JPH0568359A - Stator winding for low voltage rotating machine - Google Patents

Abstract

PURPOSE:To obtain a stator winding for low voltage rotating machine excellent in insulation reliability wherein fabrication process is simplified by eliminating varnish treatment step and varnish cleaning step. CONSTITUTION:The stator winding comprises a slot insulating layer 12 of self- fusing thin material previously inserted along the wall face of a slot 1A, a stator coil 13 formed by winding a self-fusing magnet wire 15 by a plurality of turns in automatic inserter system, and a wedge 14 of self-fusing thin material inserted to choke the opening of the slot 1A, which are then thermally fused to produce an integrated stator coil 13. Alternately, the stator coil 13 is formed by winding the self-fusing magnet wire 15 by a plurality of turns and binding the wire 15 with a binding taping layer 12 made of self-fusing thin material, and then the stator coil 13 is manually inserted to the inside of the slot insulating layer 12 made of self-fusing thin material and the opening of the slot is choked with a wedge of laminate thus obtaining a stator winding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a stator winding in a low-voltage rotating machine such as a general-purpose induction motor, and more particularly to a stator winding insulation system having a simplified insulation treatment process.

[0002]

2. Description of the Related Art In a low-voltage rotating machine such as an induction motor used in connection with a low-voltage distribution system having a voltage of 440 V or less, the insulation structure of the stator winding is varnished on a coil made of a magnet wire having an enamel coating. A simple insulation method that is impregnated is used. For the coil winding method, an automatic winding machine (automatic inserter) is used to wind (drop) a magnet wire in one slot into two slots of the stator core, and a magnet. Prepare a coil in which multiple wires are wound and an insulating tape is wound around the part to be inserted into the slot to form a binding tape layer, and this coil is manually inserted into the slot of the stator core. It is roughly divided into the maintenance method to drop.

FIG. 7 is a sectional view showing a main part of a stator winding according to an automatic inserter system. A slot 1A formed at a predetermined pitch in a stator core 1 has thin leaves along its inner wall surface. A slot insulating layer 2 made of an insulating material is inserted, and a slot corresponding to two coils is provided in a slot surrounded by the slot insulating material 2 across two specific two slots 1A.
The number of magnet wires 5 is 1 by the automatic inserter.
The windings are sequentially wound (dropped), the wedge 4 of the film base material is inserted into the opening of the slot 1A, and the interphase insulating material is inserted between the coils at the coil ends (not shown) of the two coils. The unimpregnated stator coil (white coil) 3 is formed. Further, at the time when the winding of the plurality of white coils is completed, the electrical connection work between the coils, the forming work of the coil end, and the binding work are performed to form the unimpregnated stator winding. Furthermore, the unimpregnated stator coil is impregnated with solvent-based varnish such as polyester-based, polyester-modified epoxy-based, polyimide-based or solvent-free varnish by an impregnation method such as a drop impregnation method, an immersion impregnation method, or a vacuum impregnation method. Then, heat treatment is performed to form a stator winding in which the respective members are fixed to each other with the cured product of the impregnated varnish.

[0004]

In the conventional stator winding of the low voltage rotating machine, the white coil is varnished to impregnate the windings of the magnet wire, the slot insulation, the wedge, and the stator core. The cured products of the varnish are integrated with each other to obtain desired withstand voltage characteristics, vibration resistance,
It is possible to obtain a stator winding having high heat resistance and weather resistance and excellent insulation reliability. Therefore, varnishing has been an important part of the winding manufacturing process for low voltage rotating machines. However, varnish processing requires large-scale equipment including environmental protection equipment, and its processing time is long, so that it has drawbacks of increasing cost of the low-voltage rotating machine and prolonging delivery time. In addition, the varnish attached to the surface of the stator core that does not require varnishing forms a resin pool and adversely affects the dimensional accuracy. However, not only a great amount of processing time is required for this step, but also a problem arises that the working environment is deteriorated because the adhered varnish is mechanically or chemically removed.

