CN218276241U - Hairpin coil, hairpin winding and hairpin motor - Google Patents
Hairpin coil, hairpin winding and hairpin motor Download PDFInfo
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- CN218276241U CN218276241U CN202222197538.9U CN202222197538U CN218276241U CN 218276241 U CN218276241 U CN 218276241U CN 202222197538 U CN202222197538 U CN 202222197538U CN 218276241 U CN218276241 U CN 218276241U
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- 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
- H02K3/32—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
-
- 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
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacture Of Motors, Generators (AREA)
- Windings For Motors And Generators (AREA)
Abstract
The utility model discloses a hairpin coil, hairpin winding and hairpin machine, hairpin coil includes: hairpin conductors and insulating layers; wherein, hairpin conductor includes: the hairpin-shaped conductor comprises hairpin-shaped conductor main bodies and two conductor connecting parts electrically connected with the hairpin-shaped conductor main bodies, wherein the two conductor connecting parts are respectively positioned at two ends of each hairpin-shaped conductor; the insulating layer only electrophoreses in the surface of hairpin form conductor main part, and conductor connecting portion exposes the setting, and the insulating layer is the polyimide coating. The hairpin coil is provided with the insulating layer in an electrophoresis mode, and the insulating layer is a polyimide coating, so that the toughness, heat resistance, voltage resistance, scratch resistance and other properties of the insulating layer are effectively improved, namely the performance of the hairpin coil is improved; the insulating layer only electrophoreses in hairpin form conductor main part, and conductor connecting portion expose and set up, then need not to get rid of the insulating layer of conductor connecting portion before the hairpin winding of preparation, simplified hairpin winding preparation technology, improved hairpin winding's production efficiency.
Description
Technical Field
The utility model relates to a motor winding technical field, more specifically say, relate to a hairpin coil, hairpin winding and hairpin motor.
Background
At present, a winding of a high-power motor is generally formed by adopting a hairpin coil, so that the motor has the advantages of high power density, low cost, good heat resistance and the like.
The hairpin coil is formed by bending an insulated flat wire. In the bending process, the bending position of the insulating layer of the insulating flat wire is easy to change, for example, the insulating layer cracks, falls off or the thickness changes, so that the heat resistance, voltage resistance, scratch resistance and other performances of the hairpin coil are reduced, and the overall performance of the motor is reduced.
Before the hairpin coil leaves the factory, the whole hairpin-shaped conductor in the insulating flat wire is provided with the insulating layer, however, the two ends of the hairpin coil need to be welded with the two ends of other hairpin coils to form a winding, so that the insulating layers at the two ends of the hairpin coil need to be removed by laser before the winding is manufactured to be welded, the whole process is complex, the equipment cost is high, and the production efficiency is low.
In summary, how to arrange the hairpin coil to improve the performance of the hairpin coil and simplify the manufacturing process of the hairpin coil is an urgent problem to be solved by those skilled in the art.
SUMMERY OF THE UTILITY MODEL
In view of the above, the present invention is to provide a hairpin coil to improve the performance of the hairpin coil and simplify the manufacturing process of the hairpin coil. Another object of the present invention is to provide a hairpin winding having the above hairpin coil, and a hairpin motor having the above hairpin winding.
In order to achieve the above object, the utility model provides a following technical scheme:
a hairpin coil comprising: hairpin conductors and insulating layers;
wherein the hairpin conductor comprises: the hairpin-shaped conductor comprises hairpin-shaped conductor main bodies and two conductor connecting parts electrically connected with the hairpin-shaped conductor main bodies, wherein the two conductor connecting parts are respectively positioned at two ends of the hairpin-shaped conductor;
the insulating layer only electrophoreses in the surface of hairpin form conductor main part, the conductor connecting portion exposes the setting, just the insulating layer is the polyimide coating.
Optionally, the conductor connection portions are located at ends of the hairpin conductors, and the insulating layer extends from one of the conductor connection portions to the other of the conductor connection portions.
Optionally, the insulation layer includes a first insulation layer and a second insulation layer, the two second insulation layers are respectively located at the end portions of the two ends of the hairpin-shaped conductor, and one of the second insulation layers, one of the conductor connecting portions, the first insulation layer, the other of the conductor connecting portions, and the other of the second insulation layers are sequentially distributed.
Optionally, the hairpin-shaped conductors are formed by placing the conductors in an electrophoresis apparatus to form the insulation layer, or the hairpin coils are formed by bending the conductors electrophoresed with the insulation layer.
