CN117543869A - Motor, insulation system thereof and processing method - Google Patents
Motor, insulation system thereof and processing method Download PDFInfo
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- CN117543869A CN117543869A CN202311350025.XA CN202311350025A CN117543869A CN 117543869 A CN117543869 A CN 117543869A CN 202311350025 A CN202311350025 A CN 202311350025A CN 117543869 A CN117543869 A CN 117543869A
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- 238000013461 design Methods 0.000 description 4
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/38—Windings characterised by the shape, form or construction of the insulation around winding heads, equalising connectors, or connections thereto
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/10—Applying solid insulation to windings, stators or rotors
- H02K15/105—Applying solid insulation to windings, stators or rotors to the windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/28—Layout of windings or of connections between windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/30—Windings characterised by the insulating material
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
- H02K3/345—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation between conductor and core, e.g. slot insulation
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/40—Windings characterised by the shape, form or construction of the insulation for high voltage, e.g. affording protection against corona discharges
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/06—Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
- H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Insulation, Fastening Of Motor, Generator Windings (AREA)
Abstract
The application provides an insulation system of an electric machine, the insulation system comprising a profiled coil and an insulation structure. The forming coil comprises a multi-layer wire wound into a loop, the forming coil is provided with a straight line part and end parts, and the two ends of the straight line part are connected with the end parts. The insulation structure comprises an inter-turn insulation layer, a ground insulation layer and an anti-corona layer, wherein the inter-turn insulation layer is coated on the conducting wire, the ground insulation layer is coated on the Cheng Xingxian ring, and the anti-corona layer is coated on at least part of the ground insulation layer. Wherein the insulating layer to the ground comprises a multi-glue mica tape, and the multi-glue mica tape is configured so that the mica content is more than or equal to 45%. The insulation system provided by the application can bear a high-voltage working environment. The application also provides a processing method of the insulation system of the motor.
Description
Technical Field
The application relates to the field of motors, in particular to a motor, an insulation system thereof and a processing method.
Background
In the related technology, the higher the grid-connected voltage of the generator is, the lower the power of the connected transformer is, the lower the power of the used connecting cable is, the lower the power generation cost is limited by the insulating capability of a motor stator, and the highest grid-connected voltage of the high-voltage generator in China is 27kV at present, so that the reduction effect on the power generation cost is limited.
Disclosure of Invention
In view of the foregoing, it is desirable to provide a motor, an insulation system thereof, and a processing method thereof, so as to reduce the overall cost of the generator set.
An embodiment of the application provides an insulation system of a motor, which comprises a forming coil and an insulation structure. The forming coil comprises a multi-layer wire wound into a loop, the forming coil is provided with a straight line part and end parts, and the two ends of the straight line part are connected with the end parts. The insulation structure comprises an inter-turn insulation layer, a ground insulation layer and an anti-corona layer, wherein the inter-turn insulation layer is coated on the conducting wire, the ground insulation layer is coated on the Cheng Xingxian ring, and the anti-corona layer is coated on at least part of the ground insulation layer.
Wherein the insulating layer to the ground comprises a multi-glue mica tape, and the multi-glue mica tape is configured so that the mica content is more than or equal to 45%.
In some embodiments, the multi-glue mica tape is configured with an adhesive content of 35% -40%, a tensile strength of greater than or equal to 160N/10mm, a dielectric strength of greater than or equal to 35KV/mm, a volatile content of less than or equal to 1.0%, and a gel time of less than or equal to 10min.
In some embodiments, the thickness of the insulating layer to ground is 7 to 9mm.
In some embodiments, the wire is a flat wire, and the fillet radius of the wire is greater than or equal to 1.8mm.
In some embodiments, the inter-turn insulating layer comprises a polyimide film coated on the wire and a glass fiber coated on the polyimide film.
In some embodiments, the anti-corona layer comprises a low stop band, a first mid stop band, a second mid stop band and a high stop band in sequence along the length direction of the wire.