The present invention simplifies the manufacturing process of the stator winding by eliminating the varnishing process and the varnish cleaning process, and has the same performance as the varnishing process. To get the line.

[0006]

In order to solve the above-mentioned problems, according to the present invention, a plurality of turns of magnet wire are wound in slots formed in a stator core at a predetermined pitch to form a stator coil. A slot insulating layer made of a self-bonding thin leaf material previously inserted along the inner wall surface of the slot, and a plurality of self-bonding magnet wires inside the slot insulating layer by an automatic inserter method. A stator coil formed by winding a coil and a wedge made of a self-sealing thin leaf material inserted so as to close the opening of the slot are provided and integrated by heating and fusion.

The stator coil is formed by winding a plurality of turns of a self-adhesive magnet wire and binding them with a binding tape layer made of a self-adhesive thin leaf material, which is previously inserted along the inner wall surface of the slot. Inserted by a care method inside the slot insulating layer made of self-fusing thin leaf material,
The slot is formed so as to be closed by a wedge made of a laminated material.

The self-fusing thin sheet material comprises a heat-resistant film substrate and a self-fusing adhesive layer fixed to one surface thereof.

The self-fusing thin sheet material is a self-fusing adhesive layer, and two heat-resistant film base materials having through-holes distributed and formed, which are attached via the self-fusing adhesive layer. Shall consist of

2 having a self-fusion-bonding adhesive layer and through-holes distributed and formed by being stuck through the self-fusion-bonding adhesive layer 2
A self-fusing thin sheet material composed of a sheet of heat-resistant film base material has a self-fusing adhesive layer formed on the surface of each of the two heat-resistant film base materials having through holes.

[0011]

In the structure of the present invention, the slot insulation made of the self-bonding thin leaf material is previously inserted along the inner wall surface of the slot, and the self-bonding magnet wire is provided inside the slot insulation by a plurality of types, for example, by an automatic inserter system. -Heating by forming a coil by winding a coil, inserting a wedge made of self-bonding thin leaf material so as to close the opening of the slot, and performing heat fusion treatment to integrate the whole The self-fusing adhesive layer that has become sticky due to acts as an adhesive that replaces the impregnated varnish, and when heated and cured, the contact parts of each member are firmly bonded by the cured adhesive layer and integrated low voltage Since the stator winding of the rotating machine can be obtained,
The varnishing process and varnish cleaning process are not required, simplifying the manufacturing process of the stator winding and maintaining the working environment, and withstand voltage characteristics and withstand voltage equivalent to those of varnishing by the automatic inserter method. A stator winding with vibration resistance, heat resistance, and weather resistance and excellent insulation reliability can be obtained.

Further, a plurality of turns of the self-adhesive magnet wire are wound and bound by a binding tape layer made of a self-adhesive thin sheet, and a stator coil is previously inserted along the inner wall surface of the slot. By inserting the inside of the slot insulation layer made of self-fusing thin sheet material by the maintenance method and closing the slot opening with the wedge made of the laminated material, the varnish processing step and the varnish cleaning step can be performed even by the maintenance method. It becomes unnecessary, simplifies the manufacturing process of the stator winding, and maintains the working environment, and also has the same withstand voltage characteristics, vibration resistance, and heat resistance as the varnished one.
Also, a stator winding having weather resistance and excellent insulation reliability can be obtained.

On the other hand, if the self-fusing thin leaf material is composed of a heat-resistant film base material and a self-fusing adhesive layer fixed to one surface thereof, a thin self-fusing thin leaf material having a two-layer structure. Thus, the slot insulating layer and the binding tape layer can be formed. Further, if the self-fusing adhesive layer is inserted outside into the slot, a strong adhesive layer is formed between the core and the core,
The smooth heat-resistant film base sliding surface is located on the coil side, so that the winding work of the self-bonding magnet wire by the automatic inserter system can be facilitated.