Optionally, the length of the conductor connecting part is 1cm-100cm, and/or the hairpin-shaped conductor body and the conductor connecting part are of an integral structure.
Optionally, the thickness of the polyimide coating is δ, and the value range of δ is 30 μm to 200 μm; the difference between the maximum thickness of the polyimide coating and the minimum thickness of the polyimide coating in the same hairpin is no greater than 20% δ.
Optionally, the insulating layer is only one layer of the polyimide coating; and/or the hairpin conductor is a copper piece.
Based on the hairpin coil that above-mentioned provided, the utility model also provides a hairpin winding, this hairpin winding include the hairpin coil of two at least electricity connections, wherein, the hairpin coil is above-mentioned arbitrary hairpin coil.
Optionally, the hairpin winding is a stator winding of a hairpin motor.
Based on the hairpin winding that above-mentioned provided, the utility model also provides a hairpin machine, this hairpin machine includes hairpin winding, wherein, hairpin winding is above-mentioned arbitrary hairpin winding.
The utility model provides a hairpin coil, insulating layer electrophoresis are on the surface of hairpin form conductor main part, set up the insulating layer through the mode of electrophoresis, have effectively improved the toughness of insulating layer, have reduced the change that the insulating layer takes place in the course of buckling to improve heat-resisting, withstand voltage and resistant scraping performance of insulating layer, improved the performance of hairpin coil promptly, thus improved the wholeness ability of hairpin motor; through the electrophoresis mode, an insulating layer can be directly formed on the surface of the hairpin-shaped conductor main body, namely, the insulating layer is not required to be bent after being formed, so that the change of the insulating layer in the bending process is avoided, the heat resistance, voltage resistance, scratch resistance and other performances of the insulating layer are improved, namely, the performance of the hairpin coil is improved, and the overall performance of the hairpin motor is improved; meanwhile, the insulating layer is selected as the polyimide coating, so that the heat resistance, voltage resistance, scratch resistance and other performances of the insulating layer are further improved, namely the performance of the hairpin coil is improved, and the overall performance of the hairpin motor is improved.
Furthermore, the utility model provides an among the hairpin coil, the insulating layer only electrophoresis is in hairpin form conductor main part, and conductor connecting portion exposes the setting, then need not to get rid of the insulating layer of conductor connecting portion before making hairpin winding, has reduced operating procedure to simplify hairpin winding preparation technology, improved hairpin winding's production efficiency.
Therefore, the utility model provides a hairpin coil had both improved hairpin coil's performance, had also simplified hairpin winding manufacture craft.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required to be used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the provided drawings without creative efforts.
Fig. 1 is a schematic structural diagram of a hairpin coil according to an embodiment of the present invention;
FIG. 2 is an enlarged view of a portion of FIG. 1;
FIG. 3 is a schematic diagram of a cross-section of the hairpin coil of FIG. 1 at a first location (1);
figure 4 is a partial schematic view in longitudinal section of the region of the hairpin coil in figure 1 at a sixth position (6);
fig. 5 is another schematic structural diagram of a hairpin coil according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments in the present invention, all other embodiments obtained by a person skilled in the art without creative work belong to the protection scope of the present invention.
As shown in fig. 1 and 5, the hairpin coil provided by the embodiment of the present invention includes a hairpin conductor 1 and an insulating layer 2.
The hairpin conductor includes: the hairpin conductor 1 comprises a hairpin conductor body 12 and two conductor connecting parts 11 electrically connected with the end parts of the hairpin conductor body 12, wherein the two conductor connecting parts 11 are respectively positioned at two ends of the hairpin conductor 1. It will be appreciated that the conductor connection 11 of one hairpin coil and the conductor connection 11 of the other hairpin coil are electrically connected to achieve an electrical connection of the two hairpin coils.
As shown in fig. 1 to 5, the insulating layer 2 is electrophoresed only on the surface of the hairpin conductor body 12, and the conductor connecting portion 11 is exposed. It will be understood that the insulating layer 2 is not electrophoresed on the conductor connecting portion 11.
The insulating layer 2 is a polyimide coating. The polyimide coating is formed by performing electrophoretic deposition on a polyimide electrophoretic solution and then drying to form a film.
Specifically, the polyimide coating is formed on the surface of the hairpin conductor body 12 by an anodic electrophoresis process, and is a compact, uniform-thickness, high-temperature-resistant, corrosion-resistant and voltage-resistant film layer, and the film layer has good toughness and does not have wrinkles, cracks and other defects when being bent at will.