The low stop band is arranged on the straight line part and is coated on part of the insulating layer to the ground, and the surface resistance of the low stop band is that<10 5 Ω。
The first middle stop band is at least partially arranged on the end part and is coated on part of the ground insulating layer to overlap with the low stop band surface, and the surface resistance of the first middle stop band is 10 6 ～10 8 Ω。
The second middle stop band is arranged on the end part and is coated on part of the ground insulating layer to overlap with the surface of the first middle stop band, and the surface resistance of the second middle stop band is 10 8 ～10 10 Ω。
The high stop band is arranged on the end part and is coated on part of the insulating layer to the ground and is overlapped with the surface of the second middle stop band, and the surface resistance of the high stop band is 10 11 ～10 14 Ω。
In some embodiments, the overlapping length of the first middle stop band and the low stop band surface is 20-30 mm, and the covering length of the first middle stop band is 80-110 mm; the second middle stop band is overlapped with the surface of the first middle stop band by 20-30 mm, and the coverage length of the second middle stop band is 110-130 mm; and the high stop band is overlapped with the surface of the second middle stop band by 20-30 mm, and the coverage length of the high stop band is 130-160 mm.
The application also provides an electric motor, comprising an insulation system of the electric motor described in any one of the above.
The application also provides a processing method of the insulation system of the motor, which comprises the following steps:
forming a coil, including winding a wire with an inter-turn insulating layer into multiple layers and expanding to form the coil;
inter-turn hot pressing, including inter-turn hot pressing the coil;
insulating and wrapping, including performing primary insulating and wrapping on the coil after inter-turn hot pressing;
performing hot press curing, namely performing primary hot press curing on the coil after insulation wrapping;
the step of processing in batches comprises the steps of repeating the insulating wrapping and the hot pressing solidification until the thickness of the insulating layer to the ground of the coil reaches a preset value after the hot pressing solidification;
and the anti-corona treatment comprises the step of carrying out anti-corona treatment on the coil after the completion of the separate processing.
In some embodiments of the method, the number of repetitions in the step of dividing into the steps of processing is 1 to 3
In some embodiments of the method, in the thermocompression curing step, the end portion and the linear portion of the coil are simultaneously heat-cured.
In some embodiments of the method, the insulation wrapping step includes insulation wrapping using a wrapping device with constant tension, the tension being 47-65N.
The insulation system of the motor comprises a forming coil and an insulation structure. The forming coil comprises a multi-layer wire wound into a loop, the forming coil is provided with a straight line part and end parts, and the two ends of the straight line part are connected with the end parts. The insulation structure comprises an inter-turn insulation layer, a ground insulation layer and an anti-corona layer, wherein the inter-turn insulation layer is coated on the conducting wire, the ground insulation layer is coated on the Cheng Xingxian ring, and the anti-corona layer is coated on at least part of the ground insulation layer. Wherein the insulating layer to the ground comprises a multi-glue mica tape, and the multi-glue mica tape is configured so that the mica content is more than or equal to 45%. The insulation system provided by the application can bear a high-voltage working environment, so that the power generation cost is effectively reduced. The application also provides a processing method of the motor and the insulation system thereof, and the processing method can be used for producing the insulation system.
Drawings
FIG. 1 is a schematic diagram of a molded coil in some embodiments provided herein;
FIG. 2 is a cross-sectional view of a formed coil in some embodiments provided herein, wherein the broken lines only schematically represent the split process;
FIG. 3 is a schematic structural view of an anti-corona layer on a molded coil in some embodiments provided herein, wherein only portions of the structures of straight portions and end portions are schematically shown;
fig. 4 is a flow chart illustrating a method of processing an insulation system according to some embodiments provided herein.
Description of the reference numerals
Forming a coil 10;
a straight line portion 11; an end 12; a wire 100;
an insulating structure 20;
an inter-turn insulating layer 21; a ground insulating layer 22; an anti-corona layer 23; a low stop band 231; a first mid-stop band 232; a second mid-stop band 233; high stop band 234.