Further, the self-fusing thin sheet material is composed of a self-fusing adhesive layer and two heat-resistant film bases having through holes attached through the self-fusing adhesive layer. With a layered structure, the exposed area of the self-adhesive adhesive layer is reduced and a slot insulating layer with good slipperiness and a binding tape layer can be obtained, which facilitates winding work by the automatic inserter method and maintenance method. In addition, the members can be firmly bonded to each other by the self-melting adhesive that oozes out of the through holes.

Further, it has a self-fusing adhesive layer and a large number of through-holes attached through the self-fusing adhesive layer.
If the self-bonding thin sheet material composed of one heat-resistant film base material has a multi-layer structure having a self-bonding adhesive layer formed on the surface of each of the two heat-resistant film base materials having through holes, A self-fusing thin sheet having excellent insulation reliability and adhesiveness can be obtained.

[0016]

EXAMPLES The present invention will be described below based on examples. FIG. 1 is a sectional view showing a stator coil of an automatic inserter system for a low voltage rotating machine according to an embodiment of the present invention. In the figure, a slot insulating layer 12 made of a self-fusing thin sheet material is inserted along the inner wall surface of the slots 1A formed at a predetermined pitch in the stator core 1 to straddle two specific slots 1A. Then, in the slot surrounded by the slot insulating material 12, the self-bonding magnet wire 15 having the number of turns corresponding to two coils is automatically inserted.
A stator coil 13 is formed by sequentially winding (dropping) one turn for each turn, and inserting a wedge 14 made of a self-bonding thin leaf material into the opening of the slot 1A. Further, an interphase insulating material is inserted between the coils of coil ends (not shown) of the two coils, and when the winding of the plurality of stator coils is completed, electrical connection work between the coils, coil end forming work, and bundling work are performed. Work is done,
By performing the heat fusion treatment at the end of all these winding steps, the self-fusion coating on the surface of the self-adhesive magnet wire and the self-fusion adhesive layer of the self-adhesive thin leaf material are softened. And the stickiness of the coil
Between the coil and the slot insulating layer, and between the slot insulating layer and the iron core, the contact surfaces of the members are fused, and when the heat fusion treatment is completed, the adhesive layer is cured and integrated stator winding Is formed.

In the stator winding of the low-voltage rotating machine configured as described above, the self-fusing adhesive layer, which has been made sticky by heating, functions as an adhesive in place of the impregnated varnish and is heat-cured. At this point, the contact parts of each member are firmly joined by the cured adhesive layer, and the stator winding of the low-voltage rotating machine that is integrated can be obtained, so that the varnishing process and the varnish cleaning process are unnecessary, and the stator It simplifies the winding manufacturing process and maintains the work environment, and
With the automatic inserter method, it is possible to obtain a stator winding that has the same withstand voltage characteristics, vibration resistance, heat resistance, and weather resistance as those obtained by varnishing and has excellent insulation reliability.

FIG. 2 is a sectional view showing a stator coil according to a maintenance method according to another embodiment of the present invention. In the case of the maintenance method, a pair of upper and lower stator coils in which a slot insertion portion of a coil formed by winding a plurality of turns of the self-bonding magnet wire 15 is bound by a binding tape layer 22 made of a self-bonding thin leaf material. 23 is inserted by a care method into the inside of the slot insulating layer 12 made of a self-fusing thin sheet material that has been previously inserted along the inner wall surface of the slot, and a laminated material such as FRP is placed in the wedge groove of the slot 1B having a large opening. By inserting the wedge 9 made of a material to close the opening and performing heat fusion processing, the varnish processing step and the varnish cleaning step are unnecessary even by the maintenance method, and the stator winding manufacturing process is simplified and the working environment is improved. It is possible to obtain a stator winding with excellent insulation reliability that has the same withstand voltage characteristics, vibration resistance, heat resistance, and weather resistance as varnished. . In the figure, two stator coils 23
A wedge 24 made of a self-bonding thin leaf material is provided to cover the upper side in a U shape from the upper side to prevent the coil from being damaged at the time of maintenance work and at the time of inserting the wedge 9, and to strengthen the coil interphase insulation. It