The voltage of the electrophoresis may be 20V-80V, and in practical applications, the voltage value may be adjusted appropriately, which is not limited in this embodiment.
The drying mode is as follows: drying at constant temperature of 70-90 deg.C for 10-60 min, heating to 100-140 deg.C, drying at constant temperature of 100-140 deg.C for 10-60 min, heating to 180-210 deg.C, drying at constant temperature of 180-210 deg.C for 10-60 min, heating to 220-250 deg.C, and drying at constant temperature of 220-250 deg.C for 10-60 min.
In the electrophoresis process, the specific operation steps involved are selected according to actual needs, and this embodiment does not limit this.
In the hairpin coil provided by the embodiment, the insulating layer 2 is electrophoresed on the surface of the hairpin-shaped conductor main body 12, and the insulating layer 2 is arranged in an electrophoresis mode, so that the toughness of the insulating layer 2 is effectively improved, and the change of the insulating layer 2 in the bending process is reduced, thereby improving the heat resistance, voltage resistance, scraping resistance and other performances of the insulating layer 2, namely improving the performance of the hairpin coil, and further improving the overall performance of the hairpin motor; through the electrophoresis mode, the insulating layer 2 can be directly formed on the surface of the hairpin-shaped conductor main body 12, namely the insulating layer 2 is not required to be bent after being formed, so that the change of the insulating layer 2 in the bending process is avoided, the heat resistance, voltage resistance, scratch resistance and other performances of the insulating layer 2 are improved, namely the performance of the hairpin coil is improved, and the overall performance of the hairpin motor is improved; meanwhile, the insulating layer 2 is selected as a polyimide coating, so that the heat resistance, voltage resistance, scratch resistance and other performances of the insulating layer 2 are further improved, namely the performance of the hairpin coil is improved, and the overall performance of the hairpin motor is improved.
Moreover, in the hairpin coil provided by the above embodiment, the insulating layer 2 is only electrophoresed in the hairpin-shaped conductor main body 12, and the conductor connecting portion 11 is exposed, that is, the insulating layer 2 is not disposed on the conductor connecting portion 11 in the process of disposing the insulating layer 2, so that the insulating layer 2 outside the conductor connecting portion 11 does not need to be removed before the hairpin winding is manufactured, and the operation steps are reduced, thereby simplifying the manufacturing process of the hairpin winding and improving the production efficiency of the hairpin winding.
Therefore, the hairpin coil provided by the embodiment not only improves the performance of the hairpin coil, but also simplifies the manufacturing process of the hairpin winding.
In the hairpin coil provided in the above embodiment, two conductor connection portions 11 are provided and are respectively located at both ends of the hairpin conductor 1. Specifically, the conductor connection portion 11 may be located at an end portion of one end of the hairpin conductor 1, or may be located at a non-end portion of one end of the hairpin conductor 1.
In one embodiment, as shown in fig. 1, the conductor connection portions 11 are located at the ends of the hairpin conductors 1, and the insulating layer 2 extends from one conductor connection portion 11 to the other conductor connection portion 11. At this time, the entire insulating layer 2 is located between the two conductor connecting portions 11.
In another embodiment, as shown in fig. 5, the conductor connecting portion 11 is located at a non-end portion of one end of the hairpin conductor 1. Specifically, the insulating layer 2 includes a first insulating layer 21 and a second insulating layer 22, the second insulating layers 22 are two and are respectively located at the end portions of the two ends of the hairpin conductor 1, and one second insulating layer 22, one conductor connecting portion 11, the first insulating layer 21, the other conductor connecting portion 11, and the other second insulating layer 22 are sequentially distributed.
It is to be understood that the above-described first insulating layer 21 extends from one conductor connecting portion 11 to the other conductor connecting portion 11, one conductor connecting portion 11 is located between one end of the first insulating layer 21 and one second insulating layer 22, and the other conductor connecting portion 11 is located between the other end of the first insulating layer 21 and the other second insulating layer 22.
In the hairpin coil provided in the above embodiment, the hairpin conductor 1 may be selected to form the insulating layer 2 by being placed in an electrophoresis apparatus. It can be understood that the straight conductive wire is bent into a hairpin shape to form the hairpin conductor 1, and then the insulating layer 2 is electrophoretically formed directly on the surface of the hairpin conductor body 12 of the hairpin conductor 1.
