CN118211348A - Enameled wire bending fillet parameter optimization method and enameled wire bending method - Google Patents

Enameled wire bending fillet parameter optimization method and enameled wire bending method Download PDF

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Publication number
CN118211348A
CN118211348A CN202410612387.XA CN202410612387A CN118211348A CN 118211348 A CN118211348 A CN 118211348A CN 202410612387 A CN202410612387 A CN 202410612387A CN 118211348 A CN118211348 A CN 118211348A
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enameled wire
bending
delta
fillet
sample
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CN118211348B (en
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郑广会
张铃
王文
袁小庆
任莹
郑金泽
郑金宇
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Tianweilan Electric Drive Technology Jiangsu Co ltd
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Tianweilan Electric Drive Technology Jiangsu Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F1/00—Bending wire other than coiling; Straightening wire
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/10—Geometric CAD
    • G06F30/17—Mechanical parametric or variational design
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/20—Design optimisation, verification or simulation
    • H02K15/0435—
    • 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
    • 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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  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Theoretical Computer Science (AREA)
  • General Physics & Mathematics (AREA)
  • General Engineering & Computer Science (AREA)
  • Evolutionary Computation (AREA)
  • Computer Hardware Design (AREA)
  • Mechanical Engineering (AREA)
  • Power Engineering (AREA)
  • Computational Mathematics (AREA)
  • Mathematical Analysis (AREA)
  • Mathematical Optimization (AREA)
  • Pure & Applied Mathematics (AREA)
  • Investigating Strength Of Materials By Application Of Mechanical Stress (AREA)

Abstract

The application provides an enameled wire bending fillet parameter optimization method and an enameled wire bending method, comprising the following steps: s1, acquiring a plurality of enameled wire samples with different original paint film thicknesses delta; s2, measuring breakdown voltages U of different enameled wire samples, and establishing a function F U =F (delta) according to the mapping relation of delta and U; s3, acquiring a plurality of sample groups, wherein delta of enameled wire samples in the same sample group is the same, and delta of enameled wire samples in different sample groups is different; s4, selecting any sample group, and bending a plurality of enameled wire samples according to different bending fillet diameters 2R; s5, obtaining a plurality of minimum paint film thicknesses delta min corresponding to bent parts of different enameled wire samples in a sample group, and substituting a plurality of delta min into a function F U =F (delta) respectively to obtain a corresponding minimum breakdown voltage U min; establishing a function f 2R=F(Umin according to the mapping relation between 2R and U min); s6, repeating the steps S4-S5, and respectively establishing functions f 2R=F(Umin corresponding to all sample groups; s7, obtaining an enameled wire to be processed, selecting a corresponding function f 2R=F(Umin according to delta), and calculating the minimum bending fillet diameter 2R min of the enameled wire according to the required U min.

Description

Enameled wire bending fillet parameter optimization method and enameled wire bending method
Technical Field
The invention relates to the technical field of stator enameled wire processing, in particular to an enameled wire bending fillet parameter optimization method and an enameled wire bending method.
Background
The stator is an important component of the motor, and under the same volume, a plurality of stators adopt enameled wire profiles (namely rectangular enameled wires, also called flat copper wires or flat wires) to manufacture hairpin windings to replace round wire windings so as to improve the slot filling rate of the iron core. Rectangular enameled wires are inserted into slots of an iron core in a hairpin mode, and exposed copper wire ends are bent and welded to form a complete coil winding.
A typical flat wire is generally U-shaped, which is obtained by bending a straight wire using a flat wire bending processing apparatus. After the enameled wires are processed, a plurality of bending arms which are arranged in an included angle manner are formed, and bending parts which are approximately arc-shaped are arranged between the adjacent bending arms. The diameter of the fillet of the bending part influences the axial length of the end part (also called as the crown end) of the enameled wire, and the smaller the diameter of the fillet is, the smaller the axial dimension of the crown end is.