Detailed Description
Embodiments of the present application are described in further detail below with reference to the accompanying drawings and examples. The following examples are illustrative of the present application but are not intended to limit the scope of the present application.
In the description of the embodiments of the present application, it should be noted that, the orientation or positional relationship indicated by the terms "upper" or "lower" and the like is based on the orientation or positional relationship shown in the drawings, and is merely for convenience of describing the embodiments of the present application and simplifying the description, and does not indicate or imply that the apparatus or element in question must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the embodiments of the present application. Furthermore, the terms "first" or "second" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In the description of the embodiments of the present application, it should be noted that, unless explicitly specified and limited otherwise, the terms "connected," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium. The specific meaning of the terms in the embodiments of the present application will be understood by those of ordinary skill in the art in a specific context.
In the examples herein, unless expressly stated or limited otherwise, a first feature "up" or "down" on a second feature may be that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature via an intervening medium. Moreover, a first feature being "above," "over" and "on" a second feature may be a first feature being directly above or obliquely above the second feature, or simply indicating that the first feature is level higher than the second feature. The first feature being "under", "below" and "beneath" the second feature may be the first feature being directly under or obliquely below the second feature, or simply indicating that the first feature is less level than the second feature.
In the description of the present specification, reference to the term "some embodiments" or "particular embodiments" or the like means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the embodiments. In this specification, schematic representations of the above terms are not necessarily directed to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, the different embodiments or examples described in this specification and the features of the different embodiments or examples may be combined and combined by those skilled in the art without contradiction.
The present application provides an insulation system of an electric machine, please refer to fig. 1 to 2, which includes a molded coil 10 and an insulation structure 20. The molded coil 10 includes a multi-layered wire 100 wound in a loop, and the molded coil 10 has a straight portion 11 and end portions 12, and both ends of the straight portion 11 are connected to the end portions 12. Insulation structure 20 includes inter-turn insulation layer 21, ground insulation layer 22, and anti-corona layer 23, inter-turn insulation layer 21 being coated on wire 100, ground insulation layer 22 being coated on molded coil 10, and anti-corona layer 23 being coated on at least a portion of ground insulation layer 22.
Wherein the earth insulating layer 22 comprises a multi-glue mica tape, and the multi-glue mica tape is configured to have mica content of more than or equal to 45%.
An inter-turn insulating layer 21 is coated on each layer of wires 100, and adjacent wires 100 are insulated from each other. The linear portions 11 of the molded coil 10 may be fitted into slots of the stator core, with the end portions 12 exposed to the outside of the stator core.
The multi-glue mica tape is an insulating material based on mica, and the mica is a double silicate crystal and can be referred to national standard GB/T5019.1-2009. The insulating material made of mica has good insulativity and heat resistance, and the mica tape with the mica content more than or equal to 45 percent has better insulativity so as to adapt to high-voltage working conditions.
In some embodiments, the multi-glue mica tape is configured with an adhesive content of 35% -40%, a tensile strength of greater than or equal to 160N/10mm, a dielectric strength of greater than or equal to 35KV/mm, a volatile content of less than or equal to 1.0%, and a gel time of less than or equal to 10min.
The multi-glue mica tape is used as a constituent material of the ground insulating layer 22, and the selection thereof influences the insulating performance of the ground insulating layer 22 of the insulating system finally formed, and each parameter influences the insulating performance and the processing performance of the multi-glue mica tape. The above parameters can be referred to national standard GB/T5019.2-2009 and its normative reference.
The function of the adhesive in the mica product is mainly to bond the dispersed and fine mica flakes together, and generally, the higher the adhesive content is, the more stable the mica is bonded with a matrix material, and the powder is not easy to fall off.
Tensile strength is a mechanical property parameter of the multi-ply mica tape, to which the magnitude of the tension that the multi-ply mica tape can withstand when wrapped is related. Dielectric strength is an electrical property parameter of the multi-glue mica tape, and the insulating property strength of the multi-glue mica tape is related to the dielectric strength.