Specifically, the hairpin conductor 1 is subjected to acid-base washing to remove surface oil stains, the hairpin conductor body 12 of the hairpin conductor 1 is placed in an electrophoresis solution after washing, the hairpin conductor 1 is used as a positive electrode, a voltage of 20V-80V is applied, and electrophoresis is performed by electrifying. The polyimide coating can slowly grow on the surface of the hairpin conductor main body 12 by controlling the current and the electrifying time, finally the polyimide coating is obtained, the hairpin conductor 1 with the polyimide coating is hung in an oven after the electrophoresis is finished, and drying is carried out at different temperatures. And cooling after drying to obtain the hairpin coil.
In practical applications, the hairpin coil may be formed by bending a conductor having an insulating layer 2 by electrophoresis. It is understood that the hairpin coil is formed by first electrophoresing the insulating layer 2 on a conductor and then bending the conductor electrophoresing the insulating layer 2 into a hairpin shape.
Specifically, the conductors are subjected to acid-base washing treatment to remove oil stains on the surfaces, the electrophoresis scheme is as described above, and the conductors are bent into hairpin coils according to specified angles and sizes after the surfaces of the conductors are provided with polyimide coatings.
In the hairpin coil described above, the length of the conductor connecting portion 11 is selected according to actual needs, for example, set according to welding requirements. The length of the conductor connection 11 can be chosen to be 1cm-100cm for ease of subsequent winding manufacture.
In practical applications, the length of the conductor connecting portion 11 can be adjusted as appropriate, and is not limited to the above embodiment.
In the hairpin coil, the hairpin-shaped conductor main body 12 and the conductor connecting portion 11 may be of an integral structure or a split structure, and are selected as required. In order to simplify the structure and facilitate the production, the hairpin conductor body 12 and the conductor connecting portion 11 may be selected to be of an integral structure.
The thickness of the polyimide coating is set as required. Optionally, the thickness of the polyimide coating is δ, and δ ranges from 30 μm to 200 μm.
The polyimide coating is electrophoresed on the hairpin conductor body 12, which can effectively reduce thickness variation. Optionally, the difference between the maximum thickness of the polyimide coating and the minimum thickness of the polyimide coating in the same hairpin coil is no greater than 20% δ.
Specifically, taking the maximum thickness of the polyimide coating as 32 μm and the minimum thickness of the polyimide coating as 30 μm as an example, the thickness of the polyimide coating is δ, the value of δ ranges from 30 μm to 32 μm, the difference between the maximum thickness of the polyimide coating and the minimum thickness of the polyimide coating is 2 μm, and 2 μm is less than 20% δ, i.e., 2 μm is less than 6 μm and 2 μm is less than 6.4 μm.
In practical applications, the thickness of the polyimide coating and the difference between the maximum thickness of the polyimide coating and the minimum thickness of the polyimide coating may be appropriately adjusted according to the performance requirements of the hairpin coil, and the invention is not limited to the above embodiments.
As shown in fig. 1, the hairpin coil includes eight sequentially connected coil segments, namely, a first coil segment 01, a second coil segment 02, a third coil segment 03, a fourth coil segment 04, a fifth coil segment 05, a sixth coil segment 06, a seventh coil segment 07, and an eighth coil segment 08, which are sequentially connected. The first coil section 01, the second coil section 02, the third coil section 03, the sixth coil section 06, the seventh coil section 07, and the eighth coil section 08 are all linear, and the fourth coil section 04 and the fifth coil section 05 are all linear or curved.
The first coil section 01 is located at one end of the hairpin coil, and the eighth coil section 08 is located at the other end of the hairpin coil; the first coil segment 01 and the eighth coil segment 08 each include the above-described conductor connecting portion 11.
The first coil section 01 and the eighth coil section 08 are arranged in parallel, the third coil section 03 and the sixth coil section 06 are arranged in parallel, and the second coil section 02 and the seventh coil section 07 are inclined with respect to each other. The joint between the fourth coil section 04 and the fifth coil section 05 protrudes in a direction away from the third coil section 03 and the sixth coil section 06, and if the fourth coil section 04 and the fifth coil section 05 are both linear, an included angle is formed between the fourth coil section 04 and the fifth coil section 05.
The polyimide coating formed by electrophoresis has better toughness, so that the included angle between the third coil segment 03 and the fourth coil segment 04 and the included angle between the fifth coil segment 05 and the sixth coil segment 06 can be increased, the height from two ends of the hairpin coil to the vertex can be reduced, the equivalent turning radius of the hairpin coil is reduced, and the outermost end part of the hairpin coil can enter a horizontal state in advance, so that the efficiency of the hairpin motor is further improved.