While smaller crown ends are generally desirable, when bending wire sections, the paint film thickness of the bent portion at a portion thereof is thinned due to the stretching and compressing of the copper core, and the smaller the corner of the bent portion, the larger the value of the thickness thinning of the paint film, and the worse the insulation effect. In the prior art, the problem that the insulation performance of the enameled wire is reduced and the motor requirement cannot be met easily occurs because the bending fillet diameter of the enameled wire and the insulation performance of the enameled wire are difficult to balance.
In addition, the bending processing equipment comprises a straight groove for accommodating the enameled wire, the straight groove forms arc surfaces at two ends, and the arc surfaces are matched with other structures to bend the enameled wire. The round angle diameter of the circular arc surface determines the round angle diameter of the bent part of the enameled wire after being bent, ignores the deviation of the round angle diameter of the bent part caused by factors such as rebound of materials after being bent, and can be considered that the round angle diameter of the circular arc surface is approximately equal to the round angle diameter of the bent part of the enameled wire after being bent. In practice, especially in the experimental stage or the small-batch trial-manufacture stage, the proper fillet of the bending part needs to be explored by continuously adjusting the size of the fillet of the processing equipment and correspondingly testing the insulation performance of the enameled wire, and the process is tedious and has low efficiency.
Disclosure of Invention
The invention aims to overcome or at least alleviate the defects in the prior art and provides an enameled wire bending fillet parameter optimization method and an enameled wire bending method.
One or more embodiments of the present invention provide a method for optimizing parameters of bending fillet of an enameled wire, including the following steps:
s1, obtaining a plurality of enameled wire samples with different original paint film thicknesses delta.
S2, measuring breakdown voltages U of different enameled wire samples, and establishing a function F U =F (delta) according to the mapping relation of delta and U.
S3, a plurality of sample groups are obtained, delta of enameled wire samples in the same sample group is the same, and delta of enameled wire samples in different sample groups is different.
S4, selecting any sample group, and bending a plurality of enameled wire samples with different bending fillet diameters 2R.
S5, obtaining a plurality of minimum paint film thicknesses delta min corresponding to bent parts of different enameled wire samples in the sample group, and substituting a plurality of delta min into a function F U =F (delta) respectively to obtain a corresponding minimum breakdown voltage U min. The function f 2R=F(Umin is established according to the mapping relation between 2R and U min).
S6, repeating S4-S5, and respectively establishing functions f 2R=F(Umin corresponding to all sample groups.
S7, obtaining an enameled wire to be processed, selecting a corresponding function f 2R=F(Umin according to the original paint film thickness delta of the enameled wire, and calculating the minimum bending fillet diameter 2R min of the enameled wire to be processed according to the required U min.
In at least one embodiment, in S2, U is measured directly by a voltage breakdown test; or, the breakdown field strength E of the original paint film is measured, and U is obtained from the relationship of u=e/δ.
In at least one embodiment, bending the enameled wire sample by using bending equipment with an arc surface; the diameter of the arc surface is equal to the diameter of the bending fillet of the enameled wire sample.
In at least one embodiment, a section of the enameled wire sample is taken as a sample in S5, the sample comprises two bending arms forming an included angle, and a bending part is formed at the intersection of the two bending arms.
In at least one embodiment, the test coupon is embedded in a powdered epoxy and cured under pressure, the cured epoxy forming a substrate around the test coupon; the test piece is ground and polished with a plane passing through the center lines of both bending arms at the same time defined as a reference plane so that the ground plane is parallel to the reference plane to expose the copper core and paint film of the bending portion.
In at least one embodiment, a plurality of measuring points are selected along the bending inner side and the bending outer side of the bending part to measure the paint film thickness, and the minimum value in the plurality of paint film thickness measuring values is taken as the minimum paint film thickness delta min of the enameled wire sample after bending.