Volatile matters are unavoidable mixed matters in the production process of the multi-glue mica tape, the volatile matters volatilize at high temperature to generate gas, free discharge phenomenon can occur between solid insulators, the insulating performance of an insulating system is seriously damaged, and the content of the volatile matters must be controlled within a certain limit.
The gel time is the time required for the resin in the multi-glue mica tape to be in a gel state under a prescribed test condition, and in order for the multi-glue mica tape to have good flexibility and manufacturability, the gel time needs to be controlled.
In some embodiments, the thickness of the ground insulating layer 22 is 7-9 mm.
The ground insulation layer 22 is the main insulation layer in the insulation system of the motor, and its thickness affects the insulation performance, heat dissipation performance or mechanical performance of the insulation system. Specifically, the thickness of the ground insulating layer 22 is selected to be 7 to 9mm.
In some embodiments, referring to FIG. 2, the wire 100 is a flat wire, and the radius of the rounded corner of the wire 100 is equal to or greater than 1.8mm.
The flat wire may be a flat copper wire or other flat metal wire. The flat copper wire is a material commonly used for manufacturing windings of equipment such as motors, electric appliances and the like, and when the flat copper wire is provided with a round angle, the radius of the flat copper wire is in accordance with the regulations of the round angle radius and deviation of the flat copper wire and a copper strip, and the national standard GB/T5584.1-2020 can be referred to. Taking a flat copper wire as an example, in the specific embodiment of the application, the flat copper wire with the fillet radius of more than or equal to 1.8mm is adopted, and the fillet radius is larger than the national standard value in the corresponding wire model series, so that the wire 100 can effectively reduce the problems of tip discharge, stress concentration and the like after winding and forming so as to adapt to the high-voltage working condition.
In some embodiments, the inter-turn insulating layer 21 comprises a polyimide film coated on the wire 100 and a glass fiber coated on the polyimide film.
Polyimide film is a common material in the chemical industry and comprises an organic polymer material called Polyimide (PI). Polyimide film has good insulativity, and is commonly used as slot insulation and cable wrapping material of a motor. Glass fiber is a common material and is coated on the polyimide film to enhance the mechanical properties of the wire 100.
In some embodiments, referring to fig. 3, the anti-corona layer 23 includes a low stop band 231, a first mid stop band 232, a second mid stop band 233, and a high stop band 234 in order along the length of the wire 100.
The low stop band 231 is arranged on the straight line part 11 and is coated on the partial ground insulating layer 22, and the surface resistance of the low stop band 231 is<10 5 Ω。
The first intermediate stop band is at least partially disposed on the end 12 and is coated on a portion of the ground insulating layer 22 to overlap the surface of the low stop band 231, and the surface resistance of the first intermediate stop band 232 is 10 6 ～10 8 Ω。
A second intermediate stop band 233 is arranged on the end 12 and is coated on the partial ground insulating layer 22, and is overlapped with the surface of the first intermediate stop band 232, and the surface resistance of the second intermediate stop band 233 is 10 8 ～10 10 Ω。
The high stop band 234 is arranged on the end 12 and is coated on a part of the insulating layer 22 to the ground, and is overlapped with the surface of the second middle stop band 233, and the surface resistance of the high stop band 234 is 10 11 ～10 14 Ω。
In some embodiments, referring to fig. 3, the surface overlap length of the first middle stop band 232 and the low stop band 231 is 20-30 mm, and the coverage length of the first middle stop band is 80-110 mm.
The second middle stop band 233 is overlapped with the surface of the first middle stop band 232 by 20-30 mm, and the coverage length of the second middle stop band 233 is 110-130 mm.
The surface of the high stop band 234 is overlapped with the surface of the second middle stop band 233 by 20-30 mm, and the coverage length of the high stop band 234 is 130-160 mm.