It should be noted that the vertex of the hairpin coil is the connection point between the fourth coil section 04 and the fifth coil section 05. The outermost portion of the hair pin winding refers to the outermost coil portion of the hair pin winding in accordance with the concentric winding arrangement.
In the hairpin coil, the polyimide coating can be one layer or at least two layers. Because the performance of the polyimide coating is better, the insulating layer can be selected to be only one layer of polyimide coating, so that the thickness of the polyimide coating is effectively reduced, the volume of the whole hairpin winding is reduced, and the volume of the hairpin motor is correspondingly reduced.
In the hairpin coil, the type of hairpin conductor 1 is selected according to actual needs. In order to improve the conductivity, the hairpin conductor 1 may be a copper member. At this time, the hairpin conductor body 12 and the conductor connecting portion 11 are both copper pieces.
To more specifically explain the technical solution provided by the present embodiment, a detailed description is provided below.
Example one
The hairpin coil provided by the first embodiment includes hairpin conductors 1 and an insulating layer 2.
The hairpin conductor 1 includes: a hairpin conductor body 12, a conductor connecting portion 11 connected to an end of the hairpin conductor body 12; the number of the conductor connecting parts 11 is two, and the two conductor connecting parts are respectively located at two ends of the hairpin conductor 1. It will be appreciated that the conductor connection 11 of one hairpin coil and the conductor connection 11 of the other hairpin coil are electrically connected to achieve electrical connection of the two hairpin coils.
The insulating layer 2 is electrophoresed only on the surface of the hairpin-shaped conductor main body 12, the conductor connecting part 11 is exposed, and the insulating layer 2 is a polyimide coating.
The hairpin conductor 1 described above forms an insulating layer 2 by being placed in an electrophoresis apparatus.
Specifically, the method comprises the steps of bending a conductor according to a hairpin shape to form the hairpin-shaped conductor 1, carrying out acid-base washing treatment on the hairpin-shaped conductor 1 to remove oil stains on the surface, immersing a hairpin-shaped conductor main body 12 of the cleaned hairpin-shaped conductor 1 into a polyimide electrophoresis solution, taking the hairpin-shaped conductor 1 as a positive electrode, electrifying, starting electrophoresis at a direct-current voltage of 80V, controlling the electrophoresis time for 4min according to the magnitude of current, and slowly growing a polyimide coating on the surface of the hairpin-shaped conductor main body 12 to coat the surface of the hairpin-shaped conductor main body 12 with the polyimide coating.
And taking out the electrophoresis deposition product after the electrophoresis deposition is finished, blowing off the residual polyimide electrophoresis solution on the surface by using airflow, and carrying out heating and drying treatment on the electrophoresed material under the conditions that the material is dried at the constant temperature of 80 ℃ for 30min, then heated to 110 ℃ for 30min, heated to 190 ℃ for 30min, and finally heated to 230 ℃ for 30min.
The hairpin coil prepared in the above manner was subjected to a film thickness test, and the result of the film thickness test at each portion, particularly at the irregular portion such as a corner, showed 55 ± 2 μm, indicating that the thickness of the polyimide coating was uniform.
The hairpin coil prepared in the way is subjected to Voltage resistance, insulation resistance and PDIV (Partial Discharge Initiation Voltage) performance tests, and the Voltage resistance of the hairpin coil reaches 5kV; DC 1kV, the insulation resistance of the hairpin coil reaches 20G omega within 5 s; the PDIV of the card sending coil can reach 900V.
Taking the hairpin coil, putting the hairpin coil into a high-temperature oven at 350 ℃, keeping the temperature for 1h, taking out, cooling to room temperature, observing the polyimide coating on the surface layer of the hairpin coil to have good appearance, and performing performance evaluation on the polyimide coating: the withstand voltage can reach 5kV; DC 1kV, the insulation resistance of the hairpin coil reaches 20G omega within 5 s; the PDIV of the card sending coil can reach 900V.
The hairpin coils are assembled into hairpin windings, and under the same working condition, the volume reduction of the hairpin motor can reach 0.8%.
Example two
The structure of the hairpin coil provided in the second embodiment is the same as that of the hairpin coil provided in the first embodiment, and the difference is the manufacturing process. Specifically, the voltage in the electrophoresis process is different, and the voltage in the electrophoresis process in this embodiment two is 40V.
