CN107705977B - 干式变压器阻燃防裂线圈的加工方法 - Google Patents
干式变压器阻燃防裂线圈的加工方法 Download PDFInfo
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- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/122—Insulating between turns or between winding layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/125—Other insulating structures; Insulating between coil and core, between different winding sections, around the coil
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/127—Encapsulating or impregnating
Abstract
干式变压器阻燃防裂线圈的加工方法,该绝缘层为阻燃性材料,包括质量百分百比为65%的细硅微粉;玻璃纤维5%‑10%;双酚A环氧树脂和双酚F环氧树脂占15%‑20%;羟酸酐固化剂占15%。在真空条件下,在模具内浇注混合原料,通过对模具加压加热,温度在95℃‑105℃之间,维持7.5‑8.5小时,促使混合料凝胶,继续对模具内的混合料加热,进行逐级升温达到140℃,混合料固化,保持恒温10~12小时,逐级降温冷却。在使用该线圈装配的变压器上,在恶劣环境下经过多次重复试验,经检测,自熄火时间短,其阻燃性高于国家标准,安全性极大提高,并且该线圈的绝缘层在变压器运行过程中,不会造成环境污染。
Description
技术领域
本技术属于变压器技术领域,涉及一种干式变压器阻燃防裂线圈的加工方法。
背景技术
干式变压器的线圈之间采用环氧树脂紧密填充,环氧树脂固化后起到支撑固定、绝缘导热的作用,具有阻燃、防爆、不污染环境、运行可靠、免维护等优点。随着安全环保性意识的提高,由于很多变压器使用在人口密集区,在实际使用中对变压器的可靠性要求越来越高,尤其是对变压器的阻燃防火性和有害气体挥发量要求越来越高。
干式变压器主要发热部位是线圈,为了增加线圈的阻燃性,需要在线圈的线匝和线层之间填充的环氧树脂中加入阻燃材料,现有技术中,采用在环氧树脂中增加氢氧化镁、氧化铝粉、氮化硼粉等无卤阻燃材料,达到增加线圈阻燃性的目的,但是在添加了此类材料后,会使环氧树脂变脆,使固化在线圈之间的环氧树脂中电气性能和韧性降低,电气性能降低会使局部放电量增加,超出国家标准;韧性降低会使变压器线圈耐不住热冲击,开裂,从而使局部放电量增加,减少变压器寿命,最终烧毁变压器。
为解决环氧树脂中添加无卤阻燃材料导致变压器线圈的阻燃性和韧性降低影响变压器性能的问题,现有技术中采用降低环氧树脂中无卤阻燃材料含量的办法加以解决,但这种办法需要增加线圈中的导线之间距离,及层间和段间距离,增加变压器的体积,增大制造成本。
发明内容
本发明的目的是提供一种干式变压器阻燃防裂线圈的加工方法,通过该方法制造干式变压器阻燃防裂线圈,解决现有技术中,干式变压器线圈中绕注的环氧树脂存在的局部放电量大和韧性不高的问题。
本发明的技术方案是:一种干式变压器阻燃防裂线圈的加工方法,该方法包括以下步骤:
(1)在金属裸导线的表面,直接包裹一层平纹玻璃纤维带;
(2)在平纹玻璃纤维带层上再包绕一层硅烷化玻璃纤维多棱带;编织成多棱带的纬线用直径相同的原纱线排布,经线用直径大小不一的玻璃纤维线交错排布,在多条细线之间排列一条粗线,编织形成高低起伏的带棱玻璃纤维多棱带;
(3)将包裹好的导线装在模具上分层绕制变压器线圈,每一层上分多段绕制;
(4)在每层的各段线圈之间采用硅烷化玻璃纤维布和玻璃纤维短切毡进行分隔填充,多层绕制后形成白坯线圈;
(5)增韧填充料准备:按质量百分比为1:1的比例,将双酚A和双酚F混合组成增韧环氧树脂,按质量百分比为65:35的比例将超细硅微粉加入增韧环氧树脂中,通过乳释泵进行混合,制成改性增韧填充料,其中超细硅微粉的目数为600~2000目;
(6)固化剂准备:将目数为600~2000目之间的超细硅微粉加入羟酸酐中,混合物的重量比为65:35,制成固化剂;
(7)在固定的振动模具内,放入线圈,抽真空,使模具内压强为1mbar,温度为85℃的条件;
(8)将改性增韧填充料和固化剂按照1:1的比例,搅拌混合均匀后注入模具内,在负压作用下物料填充到线圈的缝隙中;
(9)浇注结束后解除真空,将压力加至3-4bar,在该压强下维持14—15分钟,进行加压渗透;
(10)对模具内的混合料加热,温度在95℃-105℃之间,维持7-9小时,使混合料凝胶;
(11)继续对模具内的混合料加热,均匀升温达到140℃, 保持恒温10~12小时,均匀降温冷却至60℃以下,混合料完成固化,制成干式变压器阻燃防裂线圈。
采用本发明的技术方案:由于在阻燃剂中加入有目数在600~2000间的硅粉,使得颗粒小的硅粉可以填充在颗粒较大的硅粉形成的空间中,确保不同目数的硅粉填充均匀,提高绝缘层的导热性。
玻璃纤维带、玻璃纤维布、短切毡和绝缘强度较高的环氧树脂相结合,硅微粉和玻璃纤维带、玻璃纤维布、短切毡性质相近,互相融合,结合牢固,形成一定阻燃物,增强变压器阻燃性。
