of conveying belt and is stopped, and makes electric steel disc transverse shifting, and position motors drives adjacent plasma spraying machine and the ultrasonic generator being arranged on guide rail to vertically move.
Control computer according to the image of described image sensor, adjust the relative position of electric steel disc and plasma spraying machine.
Electric steel disc after the method for the invention is processed, even under rugged environment very, as mine, ventilation condition extreme difference, high humidity, often mobile, the situation that maintenance condition is difficult to catch up with, also can reach high temperature resistant, good insulating, ageing-resistant ability, guarantees that high-capacity non-explosive transformer also can safe operation under at full capacity.
Accompanying drawing explanation
Fig. 1 is explosion proof transformer electric steel sheet insulating coating new technological flow schematic diagram;
Fig. 2 is plasma pyrolytic coating device structure schematic diagram, comprises conveying belt 1, plasma spraying machine 2, ultrasonic generator 3, position motors 4, guide rail 5, image sensor 6, driving motor 7.
Embodiment
Below with reference to accompanying drawing and example, describe embodiments of the present invention in detail, to the present invention, how utilisation technology means solve technical problem whereby, and the implementation procedure of reaching technique effect can fully understand and implement according to this.
As shown in Figure 1, required technique of the present invention need to complete through three process, this three process respectively: stress peening, laser shock peening and plasma pyrolytic coating.They complete respectively in following three kinds of equipment, these three kinds of equipment respectively: sand-blast device, laser shock peening room equipment, plasma pyrolytic coating equipment.
The first step, electric steel disc 8 is admitted in sand-blast device, takes turns sandblast through one, and electric steel disc 8 outside surface oxide compounds are cleaned, and electric steel disc 8 surfaces have obtained strengthening, and this improves electric steel disc 8 surface microstructures greatly, improves the bonding strength of electric steel disc 8 and coating.Wherein, sandblast process completes in sand blasting room, and sand blasting room is provided with intake pressure, blasting pressure demonstration etc., realizes automatic blasting completely, used material spray mechanize the automatic recovery.Material spray is purity quartzite (SiO
2>=88-99.8%, Fe
2o
3≤ 0.1-0.005%), refractoriness 1450-1800 ℃, outward appearance uniform particles, conventional granularity is 0.1-0.3mm, granularity 270-325 order.The pressure fixing of sandblast required air is at 0.4MPa.
Second step, the electric steel disc 8 through common sandblasting, is admitted to laser shock peening equipment, and through strengthening sandblasting, electric steel disc surface is further level and smooth.Wherein, the model that the preferred Beijing of laser apparatus Lei Bao photoelectricity technology corporation, Ltd. produces is SGR-Extra-25 macro-energy high-peak power solid statelaser, output energy region 10J-25J, repetition 1-10Hz.High light beam quality, super-Gaussian is uniformly distributed, 10ns pulsewidth, high-peak power, high-energy, 1064nm output energy can reach 25J, and 532nm energy can reach 10J, Engineering Design, vibrator adopts indium steel construction, ultrastability and reliability.
The 3rd step, electric steel disc 8 is admitted to plasma pyrolytic coating chamber, and as shown in Figure 2, a driving motor 7 (AC servo motor) drives conveying belt 1 operation, and electric steel disc 8 is placed on conveying belt 1.Along with the operation of conveying belt 1, electric steel disc 8 is transferred the spray gun below that is placed in plasma spraying machine 2.Conveying belt is out of service.
Driving motor 7 driving conveying belt 1 microinchings, electric steel disc 8 transverse shifting on conveying belt 1; Position motors 4 (stepper-motor) drives the leading screw on guide rail 5 to rotate, thereby drives the plasma spraying machine 2 and the ultrasonic generator 3 that are arranged on guide rail 5 to vertically move.
Control computer according to the image of image sensor 6, analyze the position of electric steel disc 8, adjust the relative position of electric steel disc 8 and plasma spraying machine 2.
Spraying stage, ultrasonic generator 3 and plasma spraying machine 2 intermittently startings.After plasma spraying machine 2 spraying certain hours, open ultrasonic generator 3, now the two moves simultaneously, time remaining 0.2s, then plasma spraying machine 2 is closed; Only move ultrasonic generator 3, after for some time, open plasma spraying machine 2, the two is operation simultaneously again, time remaining 0.2s, and ultrasonic generator 3 cuts out, and only moves plasma spraying machine 2.So move in circles.