The hairpin coil prepared in the above manner was subjected to a film thickness test, and the result of the film thickness test at each portion, particularly at the irregular portion such as a corner, showed 28 ± 2 μm, indicating that the thickness of the polyimide coating was uniform.
The hairpin coil prepared by the method is subjected to voltage resistance, insulation resistance and PDIV performance tests, and the voltage resistance of the hairpin coil reaches 2kV; DC 1kV, the insulation resistance of the hairpin coil reaches 16G omega for 5 s; the PDIV of the card sending coil can reach 600V.
Taking the hairpin coil, putting the hairpin coil into a high-temperature oven at 350 ℃, keeping the temperature constant for 1h, taking out, cooling to room temperature, observing the appearance of the polyimide coating on the surface layer of the hairpin coil to be good, and carrying out performance evaluation on the polyimide coating: the voltage resistance of the polyimide reaches 2kV; DC 1kV, the insulation resistance of the hairpin coil reaches 16G omega under 5s, and the PDIV of the hairpin coil can reach 600V.
The hairpin coils are assembled into hairpin windings, and under the same working condition, the volume reduction of the hairpin motor can reach 1.0%.
EXAMPLE III
The difference between the hairpin coil provided by the third embodiment and the first embodiment is mainly as follows: the hairpin coil is formed by bending a conductor having an insulating layer 2 by electrophoresis.
Specifically, firstly, conducting acid-base washing treatment on a conductor to remove surface oil stains, after washing, immersing a part of the conductor, which is used for forming the hairpin-shaped conductor main body 12, into a polyimide electrophoresis solution, taking the conductor as a positive electrode, electrifying, starting electrophoresis at a direct-current voltage of 80V, controlling the electrophoresis time for 4min through the current magnitude, and enabling a polyimide coating to slowly grow on the surface of the conductor so that the surface of the conductor is coated by the polyimide coating.
And taking out the electrophoresis deposition product after the electrophoresis deposition is finished, blowing off the residual polyimide electrophoresis solution on the surface by using airflow, and carrying out temperature programming drying treatment on the electrophoresed material, wherein the conditions are that the temperature is 80 ℃ and the constant temperature is dried for 30min, then the temperature is increased to 110 ℃ and the constant temperature is dried for 30min, then the temperature is increased to 190 ℃ and the constant temperature is dried for 30min, and finally the temperature is increased to 230 ℃ and the constant temperature is dried for 30min.
The polyimide-coated conductor prepared in the above manner was bent in a hairpin shape, the angle and size of the bend were confirmed to form a hairpin coil, and the thickness of the hairpin coil was measured, and the thickness of the coated conductor was 55 ± 2 μm in each portion, particularly in the corners and other irregular portions, indicating that the polyimide coating was uniform in thickness.
The hairpin coil prepared by the method is subjected to voltage resistance, insulation resistance and PDIV performance tests, and the voltage resistance of the hairpin coil reaches 5kV; DC 1kV, the insulation resistance of the hairpin coil reaches 20G omega within 5 s; the PDIV of the card sending coil can reach 900V.
Taking the hairpin coil, putting the hairpin coil into a high-temperature oven at 350 ℃, keeping the temperature for 1h, taking out, cooling to room temperature, observing the polyimide coating on the surface layer of the hairpin coil to have good appearance, and performing performance evaluation on the polyimide coating: the withstand voltage of the hairpin coil reaches 5kV; DC 1kV, the insulation resistance of the hairpin coil reaches 20G omega within 5 s; the PDIV of the card sending coil can reach 900V.
The hairpin coils are assembled into hairpin windings, and under the same working condition, the volume reduction of the hairpin motor can reach 0.8%.
Comparative example 1
The hairpin conductor 1 is soaked in water-based polyester insulating electrophoretic paint after acid-base washing treatment, electrophoresis is started under the condition of electrified direct-current voltage of 80V, the electrophoresis time is controlled for 4min through the current magnitude, the polyester coating slowly grows on the surface of the hairpin conductor 1, and the surface of the hairpin conductor 1 is coated by the polyester coating.
And taking out the electrophoresis deposition product after the electrophoresis deposition is finished, blowing off the polyester paint residual on the surface by using airflow, carrying out temperature programming drying treatment on the electrophoresis product for 30min at the constant temperature of 80 ℃, and then heating to 150 ℃ for 30min at the constant temperature.
The hairpin coil prepared in the above manner was subjected to a film thickness test, and the film thickness test at each portion, particularly at a corner or other irregular portion, showed a result of 33 ± 5 μm.