During operation of the motor, there is a risk of corona phenomena, and the anti-corona layer 23 is configured to reduce the occurrence of corona phenomena, and is usually manufactured by an anti-corona belt. The corona-proof belt is a common motor corona-proof material, and the manufacturing materials comprise acetylene black, silicon carbide, alkali-free glass fiber and the like. The low stop band 231, the first mid stop band 232, the second mid stop band 233 and the high stop band 234 all belong to the anti-corona band, and the surface resistance of the anti-corona band is an important parameter for measuring the anti-corona performance of the anti-corona band, for example, the surface resistance of the low stop band is less than 10 5 Omega, i.e. the resistance between the edges of the low stop band sample surface is less than 10 5 Omega, certain errors are allowed in measuring the surface resistance according to the measured value, for example, the resistance is lower than 10 10 Omega, the measurement error is not more than + -10%, see national standard GB/T531838.3-2019.
When the insulation system of the motor is in a working state, current is converged to the notch from the slot core of the stator core, namely, the current of the linear part 11 is concentrated to the end part 12, and the temperature rise phenomenon occurs. In order to avoid abrupt change of temperature, the notch leading-out position needs to gradually increase the anti-corona band resistance value, and the surface resistance is gradually increased, so that the probability of breakdown or burning of the insulating material can be effectively reduced.
And the adjacent anti-corona belts are lapped with each other for 20-30 mm, so that the point discharge phenomenon at the edge of the anti-corona belt is not easy to occur at the joint of the adjacent anti-corona belts.
Another aspect of the present application also provides an electric machine, including an insulation system according to any of the above aspects.
In another aspect, the present application further provides a method for processing an insulation system of an electric motor, referring to fig. 4, including:
forming a coil, including winding a wire 100 having an inter-turn insulation layer into a plurality of layers and expanding to form a coil;
inter-turn hot pressing, including inter-turn hot pressing the coil;
insulating and wrapping, including performing primary insulating and wrapping on the coil after inter-turn hot pressing;
performing hot press curing, namely performing primary hot press curing on the coil after insulation wrapping;
the step of processing in batches comprises the steps of repeating the insulating wrapping and the hot pressing solidification until the thickness of the insulating layer to the ground of the coil reaches a preset value after the hot pressing solidification;
and the anti-corona treatment comprises the step of carrying out anti-corona treatment on the coil after the completion of the separate processing.
The coil forming step includes winding the wire 100 having the inter-turn insulation layer on a mold using a winding machine, and then taking out and expanding to form a shape including a diamond shape and a shuttle shape.
The insulation wrapping step includes wrapping the coil after inter-turn hot pressing around a ground insulating material to form a ground insulating layer 22.
The anti-corona treatment step includes wrapping or spraying an anti-corona material on the coil after the completion of the separate processing to form an anti-corona layer 23.
In some embodiments, the number of repetitions in the step of dividing is 1 to 3.
In the related technology, the coil after inter-turn hot pressing is wrapped with the insulating material to the ground, the insulating layer to the ground is formed at one time, and then hot pressing solidification is carried out, so that the coil has good economical efficiency. In some embodiments provided herein, the steps of insulation wrapping and thermocompression curing of the coil after inter-turn thermocompression are performed in multiple times.
In a specific embodiment, the insulating material includes the multi-glue mica tape, each time the insulating binding step, according to the preset thickness of the insulating layer 22 to the ground and the repetition number of the sub-processing steps, the thickness of the multi-glue mica tape bound this time is established, each binding thickness may be equal, and a certain margin should be reserved, because the thickness of the multi-glue mica tape is reduced by the hot press curing step. The multi-glue mica tape has higher mica content, the multi-glue mica tape can be fully solidified by a fractional processing technology, the structural stability of the multi-glue mica tape is improved, the insulating capability of the insulating system is improved, and the design capacity of the wind driven generator can be improved.
In some embodiments, in the thermocompression curing step, the end portion 12 and the linear portion 11 of the coil are simultaneously heat-cured.
