CN114141436A - Method for manufacturing mica tape wrapped copper flat wire with uniformly staggered adjacent layers of wrapped insulating layers - Google Patents

Abstract

The invention relates to the technical field of processing of mica tape wrapped copper flat wires, in particular to a method for manufacturing mica tape wrapped copper flat wires with uniformly staggered adjacent layers of wrapped insulating layers, which comprises the following steps: placing 4 layers of mica tape wrapping materials in the same set of wrapping; fixing the lead wrapping position 100mm away from both ends by using felt splints; placing the lapping positions of the 4 layers of mica tapes in the same lapping pitch; the wrapping pitch is controlled to be 16 mm; the staggered spacing of adjacent layers is controlled to be 25% +/-10%; monitoring staggered intervals of adjacent layers in real time by adopting a visual monitoring system; the linear velocity is controlled to be 4.5-5.5 m/min; then, winding the wire on a take-up reel through traction and take-up to form a finished product; and each wire is subjected to bending performance and breakdown voltage performance test. According to the invention, the lapping positions of 4 layers of mica tapes are controlled within one lapping pitch, so that the stability of staggered intervals of adjacent layers of the mica tape lapping layer is effectively controlled.

Description

Method for manufacturing mica tape wrapped copper flat wire with uniformly staggered adjacent layers of wrapped insulating layers

Technical Field

The invention relates to the technical field of processing of mica tape wrapped copper flat wires, in particular to a method for manufacturing mica tape wrapped copper flat wires with uniformly staggered wrapped insulating layers.

Background

At present, the conventional winding wire insulating tape material of the mica tape wrapped copper flat wire for the wind power generator adopts a gap wrapping mode; the gap wrapping is a wrapping mode that the edges of adjacent paper tapes of the same wrapping layer are not mutually lapped and a certain gap is left, and the overall external dimension of the winding wire in the gap wrapping mode is flat and uniform, so that the dimension control after winding or slotting of a coil is more facilitated; therefore, the winding wire design wrapping mode mainly adopts gap wrapping; however, in the gap-lapping mode, each layer has a gap in one lapping period, taking 3 layers of insulating strips as an example, the thinnest part of the overall insulating structure in the gap-lapping mode is 2 layers of insulating materials, and the thickest part of the insulating thickness is 3 layers of insulation; if the staggered spacing of the gaps of the adjacent layers cannot be well controlled, the gaps of the adjacent layers can be overlapped, the main integral insulation structure has weak points, and the integral insulation level of the winding wire is reduced, even the integral insulation level of the motor is reduced.

Therefore, it is one of the problems to be solved by those skilled in the art to provide a processing method for controlling the gaps between adjacent layers of mica tape-wrapped copper flat wire to be uniformly staggered.

Disclosure of Invention

In order to effectively solve the problems in the background art, the invention provides a method for manufacturing a mica tape wrapped copper flat wire with uniformly staggered adjacent layers of wrapped insulating layers.

The specific technical scheme is as follows;

the manufacturing method of the mica tape wrapped copper flat wire with the uniformly staggered wrapped insulating layer adjacent layers is characterized by comprising the following steps of: the method comprises the following steps:

placing 4 layers of mica tape wrapping materials in the same set of wrapping;

secondly, fixing the positions of the conducting wires, which are 100mm away from the two ends of the conducting wires, by using felt clamping plates;

thirdly, placing the 4 layers of mica tape wrapping positions in the same wrapping pitch; the wrapping pitch is controlled to be 16 mm;

(IV) the staggered spacing of the gaps of the adjacent layers is controlled to be 25% +/-10%;

fifthly, monitoring staggered intervals of adjacent layers in real time by adopting a visual monitoring system;

(VI) controlling the linear speed to be 4.5-5.5 m/min;

drawing and winding to form a finished product;

(eighthly), testing the bending performance and the breakdown voltage performance of each wire; the test indexes are as follows:

(1) bending property: the narrow side is required to be bent by 180 degrees on the diameter of a round rod with the diameter phi of 11.2 +/-2 mm, and the insulating layer can not crack under visual inspection; the wide side is required to be bent by 180 degrees on the diameter of a round rod with the diameter phi of 42 +/-2 mm, and the insulating layer can not crack under visual inspection;