采用在真空负压的条件下在微振动的模具内浇注含有环氧树脂的混合料,负压线束后再进行加压渗透,保证线圈与混合料结合充分,固化后的混合料与线圈之间结合紧密,形成一层无气泡的绝缘层。
加入填充料环氧树脂与玻璃纤维相结合,帮助线圈散热,使整个线圈内部温度均匀,并且升温速度一致,内层和外层的温差小,内应力小。导热性能的提高,增加了变压器的热容量性。
经过检测,本发明中加入填充料环氧树脂的固化物的膨胀系数为0.000016(1/K)和铜导体的膨胀系数相接近,可保证环氧树脂绝缘层不会出现开裂现象,加入填充料环氧树脂的韧性大幅增加。
本发明中,线圈固化后的绝缘物,燃烧时氧指数≥39%,远大于国家标准的27%,属于难燃材料;经过垂直燃烧试验,离火自息时间小于1秒,小于UL94标准的10秒。
在同一台变压器上,先进行环境试验,没有出现闪络和击穿等现象,在表面也没有放电痕迹;再进行气候试验,结果显示:经过热冲击后,没有出现无开裂,局部放电量<5Pc;接着燃烧试验,自息时间短。绝缘层在高温下燃烧,没有出现烟雾,也没有分解有毒物质,对环境没有污染。
经试验检测,采用本发明技术的变压器可达到H级180℃绝缘耐热等级,符合高阻燃防开裂干式变压器的国家标准。
具体实施例
实施例,干式变压器阻燃防裂线圈的加工方法,该方法包括以下步骤:
(1)在金属裸导线的表面,直接包裹一层平纹玻璃纤维带;
(2)在平纹玻璃纤维带层上再包绕一层硅烷化玻璃纤维多棱带;编织成多棱带的纬线用直径相同的原纱线排布,经线用直径大小不一的玻璃纤维线交错排布,在多条细线之间排列一条粗线,编织形成高低起伏的带棱玻璃纤维多棱带;
(3)将包裹好的导线装在模具上分层绕制变压器线圈,每一层上分多段绕制;
(4)在每层的各段线圈之间采用硅烷化玻璃纤维布和玻璃纤维短切毡进行分隔填充,多层绕制后形成白坯线圈;
(5)增韧填充料准备:按质量百分比为1:1的比例,将双酚A和双酚F混合组成增韧环氧树脂,按质量百分比为65:35的比例将超细硅微粉加入增韧环氧树脂中,通过乳释泵进行混合,制成改性增韧填充料,其中超细硅微粉的目数为600~2000目;
(6)固化剂准备:将目数为600~2000目之间的超细硅微粉加入羟酸酐中,混合物的重量比为65:35,制成固化剂;
(7)在固定的振动模具内,放入线圈,抽真空,使模具内压强为1mbar,温度为85℃的条件;
(8)将改性增韧填充料和固化剂按照1:1的比例,搅拌混合均匀后注入模具内,在负压作用下物料填充到线圈的缝隙中;
(9)浇注结束后解除真空,将压力加至3-4bar,在该压强下维持14—15分钟,进行加压渗透;
(10)对模具内的混合料加热,温度在95℃-105℃之间,维持7-9小时,使混合料凝胶;
(11)继续对模具内的混合料加热,均匀升温达到140℃, 保持恒温10~12小时,均匀降温冷却至60℃以下,混合料完成固化,制成干式变压器阻燃防裂线圈。
Claims (1)
1.干式变压器阻燃防裂线圈的加工方法,该方法包括以下步骤:
(1)在金属裸导线的表面,直接包裹一层平纹玻璃纤维带;
(2)在平纹玻璃纤维带层上再包绕一层硅烷化玻璃纤维多棱带;编织成多棱带的纬线用直径相同的原纱线排布,经线用直径大小不一的玻璃纤维线交错排布,在多条细线之间排列一条粗线,编织形成高低起伏的带棱玻璃纤维多棱带;
(3)将包裹好的导线装在模具上分层绕制变压器线圈,每一层上分多段绕制;
(4)在每层的各段线圈之间采用硅烷化玻璃纤维布和玻璃纤维短切毡进行分隔填充,多层绕制后形成白坯线圈;
其特征在于:
(5)增韧填充料准备:按质量百分比为1:1的比例,将双酚A和双酚F混合组成增韧环氧树脂,按质量百分比为65:35的比例将超细硅微粉加入增韧环氧树脂中,通过乳释泵进行混合,制成改性增韧填充料,其中超细硅微粉的目数为600~2000目;
(6)固化剂准备:将目数为600~2000目之间的超细硅微粉加入羟酸酐中,混合物的重量比为65:35,制成固化剂;
(7)在固定的振动模具内,放入线圈,抽真空,使模具内压强为1mbar,温度为85℃的条件;
(8)将改性增韧填充料和固化剂按照1:1的比例,搅拌混合均匀后注入模具内,在负压作用下物料填充到线圈的缝隙中;
(9)浇注结束后解除真空,将压力加至3-4bar,在该压强下维持14—15分钟,进行加压渗透;
(10)对模具内的混合料加热,温度在95℃-105℃之间,维持7-9小时,使混合料凝胶;
(11)继续对模具内的混合料加热,均匀升温达到140℃, 保持恒温10~12小时,均匀降温冷却至60℃以下,混合料完成固化,制成干式变压器阻燃防裂线圈。
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CN102888081A (zh) * | 2012-09-24 | 2013-01-23 | 沈阳爱迪生科技有限公司 | 一种阻燃型灌封材料及其制备方法 |
CN104795230A (zh) * | 2015-04-14 | 2015-07-22 | 常州太平洋电力设备(集团)有限公司 | 一种干式变压器绝缘筒体线圈绕组的制备方法 |
CN106601435A (zh) * | 2017-02-16 | 2017-04-26 | 上海博纳杰陈电气有限公司 | 一种非晶合金干式变压器高压线圈 |
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