In at least one embodiment, when the curvature diameter of the bending part is in the range of 0.5-4 mm, 1 measuring point is selected every 2mm along the outer side surface of the bending part; when the curvature diameter of the bending part is 4-8 mm, 1 measuring point is selected every 5mm along the outer side surface of the bending part.
In at least one embodiment, f 2R=F(Umin) is a discrete function, and if the value of U min is not within the domain of the function f 2R=F(Umin), in S7, taking the point of the value in the domain of f 2R=F(Umin) that is greater than U min and the smallest difference from U min, the 2R min of the enamel wire is calculated.
One or more embodiments of the present invention further provide an enameled wire bending method, which uses the enameled wire bending fillet parameter optimization method, including the following steps:
S10, preparing an enameled wire to be bent and processed; and obtaining the paint film thickness delta of the enameled wire to be processed and the minimum breakdown voltage U min required by the bent enameled wire.
S20, calculating the minimum bending fillet diameter 2R min of the enameled wire to be processed according to the enameled wire bending fillet parameter optimization method.
S30, bending the enameled wire by using the minimum bending fillet diameter of 2R min.
In at least one embodiment, in S30, the enameled wire is bent by using a bending device with an arc surface, and the diameter of the arc surface of the bending device is adjusted to be equal to the minimum bending fillet diameter 2R min before the bending device is machined.
The beneficial effects of the above technical scheme are that:
in the scheme, firstly, the breakdown voltage U corresponding to the original paint film thickness delta of the enameled wire sample is measured, so that a functional relation between delta and U is conveniently obtained, then the minimum paint film thickness delta min of the enameled wire sample with different original paint film thicknesses when the diameters of bent round corners are different is measured, and the minimum breakdown voltage U min corresponding to the minimum paint film thickness delta min is obtained by substituting delta min into the functional relation between delta and U.
Firstly, the problem that voltage breakdown test cannot be carried out after the minimum paint film thickness of the bent part of the enameled wire is measured through polishing can be avoided, and the minimum breakdown voltage U min corresponding to the minimum paint film thickness delta min can be obtained conveniently.
Secondly, the method is convenient to obtain functions of the bending fillet diameter 2R and the minimum breakdown voltage U min after the enameled wire is bent under different original paint film thicknesses, and further after the paint film thickness of the enameled wire to be processed and the required minimum breakdown voltage parameter requirement are obtained, the minimum bending fillet diameter corresponding to the enameled wire to be processed is rapidly calculated and obtained as the optimal bending fillet diameter of the enameled wire, multiple tests and adjustment are not needed, and the method is convenient to balance different requirements of the bending effect and the insulating property of the enameled wire.
That is, the problem that the enameled wire breaks down at the bending part is avoided under the condition that the diameter of the bent fillet of the enameled wire is reduced, the winding effect of the enameled wire is improved, and the core slot filling rate is improved.
Drawings
Fig. 1 is a schematic flow chart of a method for optimizing parameters of bending fillet of an enameled wire in an embodiment of the invention;
Fig. 2 is a schematic top view of a partial structure of an enamel wire bending apparatus according to an embodiment of the present invention;
FIG. 3 is a graphical representation of paint film thickness delta as a function of minimum breakdown voltage U in an embodiment of the invention;
Fig. 4 is a schematic diagram of a partial structure of a bent enameled wire according to an embodiment of the invention;
fig. 5 is a schematic top view of a sample of enamel wire taken from the enamel wire in an embodiment of the invention;
Fig. 6 is a schematic illustration of sampling at a sample of enamel wire in accordance with an embodiment of the present invention;
fig. 7 is a schematic illustration of an enamel wire coupon exposing a paint film and copper core at a ground surface in an embodiment of the present invention.
List of reference numerals: 10. bending equipment; 101. a first arc surface; 102. a second arc surface; 103. a straight groove; 2. enamelled wires; 21. a bending part; 211. an intrados surface; 212. an outer cambered surface; 22. a bending arm; 201. measuring points; 202. a substrate; 203. a paint film; 204. a copper core.