(2) breakdown voltage performance: the breakdown voltage of the straight line section is more than or equal to 5.5 kV; the turn-to-turn breakdown voltage is more than or equal to 11.0 kV; the narrow edge is bent for 180 degrees on the diameter of the round rod with the diameter phi of 11.2 +/-2 mm, and the breakdown voltage is more than or equal to 4.0 kV; after the wide edge is bent for 180 degrees on the diameter phi 42 +/-2 mm of the round rod, the breakdown voltage is more than or equal to 4.0 kV;

the wire which meets the performance test and the requirements of IEC standard 60317-0-2 is a qualified product. Compared with the prior art, the invention has the beneficial effects that: according to the invention, the eccentric wrapping head is adopted to wrap 4 layers of mica tapes at the same time for insulation, the wrapping positions of the 4 layers of mica tapes are controlled within one wrapping pitch, the wrapping rotating speed and the linear speed are fixed at the same time, the influence of centrifugal force on the wrapping tension when the eccentric wrapping rotates is controlled, and simultaneously the stability of the staggered distance of adjacent layers of the mica tape wrapping layer is effectively controlled. No publication is known to date for controlling the position of a 4-layer mica tape insulation wrapping to one wrapping pitch.

Drawings

FIG. 1 is a front view of the present invention

Detailed Description

Spatially relative terms, such as "above … …," "above … …," "above … …," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial relationship to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is turned over, devices described as "above" or "on" other devices or configurations would then be oriented "below" or "under" the other devices or configurations. Thus, the exemplary term "above … …" can include both an orientation of "above … …" and "below … …". The device may also be oriented 90 degrees or at other orientations and the spatially relative descriptors used herein interpreted accordingly.

The following detailed description of the preferred embodiments will be made with reference to the accompanying drawings. As shown in fig. 1, the method comprises the following steps:

firstly, paying off and straightening a bare copper wire;

secondly, entering a wrapping head, and controlling the distance between the front and the back of the wrapping position to be 80-100 mm; the insulating lapping positions of the 4 layers of mica tape are controlled in the same lapping pitch;

thirdly, the staggered distance between adjacent layers is controlled within the range of 25% +/-10% (3.0 +/-0.3 mm) by a real-time online vision monitoring system; the lapping pitch is controlled to be 16mm, and the lapping rotating speed is controlled to be 280-340 r/min;

fourthly, passing the mixture through a traction machine, wherein the linear speed is controlled to be 4.5-5.5 m/min;

fifthly, winding the wire to a take-up reel through take-up to form a finished product;

sixthly, testing the bending performance and the breakdown voltage performance of each wire; the test indexes are as follows:

(1) bending property: the narrow side is required to be bent by 180 degrees on the diameter of a round rod with the diameter phi of 11.2 +/-2 mm, and the insulating layer can not crack under visual inspection; the wide side is required to be bent by 180 degrees on the diameter of a round rod with the diameter phi of 42 +/-2 mm, and the insulating layer can not crack under visual inspection;

(2) breakdown voltage performance: the breakdown voltage of the straight line section is more than or equal to 5.5 kV; the turn-to-turn breakdown voltage is more than or equal to 11.0 kV; the narrow edge is bent for 180 degrees on the diameter of the round rod with the diameter phi of 11.2 +/-2 mm, and the breakdown voltage is more than or equal to 4.0 kV; after the wide edge is bent for 180 degrees on the diameter phi 42 +/-2 mm of the round rod, the breakdown voltage is more than or equal to 4.0 kV;

the wire which meets the performance test and the requirements of IEC standard 60317-0-2 is a qualified product.

At present, the wrapping equipment mainly comprises two types of concentric wrapping and eccentric wrapping; the concentric wrapping is opposite to the eccentric wrapping, so that the influence of centrifugal force on wrapping tension when the eccentric wrapping rotates is improved; however, one group of concentric wrapping can only wrap one layer of insulation, if 2 or more layers of insulation are to be wrapped, multiple groups of wrapping heads are needed, and due to factors such as equipment precision errors among the wrapping heads of all groups, when the 2 or more layers of insulation are wrapped concentrically, the staggered distance between adjacent layers is difficult to control; according to the invention, the eccentric wrapping head is adopted to wrap 4 layers of mica tapes at the same time for insulation, the wrapping positions of the 4 layers of mica tapes are controlled within one wrapping pitch, the wrapping rotating speed and the linear speed are fixed at the same time, the influence of centrifugal force on the wrapping tension when the eccentric wrapping rotates is controlled, and simultaneously the stability of the staggered distance of adjacent layers of the mica tape wrapping layer is effectively controlled. No publication is known to date for controlling the position of a 4-layer mica tape insulation wrapping to one wrapping pitch.