In the related art, the coil of insulation package is hot pressed to fix the straight line part 11 on the hot pressing plate, and a certain pressure and temperature are applied to complete the solidification of the ground insulation layer. In the embodiment provided by the application, the coil end 12 and the straight line portion 11 after insulation wrapping are subjected to thermal compression curing together, for example, an end heating positioning plate is additionally arranged on equipment used for thermal compression curing, according to the technical characteristics, the end 12 of the insulation system processed has the equivalent insulation performance of the straight line portion 11, and the transition position of the straight line portion 11 and the end 12, namely, the notch position, realizes the gentle transition of the ground insulation material, so that the overall performance of the insulation system is improved.
In some embodiments, the insulation wrapping step includes insulation wrapping using a wrapping device with constant tension, the tension being 47-65N.
The equipment processing has the advantages of stable quality, low cost and the like, the equipment comprises full-automatic equipment, semi-automatic equipment and the like, and when the equipment is wrapped, the tension is controlled to be in the range of 47-65N, the tension is kept constant, and the wrapping effect is ensured.
With the continuous increase of the capacity of the wind generating set, the cost of the set is higher and higher, and the continuous reduction of the electricity price requires the set to be lower and lower. The power generated by the wind driven generator is generally transmitted through 10kV and 35kV transformation after grid connection, the power of a transformer is reduced by 70% by adopting the existing wind driven generator at present, if the voltage of the generator is increased to 35kV, the power of the 35kV transformer can be reduced by 70% while related connecting cables are saved, so that the cost of a generator set is greatly reduced, and therefore, the development of a 35kV high-voltage motor insulation system is imperative. The working voltage of the insulation system of the existing high-voltage motor is generally 27kV, the insulation system of the 35kV motor reported in foreign literature adopts a cable structure, and the design of the motor is quite different from that of the conventional motor.
Based on the above consideration, the following two specific embodiments of the application provide an insulation system of a 35kV high-voltage motor, a process for processing a grounding insulation layer in a grading manner is used in the manufacturing process of a forming coil 1, a multi-glue mica tape is adopted, the insulation performance of the grounding insulation layer is improved, the insulation requirement of the 35kV motor is met, the overall cost of a wind generating set is reduced, and the insulation system has good practicability and economy.
In a first specific embodiment, the insulation system is as follows:
the wire 100 is a flat copper wire, and the wire 100 is wound in a shuttle shape with a fillet radius of 1.8mm. The inter-turn insulating layer 21 comprises a polyimide film sintered on the surface of the wire 100, and glass filaments wrapped on the polyimide film. The ground insulation layer 22 is coated on the molded coil 10, and the ground insulation layer 22 comprises a multi-glue mica tape with a total thickness of 7.6mm, and various parameters of the multi-glue mica tape are shown in the following table.
The anti-corona layer 23 is coated on at least part of the ground insulating layer 22, and the anti-corona layer 23 sequentially comprises a low stop band 231, a first middle stop band 232, a second middle stop band 233 and a high stop band 234 along the length direction of the wire 100. Wherein, the overlap length of the surface of the first middle stop band 232 and the surface of the low stop band 231 is 25mm, and the coverage length of the first middle stop band is 80mm. The second middle stop band 233 overlaps the surface of the first middle stop band 232 by 25mm, and the second middle stop band 233 has a cover length of 120mm. The high stop band 234 overlaps the surface of the second mid stop band 233 by 25mm and the high stop band 234 has a cover length of 140mm.
The processing method of the insulation system comprises the following steps:
forming a coil, including winding a wire 100 having an inter-turn insulation layer into a plurality of layers and expanding to form a coil;
inter-turn hot pressing, including inter-turn hot pressing the coil;
insulating wrapping, namely performing primary insulating wrapping on the coil subjected to inter-turn hot pressing by using the multi-glue mica tape, and wrapping by using equipment with constant tension of 50N;
performing hot press curing, namely performing primary hot press curing on the coil after insulation wrapping, and performing hot press on both the end part 12 and the linear part 11;
the step of processing for several times comprises repeating the insulating bandaging and the step of hot pressing and curing for 1 time, wherein the thickness of bandaging in each insulating bandaging step is equal;
and the anti-corona treatment comprises the step of carrying out anti-corona treatment on the coil after the completion of the separate processing.