Detailed Description
Exemplary embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood that these specific illustrations are for the purpose of illustrating how one skilled in the art may practice the invention, and are not intended to be exhaustive of all of the possible ways of practicing the invention, nor to limit the scope of the invention.
In the present application, an electric motor (not shown) includes a rotor and a stator, and a coil winding is wound around a stator core. The coil winding is formed by bending and winding an enameled wire profile (also called a rectangular enameled wire). Compared with a round wire winding, the space between the enameled wire sections in a winding state is less, so that the core slot fullness rate is improved conveniently. For convenience of description, the enamelled wire is referred to as enamelled wire profile in the present application.
As shown in fig. 4, the enamel wire referred to in the present application is a flat wire hairpin commonly known in the art. The cross section of the enamelled wire is approximately rectangular. The enamelled wire is bent by the strip material to be approximately U-shaped. The bent portion 21 of the enamel wire particularly means a region where an angle formed by the two arms after bending is smallest (bending deformation is largest). In the case of an enameled wire inserted into the stator core, the bent portion 21 is usually exposed at the end of the core, which is often referred to in the industry as a "crown end". The bent portion 21 of the enamel wire forms an arc segment having an intrados 211 and an extrados 212, and the fillet diameter 2R of the intrados 211 in the arc segment is desired to have a small value in order to make the size of the crown end small, for example.
But the fillet size of the arc segment cannot be too small. Specifically, during the bending process of the enameled wire, the inner side surface of the bending portion 21 mainly bears pressure, and the outer side surface mainly bears tension, so that the enameled wire is easy to have uneven thickening and uneven thinning of the paint film 203 at the bending portion 21. The minimum breakdown voltage of the enameled wire is related to the minimum thickness of the paint film 203 of the enameled wire at the bending part 21, and how to optimize the bending effect of the enameled wire under the condition that the minimum breakdown voltage of the enameled wire meets the requirement is a pair of requirement conditions which are difficult to balance.
Example 1
As shown in fig. 1, the embodiment provides a method for optimizing parameters of bending fillet of an enameled wire, which includes the following steps:
S1, obtaining a plurality of enameled wire samples with different original paint film thicknesses delta. Specifically, the enameled wire sample is in an unbent state and is of a long straight structure, and the paint film thickness values of all positions of the enameled wire sample are basically equal under the condition that production and processing errors are not considered. In this example, the original paint film thickness δ of the plurality of enamel wire samples is varied in an arithmetic progression. Specifically, delta in Table 1 starts at 20 μm and increases gradually with a tolerance of 5 μm. In other embodiments, the plurality of enamel wire samples δ may also be varied in a non-uniform series of steps, regardless of the uniformity of the original film thickness δ of the enamel wire samples.
S2, the breakdown voltages U of different enameled wire samples are measured, a function F U =f (δ) is established according to the mapping relation of δ and U, and fig. 3 shows an image of the function F U =f (δ). The present embodiment may establish the function f U by a fitting method. In other embodiments, the function f U may be established by a matlab program.
Specifically, in this embodiment, U may be directly measured by a voltage breakdown test. Or the breakdown field strength E of the original paint film 203 is measured, and U is obtained from the relationship of u=e/δ. The voltage breakdown test directly measures the breakdown voltage U and the method for measuring the breakdown field strength E adopts the prior art, and will not be described here again.
Table 1
S3, a plurality of sample groups are obtained, delta of enameled wire samples in the same sample group is the same, and delta of enameled wire samples in different sample groups is different. In this example 11 sample groups were obtained, with reference to table 1, in which the delta of the enameled wire samples was increased 5 μm each time starting from 20 μm. Of the sample groups, the group with the largest paint film thickness δ has a δ value of 70 μm. Specifically, delta of the enameled wire samples in the sample group is the thickness of a paint film commonly used for enameled wires in a motor stator.