A group of wrapping heads of a traditional wrapping device are separated from the wrapping heads after a lead enters the wrapping heads and is wrapped and insulated, and the distance is generally 200-300 mm; for the wrapping requirement that the staggered distance of adjacent layers is controlled to be 25% +/-10%, the fixed distance of the wrapping position is too long, so that the eccentric wrapping centrifugal force drives the wire body to perform circumferential jumping, the staggered distance of adjacent layers among the insulating layers of the wrapping is unstable, and the overall insulation level of the wire is influenced; through process verification, the wrapping pitch is controlled to be 16mm, the linear speed is controlled to be 4.5-5.5 m/min, the wrapping rotating speed is controlled to be 280-340 r/min, a clamping plate tool is added to the distance between a lead and a wrapping head after the lead enters wrapping and is wrapped, and the distance is controlled to be 80-100 mm; the condition that the staggered distance between adjacent layers is unstable is effectively improved, and the use requirement of customers is met.

The invention adopts the technical scheme that the method for controlling the insulating lapping positions of the 4 layers of mica tapes in the same lapping pitch is established through repeated research and has creativity. When each layer of insulation is not controlled in the same wrapping pitch, the tightness of the insulation layer wrapped on the wire is inconsistent due to wrapping tension errors, and the condition that the adjacent layers are staggered and have unsatisfactory intervals can be caused by the difference of the outer insulation and the inner insulation wrapping force.

In summary, the main difference technical characteristics of the invention are that the staggered distance between adjacent layers of the wrapping insulation layer is strict with the manufacturing method of the national standard GB/T7373.3-2008 (International Standard IEC60317-28:2014) and the industry standard NB/T31048.3-2014, that is, the process, the parameters and the like are not the same as the process implemented so far, no related publication is recorded, and the invention provides a new manufacturing method for the wire with the requirement that the adjacent layers of the 4 layers of mica tape insulation layer are staggered by 25% +/-10%.

In a word, the method has the advantages of reasonable design, simple operation, stable and reliable performance, capability of effectively improving the production quality and yield and very obvious application effect.

The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.

Claims (1)

1. The manufacturing method of the mica tape wrapped copper flat wire with the uniformly staggered wrapped insulating layer adjacent layers is characterized by comprising the following steps of: the method comprises the following steps:

placing 4 layers of mica tape wrapping materials in the same set of wrapping;

secondly, fixing the positions of the conducting wires, which are 100mm away from the two ends of the conducting wires, by using felt clamping plates;

thirdly, placing the 4 layers of mica tape wrapping positions in the same wrapping pitch; the wrapping pitch is controlled to be 16 mm;

(IV) the staggered spacing of the gaps of the adjacent layers is controlled to be 25% +/-10%;

fifthly, monitoring staggered intervals of adjacent layers in real time by adopting a visual monitoring system;

(VI) controlling the linear speed to be 4.5-5.5 m/min;

drawing and winding to form a finished product;

(eighthly), testing the bending performance and the breakdown voltage performance of each wire; the test indexes are as follows:

(1) bending property: the narrow side is required to be bent by 180 degrees on the diameter of a round rod with the diameter phi of 11.2 +/-2 mm, and the insulating layer can not crack under visual inspection; the wide side is required to be bent by 180 degrees on the diameter of a round rod with the diameter phi of 42 +/-2 mm, and the insulating layer can not crack under visual inspection;

(2) breakdown voltage performance: the breakdown voltage of the straight line section is more than or equal to 5.5 kV; the turn-to-turn breakdown voltage is more than or equal to 11.0 kV; the narrow edge is bent for 180 degrees on the diameter of the round rod with the diameter phi of 11.2 +/-2 mm, and the breakdown voltage is more than or equal to 4.0 kV; after the wide edge is bent for 180 degrees on the diameter phi 42 +/-2 mm of the round rod, the breakdown voltage is more than or equal to 4.0 kV;

the wire which meets the performance test and the requirements of IEC standard 60317-0-2 is a qualified product.

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