FIG. 3 is a sectional view showing the structure of the self-bonding thin leaf material according to the present invention.
The heat-resistant film base material 32 and the self-fusing adhesive layer 33 fixed to one surface of the heat-resistant film base material 32 are formed as a two-layer structure sheet or tape. As the heat resistant film substrate 32,
A polyethylene terephthalate film (PET), a polyphenylene sulfide film (PPS), a polyimide resin film (Kapton) or the like having a thickness of about 10 to 25 μm is used, and the self-bonding adhesive layer 33 is made of the self-bonding magnet wire 15. It is preferable to use the same type of resin as the self-bonding layer, such as polybutyl butyral type,
Polyester-based or polyamide-based resin is used, and its thickness is determined in the range of 5 to 50 μm in accordance with the material configuration of the stator coil.

The thin self-bonding thin leaf material 31 thus constructed is inserted into the slot with the self-bonding adhesive layer 33 facing the iron core to form the slot insulating layer 12 shown in FIG. While the self-fusing adhesive layer 33 is fused to the iron core by the heat fusing treatment, the self-fusing film of the self-fusing magnet wire 15 is fused to the heat resistant film base material 32,
The integrated stator coil 13 can be easily formed by an automatic inserter method without requiring a varnish processing step and a varnish cleaning step. Further, even if the self-fusing thin sheet material 31 is used for the slot insulating layer 12 and the binding tape layer 22 in the maintenance method, the same effect can be obtained, and the heat resistant film base material on the slot insulating layer side is bound. It functions as a sliding surface for the self-bonding adhesive layer on the side of the taping layer, and the function of facilitating the maintenance work of the stator coil 23 can be obtained.

FIG. 4 is a cross-sectional view showing the structure of different self-bonding thin leaf materials according to the present invention. Two heat-resistant film base materials 42A and 42B having through holes 44 distributed therein are formed.
However, the self-fusing thin sheet material 4 is a composite sheet or a composite tape having a three-layer structure adhered by the self-fusing adhesive layer 43.
1 is formed, and the exposed area of the self-adhesive adhesive layer 43 is reduced, so that the slipperiness of the self-adhesive thin sheet material 41 is improved. Therefore, it is used as the slot insulating layer 12 in the automatic inserter system. By doing so, it is possible to obtain an advantage that the winding work of the self-fusion-bonding magnet wire can be efficiently performed, and the self-fusion-bonding adhesive layer that has been made fluid by the heat-fusion treatment is attached through the through hole 44. Adhesion is obtained by spreading on the surface.

FIG. 5 is a cross-sectional view showing the structure of a further different self-bonding thin sheet material according to the present invention. Two heat-resistant film base materials 42A, formed with through holes 44 distributed,
42B is a composite sheet having a three-layer structure in which the self-fusing adhesive layer 43 is adhered, and the self-fusing adhesive layers 53A and 53B are further provided on both surfaces of the heat-resistant film base material to form a five-layer structure. This is different from the above-mentioned self-fusing thin leaf material in that a self-fusing thin leaf material 51 made of a composite sheet or a composite tape is formed. By constructing the self-bonding thin leaf material in this way, a mechanically and electrically strong slot insulating layer and a self-bonding wedge can be formed, so that, for example, a low-voltage rotating machine of 440 V class or moisture resistance is required. A highly reliable stator winding can be obtained by using it as a slot insulating layer or a wedge material of a low voltage rotating machine.

FIG. 6 is a characteristic diagram showing the insulation performance evaluation test results of the test three-phase induction motor of the example in comparison with that of the conventional motor. The insulation performance evaluation test method is IEEE.
It conformed to the insulation performance evaluation test method specified in E standard 117. That is, the test motor was subjected to forced heating deterioration treatment at 200 ° C for 2 days, acceleration vibration 5G forcible vibration deterioration treatment for 1 hour, and moisture absorption treatment at 95% relative humidity for 2 days as the forced deterioration test cycle. The method was to carry out a withstand voltage test of 2000V. In addition, in order to severely evaluate the mechanical strength, the vibration condition was set to 5 G, which is higher than the standard value of 1.5 G, and the residual breakdown voltage was appropriately calculated and displayed on the vertical axis of the figure. Each of the test motors is a general-purpose three-phase induction motor with a constant voltage of 200 V. The stator winding of the automatic inserter type shown in FIG. 1 is used for the stator winding of the maintenance type shown in FIGS. A conventional automatic inserter shown in FIG.
In the comparative example 1, a stator winding having a varnish treatment is omitted, and a stator winding in which the varnish treatment is omitted is referred to as a comparative example 2.