S4, selecting any sample group, and bending a plurality of enameled wire samples with different bending fillet diameters 2R. In this embodiment, each sample group includes 9 enameled wire samples, and the radius of the bending round angle of the bending portion 21 of the 9 enameled wire samples varies from 1mm to 5mm in an equi-differential sequence, and the tolerance is 0.5mm.
S5, obtaining a plurality of minimum paint film thicknesses delta min corresponding to the bending parts 21 of different enameled wire samples in the sample group, and substituting a plurality of delta min into a function F U =F (delta) respectively to obtain a corresponding minimum breakdown voltage U min. The function f 2R=F(Umin is established according to the mapping relation between 2R and U min). Specifically, the present embodiment can obtain the function f 2R by a fitting method. In other embodiments, the function f 2R may be obtained by a matlab program.
S6, repeating S4-S5, and respectively establishing functions f 2R=F(Umin corresponding to all sample groups.
In this embodiment, the number of sample sets is 11, so that 11 corresponding functions f 2R=F(Umin are required to be established in this embodiment, corresponding to 11 kinds of enameled wires having different original paint film thicknesses δ. In other embodiments, 9, 10, or 15, etc. other numbers of functions f 2R=F(Umin may be established).
S7, obtaining an enameled wire to be processed, selecting a corresponding function f 2R=F(Umin according to the original paint film thickness delta of the enameled wire, and calculating the minimum bending fillet diameter 2R min of the enameled wire to be processed according to the required U min.
In at least one embodiment, a bending apparatus 1 with an arc surface is applied to bend the enamel wire sample. The diameter of the arc surface is equal to the diameter of the bending fillet of the enameled wire sample.
The bending device 1 of the present invention may adopt an existing structure, referring to fig. 2, where the bending device 1 includes a disc, a limiting post (not shown in the figure) is disposed around the disc, a straight groove 103 is disposed on the upper surface of the disc, two ends of the straight groove penetrate through the outer circumferential surface of the disc, and an arc surface is disposed between two ends of the straight groove and the outer circumferential surface of the disc, for example, a first arc surface 101 and a second arc surface 102 shown in fig. 2. The diameters of the first arc surface 101 and the second arc surface 102 may be the same or different. The detailed structure arrangement and the use principle of the bending structure are not repeated here, and the bending structure can be automatically arranged by a person skilled in the art.
In at least one embodiment, a section of the enameled wire sample is taken as a sample in S5, the sample comprises two bending arms 22 forming an included angle, and a bending part 21 is formed at the intersection of the two bending arms 22. Specifically, the lengths of the two bending arms 22 may be the same or different.
In at least one embodiment, the coupon is embedded in a powdered epoxy and cured under pressure, the cured epoxy forming a substrate 202 around the coupon. A plane passing through the center lines of both bending arms 22 at the same time is defined as a reference plane, and the test piece is polished so that the polished plane is parallel to the reference plane to expose the copper core 204 and the paint film 203 of the bending portion 21, see fig. 7. This arrangement facilitates measuring the minimum thickness of the paint film 203 at the bend.
In this embodiment, a cross section perpendicular to the extension direction of the enamel wire is not selected for embedding and the circumferential paint film thickness of the enamel wire is measured. By the method of the embodiment, the paint film compression part at the inner side of the bending part and the paint film stretching part at the outer side of the bending part can be completely displayed on the surface of the base material, so that the paint film thickness in the area near the bending is convenient to observe.
In at least one embodiment, referring to fig. 6, a plurality of measuring points 201 are selected along the inside and outside of the bend of the bent portion 21 to measure the paint film thickness, and the minimum value among the plurality of paint film thickness measuring values is taken as the minimum paint film thickness δ min after bending of the enamel wire sample.