The hairpin coil prepared by the method is subjected to voltage resistance, insulation resistance and PDIV performance tests, and the voltage resistance of the hairpin coil reaches 1.5kV; DC 1kV, the insulation resistance of the hairpin coil reaches 3G omega within 5 s; the card sending coil has a PDIV of 305V.
And (3) placing the hairpin coil into a high-temperature oven at 350 ℃ for constant temperature for 1h, and taking out the hairpin coil, wherein bubbles appear on the surface layer, and subsequent tests cannot be carried out.
Comparative example No. two
Firstly, conducting acid-base washing treatment on a conductor to remove surface oil stains, soaking the conductor into water-based polyester insulating electrophoretic paint after washing, starting electrophoresis by electrifying direct-current voltage of 80V, controlling the electrophoresis time for 4min through the current magnitude, and enabling a polyester coating to slowly grow on the surface of the conductor to enable the surface of the conductor to be coated by the polyester coating.
And taking out after the electrophoretic deposition is finished, blowing off the polyester paint remained on the surface by using airflow, and carrying out temperature programming drying treatment on the electrophoresed material under the conditions of constant temperature drying at 80 ℃ for 30min and constant temperature drying at 150 ℃ for 30min.
The conductor prepared in the mode is bent according to a hairpin shape, and the phenomenon of wrinkle and cracking occurs at the bent part, so that subsequent tests cannot be carried out.
The film thickness test is specifically a measurement using an eddy current type film thickness meter.
The voltage resistance test specifically comprises the following steps: preparing tinfoils with the width of 1cm, clamping a hairpin coil to be detected between the two tinfoils, switching on a circuit, gradually increasing the voltage, wherein the voltage application speed is 100V/s, reading the voltage during damage, and the voltage value is the withstand voltage value;
the insulation resistance test specifically comprises the following steps: clamping the hairpin coil to be tested between a positive electrode and a negative electrode, switching on a power supply without contacting any other substance in the middle, gradually increasing the voltage to 1kV at a voltage rising speed of not more than 100V per second, and testing the insulation impedance of the hairpin coil;
the PDIV performance test specifically comprises the steps of wiping a hairpin coil to be tested clean, brushing the middle part (the coating length is about 5 cm) of the hairpin coil with graphite, drying the hairpin coil by using a hair drier, heating the dried sample in a drying furnace, testing the relative dielectric loss value through the temperature change, and visually reflecting the value on a computer display screen in a curve form.
The hairpin coils provided in the first, second, third and comparative examples were subjected to thickness tests at seven positions on the hairpin coil, specifically, as shown in fig. 1, at the first position (1), the second position (2), the third position (3), the fourth position (4), the fifth position (5), the sixth position (6) and the seventh position (7), in units of μm. The test data are shown in the following table:
| |
1 | 2 | 3 | 4 | 5 | 6 | 7 | Dimensional tolerance |
| Example 1 | 54 | 53 | 56 | 55 | 57 | 53 | 53 | ±4 |
| Example 2 | 28 | 27 | 28 | 30 | 27 | 26 | 27 | ±4 |
| Example 3 | 53 | 55 | 55 | 53 | 57 | 57 | 55 | ±4 |
| Comparative example 1 | 29 | 35 | 38 | 28 | 30 | 37 | 29 | ±9 |
In the above table, the dimensional tolerance is a value obtained by subtracting the minimum critical dimension from the maximum critical dimension.
In the hairpin coil provided by the above embodiment, under the condition of ensuring the performance, the thickness of the insulating layer 2 is smaller, and the radial size of the hairpin winding is effectively reduced, so that the size of the hairpin motor is effectively reduced, and specifically, the volume reduction of the hairpin motor can reach 1% under the same design requirement.
Based on the hairpin coil provided by the above embodiment, this embodiment further provides a hairpin winding, which includes at least two hairpin coils electrically connected to each other, where the hairpin coil is the hairpin coil described in the above embodiment.
It is understood that two electrically connected hairpin coils, meaning that the conductor connection 11 of one hairpin coil and the conductor connection 11 of the other hairpin coil, are electrically connected.
Since the hairpin coil provided by the above embodiment has the above technical effects, and the hairpin winding includes the hairpin coil, the hairpin winding also has corresponding technical effects, and details are not repeated herein.
For the type of the hairpin winding, it is selected according to actual needs, for example, the hairpin winding is a stator winding, which is not limited in this embodiment.