Through performance verification, the dielectric loss factor and the corona onset voltage of the insulation system of the motor meet the requirements, and the voltage to ground and the voltage durability are verified through design requirements.
In a second specific embodiment, the insulation system is as follows:
the wire 100 is a flat copper wire, and the wire 100 is wound in a shuttle shape with a fillet radius of 2.0 mm. The inter-turn insulating layer 21 comprises a polyimide film sintered on the surface of the wire 100, and glass filaments wrapped on the polyimide film. The ground insulation layer 22 is coated on the molded coil 10, and the ground insulation layer 22 comprises a multi-glue mica tape with a total thickness of 8.4mm, and various parameters of the multi-glue mica tape are shown in the following table.
| Sequence number | Project | Reference value |
| 1 | Volatile content | 0.3％ |
| 2 | Mica content | 48％ |
| 3 | Adhesive content | 38％ |
| 4 | Tensile Strength | 214N/mm |
| 5 | Dielectric strength | 36kV/mm |
| 6 | Gel time | 5min |
The anti-corona layer 23 is coated on at least part of the ground insulating layer 22, and the anti-corona layer 23 sequentially comprises a low stop band 231, a first middle stop band 232, a second middle stop band 233 and a high stop band 234 along the length direction of the wire 100. Wherein, the overlap length of the surface of the first middle stop band 232 and the surface of the low stop band 231 is 25mm, and the coverage length of the first middle stop band is 100mm. The second middle stop band 233 overlaps the surface of the first middle stop band 232 by 25mm, and the second middle stop band 233 has a cover length of 120mm. The high stop band 234 overlaps the surface of the second mid stop band 233 by 25mm, and the high stop band 234 has a cover length of 150mm.
The processing method of the insulation system comprises the following steps:
forming a coil, including winding a wire 100 having an inter-turn insulation layer into a plurality of layers and expanding to form a coil;
inter-turn hot pressing, including inter-turn hot pressing the coil;
insulating wrapping, namely performing primary insulating wrapping on the coil subjected to inter-turn hot pressing by using the multi-glue mica tape, and wrapping by using equipment with constant tension of 55N;
performing hot press curing, namely performing primary hot press curing on the coil after insulation wrapping, and performing hot press on both the end part 12 and the linear part 11;
the step of processing for several times comprises repeating the insulating bandaging and the step of hot pressing and curing for 2 times, wherein the thickness of bandaging in each insulating bandaging step is equal;
and the anti-corona treatment comprises the step of carrying out anti-corona treatment on the coil after the completion of the separate processing.
Through performance verification, the dielectric loss factor and the corona onset voltage of the insulation system of the motor meet the requirements, and the voltage to ground and the voltage durability are verified through design requirements.
The various embodiments/implementations provided herein may be combined with one another without conflict.
The foregoing description is only of the preferred embodiments of the present application and is not intended to limit the same, but rather, various modifications and variations can be made by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application should be included in the protection scope of the present application.
Claims (12)
1. An insulation system for an electric machine, comprising:
a forming coil comprising a multi-layer wire wound into a loop, the forming coil having a straight portion and an end portion, both ends of the straight portion being connected to the end portion; and
the insulation structure comprises an inter-turn insulation layer, a ground insulation layer and an anti-corona layer, wherein the inter-turn insulation layer is coated on the conducting wire, the ground insulation layer is coated on the Cheng Xingxian ring, and the anti-corona layer is coated on at least part of the ground insulation layer;
wherein the insulating layer to the ground comprises a multi-glue mica tape, and the multi-glue mica tape is configured so that the mica content is more than or equal to 45%.