More specifically, when the curvature diameter of the bending portion 21 is in the range of 0.5 to 4mm, 1 measurement point 201 is selected every 2mm along the outer side surface of the bending portion 21. When the curvature diameter of the bending portion 21 is 4-8 mm, 1 measurement point 201 is selected every 5mm along the outer side surface of the bending portion 21.
In other embodiments, the selected number of measurement points 201 and the distance spacing between adjacent measurement points 201 may be set by one skilled in the art.
In at least one embodiment, f 2R=F(Umin) is a discrete function, and if the value of U min is not within the domain of the function f 2R=F(Umin), in S7, taking the point of the value in the domain of f 2R=F(Umin) that is greater than U min and the smallest difference from U min, the 2R min of the enamel wire is calculated.
Specifically, when f 2R=F(Umin) is a discrete function, the definition fields U min of the 11 functions and the corresponding function values 2R min in the embodiment may be made into a table that can be queried, and the minimum fillet diameter 2R min of the required enameled wire after bending is quickly obtained by searching the corresponding U min in the table. By way of example, table 2 below gives a table of the correspondence of the corner fillet diameter 2R of the bent portion with the minimum breakdown voltage at an original paint film thickness δ of 70 μm. Table 3 shows a table of the correspondence of the corner diameter 2R of the bent portion with the minimum breakdown voltage at an original paint film thickness delta of 100. Mu.m.
Table 2
TABLE 3
One or more embodiments of the present invention further provide a bending method of an enamel wire, including the steps of:
s10, preparing an enameled wire to be bent and processed; and obtaining the original paint film thickness delta of the enameled wire and the required U min of the enameled wire after bending.
S20, calculating the minimum bending fillet diameter 2R min of the enameled wire to be processed according to the enameled wire bending fillet parameter optimization method.
S30, bending the enameled wire by using the minimum bending fillet diameter of 2R min. Specifically, bending equipment 1 with an arc surface is utilized to bend the enameled wire, and the diameter of the arc surface of the bending equipment 1 is adjusted to be equal to the diameter 2R min of the minimum bending fillet before the bending equipment is used for processing.
Example 2
In this embodiment, the original paint film thickness of the enameled wire profile is 70 μm, the required minimum breakdown voltage is 3.90kV corresponding to the sample 2 in table 2, and then a corresponding 2R value (2r=1.5 mm) is found from table 2, and the enameled wire profile is processed by using the R value.
Example 3
In this example, the original film thickness of the enamelled wire profile was 70 μm and the minimum breakdown voltage required was a value of 5.0kV. In table 2, if 5.0kV is greater than the value corresponding to sample 2 and less than the value corresponding to sample 3, the enameled wire profile is processed with the value of 2R (2r=2mm) corresponding to sample 3 in table 2.
Of course, the present invention is not limited to the above-described embodiments, and various combinations and modifications of the above-described embodiments of the present invention may be made by those skilled in the art in light of the present teachings without departing from the scope of the present invention.

Claims (10)

1. The method for optimizing the parameters of the bending fillet of the enameled wire is characterized by comprising the following steps of:
S1, acquiring a plurality of enameled wire samples with different original paint film thicknesses delta;
S2, measuring breakdown voltages U of different enameled wire samples, and establishing a function F U =F (delta) according to the mapping relation of delta and U;
S3, acquiring a plurality of sample groups, wherein delta of enameled wire samples in the same sample group is the same, and delta of enameled wire samples in different sample groups is different;
S4, selecting any sample group, and bending a plurality of enameled wire samples according to different bending fillet diameters 2R;
S5, obtaining a plurality of minimum paint film thicknesses delta min corresponding to bent parts of different enameled wire samples in a sample group, and substituting a plurality of delta min into a function F U =F (delta) respectively to obtain a corresponding minimum breakdown voltage U min; establishing a function f 2R=F(Umin according to the mapping relation between 2R and U min);
S6, repeating the steps S4-S5, and respectively establishing functions f 2R=F(Umin corresponding to all sample groups;
S7, obtaining an enameled wire to be processed, selecting a corresponding function f 2R=F(Umin according to delta of the enameled wire, and calculating the minimum bending fillet diameter 2R min of the enameled wire to be processed according to the required U min.