In the figure, Comparative Example 1 retains a residual breakdown voltage of approximately 85% after 16 cycles of the evaluation test, while Comparative Example 2 has a residual breakdown voltage of about 20% in a test of only 2 cycles. The prior art shows that varnishing is an extremely important step in maintaining the mechanical, thermal and electrical performance of the stator winding. On the other hand, Example 1 and Example 2 show a residual breakdown voltage of 90% or more even after the evaluation test of 16 cycles, and even if the stator winding according to the embodiment of the present invention omits the varnish treatment, It has been proved that not only the stability of electrical, thermal and electrical performance but also the moisture resistance performance is superior to the conventional varnished stator winding.

[0025]

As described above, according to the present invention, the slot insulation made of the self-bonding thin leaf material is inserted in advance along the inner wall surface of the slot, and the self-bonding magnet wire is automatically inserted into the inside of the slot insulation. Thus, a coil is formed by winding a plurality of turns, and a wedge made of a self-bonding thin leaf material is inserted so as to close the opening of the slot, and heat fusion processing is performed to integrate the whole. As a result, the self-adhesive adhesive layer that has been made sticky by heating functions as an adhesive that replaces the impregnated varnish, and at the time of heating and curing, the contact parts of each member are firmly bonded by the cured adhesive layer. It is essential for the conventional technology because it is possible to obtain a stator winding with excellent insulation reliability that has a withstand voltage performance, vibration resistance performance, heat resistance performance, and weather resistance that exceed those of conventional stator windings. The varnish processing step and the varnish removing step are unnecessary. Therefore, there is no adverse effect on the working environment, which has been a problem with the conventional technology, and the simplified and time-saving manufacturing process of the automatic inserter method enables the stator winding of the low voltage rotating machine with excellent insulation reliability. The lines can be provided economically advantageously. Furthermore, the advantage of shortening the delivery time can be obtained by reducing the manufacturing time.

A stator coil formed by winding a plurality of turns of a self-adhesive magnet wire and binding them with a binding tape layer made of a self-adhesive thin sheet was inserted in advance along the inner wall surface of the slot. Even if a slot is formed by inserting the self-bonding thin leaf material into the slot insulating layer by a maintenance method and closing the opening of the slot with a wedge made of a laminated material, it is possible to obtain the same effect as the above embodiment. The stator winding of the voltage rotating machine can be easily obtained by the maintenance method.

On the other hand, if the self-fusing thin leaf material is composed of a heat-resistant film base material and a self-fusing adhesive layer fixed to one surface thereof, a thin self-fusing thin leaf material having a two-layer structure. Thus, the slot insulating layer and the binding tape layer can be formed. Further, if the self-fusing adhesive layer is inserted outside into the slot, a strong adhesive layer is formed between the core and the core,
Since the sliding surface made of a smooth heat-resistant film base material is located on the coil side, the winding work of the self-bonding magnet wire by the automatic inserter system can be facilitated.

Also, two heat-resistant film bases having a self-fusing adhesive layer, a self-fusing adhesive layer, and through holes formed by distribution formed by adhering the self-fusing adhesive layer through the self-fusing adhesive layer are provided. If the three-layer structure with the material is used, the exposed area of the self-bonding adhesive layer is reduced and a slot insulating layer and a bundling taping layer with good slipperiness are obtained, and the winding is performed by the automatic inserter method and the care method. The wire work can be facilitated, and since the self-bonding adhesive layer flows out through the through hole to bond the members to each other, an integrated stator winding of the low-voltage rotating machine can be provided. ..