2. The insulation system of claim 1, wherein the multi-glue mica tape is configured with an adhesive content of 35% -40%, a tensile strength of greater than or equal to 160N/10mm, a dielectric strength of greater than or equal to 35KV/mm, a volatile content of less than or equal to 1.0%, and a gel time of less than or equal to 10min.
3. The insulation system of claim 1, wherein the thickness of the insulating layer to ground is 7-9 mm.
4. The insulation system of claim 1, wherein the wire is a flat wire and the wire has a fillet radius of 1.8mm or more.
5. The insulation system of claim 1, wherein the inter-turn insulation layer comprises:
polyimide film coated on the wire; and
and the glass fiber is coated on the polyimide film.
6. The insulation system of claim 1, wherein the anti-corona layer comprises, in order along the length of the wire, a low stop band, a first mid stop band, a second mid stop band, and a high stop band;
the low stop band is arranged on the straight line part and is coated on part of the insulating layer to the ground, and the surface resistance of the low stop band is that<10 5 Ω；
The first middle stop band is at least partially arranged on the end part and is coated on part of the ground insulating layer to overlap with the low stop band surface, and the surface resistance of the first middle stop band is 10 6 ～10 8 Ω；
The second middle stop band is arranged on the end part and is coated on part of the ground insulating layer to overlap with the surface of the first middle stop band, and the surface resistance of the second middle stop band is 10 8 ～10 10 Omega; and
the high stop band is arranged on the end part and is coated on part of the insulating layer to the ground and is overlapped with the surface of the second middle stop band, and the surface resistance of the high stop band is 10 11 ～10 14 Ω。
7. The insulation system of claim 6, wherein the first mid-stop band has a lap length of 20-30 mm with the low stop band surface and a cover length of 80-110 mm;
the second middle stop band is overlapped with the surface of the first middle stop band by 20-30 mm, and the coverage length of the second middle stop band is 110-130 mm; and
and the high stop band is overlapped with the surface of the second middle stop band by 20-30 mm, and the coverage length of the high stop band is 130-160 mm.
8. An electric machine comprising an insulation system according to any one of claims 1-7.
9. A method of manufacturing an insulation system for an electric machine, comprising:
forming a coil, including winding a wire with an inter-turn insulating layer into multiple layers and expanding to form the coil;
inter-turn hot pressing, including inter-turn hot pressing the coil;
insulating and wrapping, including performing primary insulating and wrapping on the coil after inter-turn hot pressing;
performing hot press curing, namely performing primary hot press curing on the coil after insulation wrapping;
the step of processing in batches comprises the steps of repeating the insulating wrapping and the hot pressing solidification until the thickness of the insulating layer to the ground of the coil reaches a preset value after the hot pressing solidification;
and the anti-corona treatment comprises the step of carrying out anti-corona treatment on the coil after the completion of the separate processing.
10. The method according to claim 9, wherein in the thermocompression bonding step, the end portion and the linear portion of the coil are simultaneously heat-bonded.
11. The method of claim 9, wherein the step of insulation wrapping includes insulation wrapping using a wrapping apparatus having a constant tension of 47 to 65N.
12. The method according to claim 9, wherein the number of repetitions in the step of dividing is 1 to 3.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311350025.XA CN117543869A (en) | 2023-10-18 | 2023-10-18 | Motor, insulation system thereof and processing method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311350025.XA CN117543869A (en) | 2023-10-18 | 2023-10-18 | Motor, insulation system thereof and processing method |
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| Publication Number | Publication Date |
|---|---|
| CN117543869A true CN117543869A (en) | 2024-02-09 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311350025.XA Pending CN117543869A (en) | 2023-10-18 | 2023-10-18 | Motor, insulation system thereof and processing method |
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| Country | Link |
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| CN (1) | CN117543869A (en) |
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- 2023-10-18 CN CN202311350025.XA patent/CN117543869A/en active Pending
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