2. The method for optimizing parameters of bending fillet of enameled wire according to claim 1, wherein in S2, U is directly measured by voltage breakdown test; or, the breakdown field strength E of the original paint film is measured, U being obtained from u=e/δ.
3. The method for optimizing parameters of bending fillet of enameled wire according to claim 1, wherein in S4, bending the enameled wire sample by using bending equipment with an arc surface; the diameter of the arc surface is equal to the diameter of the bending fillet of the enameled wire sample.
4. The method for optimizing parameters of bending fillet of enameled wire according to claim 1, wherein in S5, a section of enameled wire sample is taken as a sample, the sample comprises two bending arms forming an included angle, and a bending part is formed at the intersection of the two bending arms.
5. The method for optimizing parameters of bending fillet of enamel wire according to claim 4, wherein the test piece is embedded in powder epoxy resin and cured under pressure, and the epoxy resin forms a base material around the test piece; and (3) defining a plane which passes through the central lines of the two bending arms at the same time as a reference surface, polishing the sample, wherein the polishing surface is parallel to the reference surface so as to expose the copper core and the paint film of the bending part.
6. The method for optimizing parameters of bent fillet of enameled wire according to claim 5, wherein a plurality of measuring points are selected along the inner side and the outer side of the bend of the bending portion, the paint film thickness is measured by taking the plurality of measuring points, and the minimum value in the plurality of paint film thickness measuring values is used as the minimum paint film thickness delta min of the enameled wire sample after bending.
7. The method for optimizing parameters of bending fillet of enameled wire according to claim 6, wherein when the curvature diameter of the bending part is 0.5mm-4mm, 1 measuring point is selected every 2mm along the outer side surface of the bending part; when the curvature diameter of the bending part is 4mm-8mm, 1 measuring point is selected every 5mm along the outer side surface of the bending part.
8. The method for optimizing parameters of bent fillet of enameled wire according to claim 1, wherein f 2R=F(Umin) is a discrete function, and in S7, if the value of U min is not in the definition domain of the function f 2R=F(Umin), taking f 2R=F(Umin) to calculate 2R min at a value point which is larger than U min and has the smallest difference with U min in the definition domain.
9. The enameled wire bending method is characterized by comprising the following steps of:
s10, preparing an enameled wire to be processed; obtaining the paint film thickness delta of the enameled wire to be processed and determining the minimum breakdown voltage U min required by the enameled wire after bending;
S20, calculating the minimum bending fillet diameter 2R min of the enameled wire to be processed according to the enameled wire bending fillet parameter optimization method of any one of claims 1-8;
s30, bending the enameled wire by using the minimum bending fillet diameter of 2R min.
10. The method according to claim 9, wherein in S30, the wire is bent by a bending device having an arc surface, and the arc surface diameter of the bending device is adjusted to be equal to the minimum bending fillet diameter 2R min before the bending.
CN202410612387.XA 2024-05-17 2024-05-17 Enameled wire bending fillet parameter optimization method and enameled wire bending method Active CN118211348B (en)

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CN106062890A (en) * 2014-01-22 2016-10-26 古河电气工业株式会社 Insulated wire and method for manufacturing same, and rotating electrical machine and method for manufacturing same
CN106489183A (en) * 2014-06-03 2017-03-08 古河电气工业株式会社 Insulated electric conductor and its manufacture method
CN107599278A (en) * 2017-08-17 2018-01-19 国网上海市电力公司 The dry-type air-core reactor of air gap containing fixed dimension prepares mould and preparation method of sample
CN107599279A (en) * 2017-08-17 2018-01-19 国网上海市电力公司 Gapless turn-to-turn insulation dry-type air-core reactor prepares mould and preparation method of sample
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