Based on the motor hairpin winding provided by the above embodiment, the embodiment further provides a hairpin motor, which includes the hairpin winding provided by the above embodiment.
Since the hairpin winding provided by the above embodiment has the above technical effects, and the hairpin motor includes the above hairpin winding, the above hairpin motor also has corresponding technical effects, and details are not described herein.
The type and application scenario of the card issuing motor are selected according to actual needs, and this embodiment does not limit this.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (10)
1. A card-issuing loop, comprising: hairpin conductors and insulating layers;
wherein the hairpin conductor comprises: the connector comprises a hairpin-shaped conductor main body and two conductor connecting parts electrically connected with the hairpin-shaped conductor main body, wherein the two conductor connecting parts are respectively positioned at two ends of the hairpin-shaped conductor;
the insulating layer only electrophoreses in the surface of hairpin form conductor main part, the conductor connecting portion exposes the setting, just the insulating layer is the polyimide coating.
2. The hairpin coil of claim 1 wherein the conductor connection portions are located at ends of the hairpin conductors, and the insulating layer extends from one of the conductor connection portions to the other of the conductor connection portions.
3. The hairpin coil according to claim 1, wherein the insulation layers include a first insulation layer and second insulation layers, the second insulation layers being two and respectively located at end portions of both ends of the hairpin-shaped conductor, one of the second insulation layers, one of the conductor connecting portions, the first insulation layer, the other of the conductor connecting portions, and the other of the second insulation layers being distributed in this order.
4. The hairpin coil of claim 1 wherein the hairpin conductors are formed by placing in an electrophoresis apparatus to form the insulating layer, or the hairpin coil is formed by electrophoresing a conductor bend having the insulating layer.
5. The hairpin coil of claim 1 wherein the conductor connecting portion has a length of 1cm to 100cm, and/or the hairpin conductor body and the conductor connecting portion are of unitary construction.
6. The hairpin coil of claim 1 wherein the polyimide coating has a thickness δ, δ being in the range of 30 μ ι η to 200 μ ι η; the difference between the maximum thickness of the polyimide coating and the minimum thickness of the polyimide coating in the same hairpin coil is no greater than 20% δ.
7. The card coil as in any of claims 1-6, wherein the insulating layer is only one of the polyimide coatings; and/or the hairpin conductor is a copper piece.
8. A hairpin winding comprising at least two hairpin coils electrically connected, characterized in that the hairpin coils are as claimed in any one of claims 1-7.
9. The hairpin winding of claim 8, wherein the hairpin winding is a stator winding of a hairpin machine.
10. A hair pin motor comprising a hair pin, wherein the hair pin is as claimed in claim 8 or 9.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202222197538.9U CN218276241U (en) | 2022-08-18 | 2022-08-18 | Hairpin coil, hairpin winding and hairpin motor |
| PCT/CN2023/102033 WO2024037184A1 (en) | 2022-08-18 | 2023-06-25 | Hairpin coil, hairpin winding and hairpin electric motor |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202222197538.9U CN218276241U (en) | 2022-08-18 | 2022-08-18 | Hairpin coil, hairpin winding and hairpin motor |
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Cited By (1)
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|---|---|---|---|---|
| WO2024037184A1 (en) * | 2022-08-18 | 2024-02-22 | 合肥汉之和新材料科技有限公司 | Hairpin coil, hairpin winding and hairpin electric motor |
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| JP6752323B1 (en) * | 2019-04-10 | 2020-09-09 | 三菱電機株式会社 | Stator winding of rotary electric machine and its manufacturing method |
| US20210367483A1 (en) * | 2020-05-19 | 2021-11-25 | Ge Aviation Systems Llc | Method and system for thermally insulating portions of a stator core |
| JPWO2022004299A1 (en) * | 2020-07-01 | 2022-01-06 | ||
| CN212750993U (en) * | 2020-08-25 | 2021-03-19 | 合肥汉之和新材料科技有限公司 | Power battery |
| CN218276241U (en) * | 2022-08-18 | 2023-01-10 | 合肥汉之和新材料科技有限公司 | Hairpin coil, hairpin winding and hairpin motor |
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2022
- 2022-08-18 CN CN202222197538.9U patent/CN218276241U/en active Active
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2024037184A1 (en) * | 2022-08-18 | 2024-02-22 | 合肥汉之和新材料科技有限公司 | Hairpin coil, hairpin winding and hairpin electric motor |
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| WO2024037184A1 (en) | 2024-02-22 |
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