Furthermore, a self-bonding thin sheet material comprising a self-bonding adhesive layer and two heat-resistant film base materials having through holes which are adhered via this self-bonding adhesive layer, A multilayer structure having a self-adhesive adhesive layer formed on the surface of each of the two heat-resistant film base materials having through-holes provides a self-adhesive thin sheet material having excellent insulation reliability and adhesiveness. Therefore, by using the self-bonding thin sheet material configured as described above as a self-bonding wedge that also serves as interlayer insulation, a slot insulating layer, etc., mechanical, thermal, and electrical performance and its environment resistance can be obtained. It is possible to provide a low-voltage rotating machine including a stator winding having excellent reliability and high reliability.

[Brief description of drawings]

FIG. 1 is a sectional view showing a stator coil of an automatic inserter system for a low voltage rotating machine according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a stator coil according to a maintenance method according to another embodiment of the present invention.

FIG. 3 is a sectional view showing the structure of a self-bonding thin leaf material according to the present invention.

FIG. 4 is a cross-sectional view showing the constitution of different self-bonding thin leaf materials according to the present invention.

FIG. 5 is a sectional view showing the structure of a further different self-bonding thin leaf material according to the present invention.

FIG. 6 is a characteristic diagram showing an insulation performance evaluation test result of a test three-phase induction motor according to an example in comparison with that of a conventional motor.

FIG. 7 is a sectional view showing a main part of a stator winding by an automatic inserter method.

[Explanation of symbols] 1 Stator core 1A Slot 1B Slot 2 Slot insulation layer 3 Stator coil 4 Wedge 5 Magnet wire 9 Wedge (laminated material) 12 Slot insulation layer (self-bonding thin leaf material) 13 Stator coil 14 Wedge (Self-adhesive thin leaf material) 15 Self-adhesive magnet wire 22 Binding tape layer (self-adhesive thin leaf material) 23 Stator coil 24 Wedge (self-adhesive thin leaf material) 31 Self-adhesive thin leaf material 32 Heat Resistant Film Base Material 33 Self-Fusing Adhesive Layer 41 Self-Fusing Adhesive Thin Sheet Material 42 Heat-Resistant Film Base Material 43 Self-Fusing Agent Layer 44 Through Hole 51 Self-Fusing Thin Sheet Material 53 Self-Fusing Adhesive Layer

Claims (5)

[Claims] 1. A stator core, wherein a plurality of turns of a magnet wire are wound in slots formed in a stator core at a predetermined pitch to form a stator coil, which is previously inserted along an inner wall surface of the slot. A slot insulating layer made of a self-bonding thin leaf material, a stator coil formed by winding a plurality of self-bonding magnet wires inside the slot insulating layer by an automatic inserter method, and a slot for closing the opening of the slot. A stator winding for a low-voltage rotating machine, comprising a wedge made of a self-bonding thin leaf material inserted therein, and heat-bonded to be integrated as a whole. 2. A stator coil is formed by winding a plurality of turns of a self-adhesive magnet wire and binding them with a binding tape layer made of a self-adhesive thin leaf material. Inserted by a care method inside the slot insulation layer made of the inserted self-bonding thin leaf material,
The stator winding of a low voltage rotating machine according to claim 1, wherein the opening of the slot is formed so as to be closed by a wedge made of a laminated material. 3. The self-fusing thin leaf material comprises a heat-resistant film base material and a self-fusing adhesive layer fixed to one surface thereof. Stator winding for low voltage rotating machines. 4. A heat-resistant film substrate comprising a self-bonding thin leaf material, which has a self-bonding adhesive layer and through holes distributed and formed which are adhered via the self-bonding adhesive layer. The stator winding of the low voltage rotating machine according to claim 1 or 2, wherein the stator winding is made of a material. 5. The self-bonding thin leaf material has a self-bonding adhesive layer formed on the surface of each of the two heat-resistant film base materials having through holes. Stator winding for low voltage rotating machines.