Wherein, ceramic spraying material is pressed 87wt.%Al
2o
3and 13wt.%TiO
2ingredient composition, gauge control is in 1.5um left and right, and coating preparation adopts the KD-80 type 80kW plasma spraying equipment of University of Science and Technology, Jiujiang thermal spraying apparatus company limited production.This equipment by primary source, housing, powder feeder,
The compositions such as water power transfer box, plasma gun.
Test-results is as shown below: condition, underground ventilating inclement condition
Claims (6)
1. on explosion proof transformer electric steel sheet, form a method for insulating coating, comprise the following steps,
1) stress peening: electric steel disc (8) is sent in airtight sand-blast device, and material spray forms high-velocity jet bundle and is ejected into and needs electric steel disc to be processed surface, makes electric steel disc surface obtain certain degree of cleaning and degree of making slightly;
2) laser shock peening: by through step 1) the electric steel disc (8) after processing is sent in airtight laser shock peening equipment, makes electric steel disc surface further smooth;
3) the electric steel disc (8) of plasma pyrolytic coating: by through step 2) processing is sent into plasma pyrolytic coating chamber, the mode that adopts plasma pyrolytic coating technology to combine with ultrasonic vibration, on electric steel disc surface, form the insulating coating of nano ceramic material, plasma spraying machine (2) is evenly sprayed on electric steel disc surface by nano ceramic material, ultrasonic generator (3) makes electric steel disc (8) produce vibration, and nano-ceramic particle is infiltrated in the micropore on electric steel disc surface; Described step 3) in, electric steel disc (8) is shifted into the spray gun below of plasma spraying machine (2), opens plasma spraying machine (2) and sprays; After certain hour, open ultrasonic generator (3), move 0.2s simultaneously; Then, close plasma spraying machine (2), isolated operation ultrasonic generator (3) certain hour; Open plasma spraying machine (2), the two moves 0.2s more simultaneously again; Close ultrasonic generator (3), isolated operation plasma spraying machine (2), iterative cycles like this, until sprayed.
2. a method of claim 1, is characterized in that, described nano ceramic material is 87wt.%Al
2o
3and 13wt.%TiO
2be made into.
3. a method as claimed in claim 2, is characterized in that, the gauge control of described insulating coating is at 1.5 μ m.
4. a method of claim 1, is characterized in that, the pressure fixing of sandblast required air is at 0.4MPa.
5. the method for claim 1, it is characterized in that, step 3) the plasma pyrolytic coating equipment adopting in comprises, conveying belt (1), plasma spraying machine (2), ultrasonic generator (3), position motors (4), guide rail (5), image sensor (6) and driving motor (7), driving motor (7) is controlled the operation of conveying belt (1) and is stopped, and makes electric steel disc (8) transverse shifting, and position motors (4) drives adjacent plasma spraying machine (2) and the ultrasonic generator (3) being arranged on guide rail (5) to vertically move.
6. a method as claimed in claim 5, is characterized in that, controls computer according to the image of described image sensor (6), adjusts the relative position of electric steel disc (8) and plasma spraying machine (2).
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| CN201110384151.8A CN102586715B (en) | 2011-11-17 | 2011-11-17 | New method for insulating coating of explosion proof transformer electric steel sheet |
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| CN102586715B true CN102586715B (en) | 2014-01-29 |
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| CN116251723A (en) * | 2023-03-07 | 2023-06-13 | 岚图汽车科技有限公司 | Method for improving paint falling defect of automobile exterior trim part and coating structure |
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| CN1706980A (en) * | 2004-06-11 | 2005-12-14 | 洛阳轴承集团有限公司 | Surface insulating layer treating process for roller bearing |
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| JPH0816630B2 (en) * | 1991-12-24 | 1996-02-21 | 日本碍子株式会社 | Temperature sensor protection tube and manufacturing method thereof |
| JP2005179766A (en) * | 2003-12-19 | 2005-07-07 | Murata Boring Giken Kk | Corrosion resistant and insulative material, and manufacturing method therefor |
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| CN1706980A (en) * | 2004-06-11 | 2005-12-14 | 洛阳轴承集团有限公司 | Surface insulating layer treating process for roller bearing |
Non-Patent Citations (3)
| Title |
|---|
| JP特开2005-179766A 2005.07.07 |
| JP特开平5-172648A 1993.07.09 |
| 司力琼，等.超声激励封孔对等离子喷涂Al_2O_3-13%TiO_2涂层耐腐蚀性能的影响.《腐蚀与防护》.2011,第32卷(第8期),625-629. * |
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