JPH1169687A - Electromagnetic coil and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve insulating performance by arraying a first coil formed by winding an insulated wire to one row of an electromagnetic coil, in which the insulated wires are wound in alignment in vertical two rows, in one row and a second coil formed by winding an insulating tape between vertical rows on the whole circumference or a part of the first coil in the other row. SOLUTION: One drum, in which a wound flat type electric wire 1 is housed, is arranged, the flat type electric wire 1 delivered from the drum is wound gradually on a coil former 3 in specified numbers, and the coil former 3 is disassembled and an approximately oval type coil-shaped first former-wound coil 24 is formed. Tapes 26 are wound and fixed to the rectilinear sections and curve sections of the first former-wound coil 24, and the collapse of the flat type electric wire 1 forming a layer is prevented. An insulating mica tape 20 between vertical rows as an insulating tape between the vertical rows is lap-wound on the whole circumference or a part of the first former-wound coil 24 in the half of tape width, and a second former-wound coil is formed. The first former-wound coil 24 and the second former-wound coil are arranged in vertical two rows, and molded, and manufactured as an hexagonal coil having a specified shape.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electromagnetic coil, and more particularly to an electromagnetic coil having improved insulation between at least two vertically aligned rows and a method of manufacturing the same.

[0002]

2. Description of the Related Art An electromagnetic coil wound in two rows in a row is applied to a rotating machine, a stationary device, and the like. Here, a rotating machine will be described as an example. Conventionally, the electromagnetic coil of a high-voltage motor that uses a rotating electric machine at a high voltage is formed by winding a plurality of rectangular electric wires having their surfaces insulated in parallel in the width direction, or by wrapping the wire a predetermined number of times on a winding die. This is a tortoise-shaped coil formed by forming an electromagnetic coil and forming the mold-wound electromagnetic coil into a tortoiseshell shape using a molding machine.

[0003] There are several types of this tortoise-shaped coil in the manner of arranging rectangular electric wires.
Is shown in The arrangement is broadly divided, and is shown in FIG.
(A), FIG. 7 (b) with two horizontal rows, FIG. 7 with two vertical rows
(C) and the like, and the method of winding a rectangular electric wire around an elliptical winding (not shown) differs depending on the arrangement. FIG.
In (b), two-row winding does not require inter-column insulation,
Since the flat wire 1 is wound in a U-shape, the flat wire 1 must be wound around a coil while displacing the flat wire 1 at a position corresponding to a coil end portion (not shown). It costs. In the two-row vertical winding in FIG.
It is easy to manufacture an elliptical coil, but the voltage applied between adjacent rectangular wires 1 that are side by side increases in order to double the number of turns by connecting the rectangular wires 1 between two columns, and the dielectric strength between the columns is increased. Need to be raised.

FIG. 8 shows a conventional process for manufacturing a tortoise-shaped coil formed by winding two vertical rows. FIG. 8A is a winding state diagram of the rectangular wire 1 formed by the drum 1a and the winding form 3 capable of forming a substantially coiled coil.
a are arranged in parallel, the rectangular electric wire 1 released from each of the drums 1a is wound around the former 3 in parallel for a predetermined number of times, and the former 3 is disassembled and substantially as shown in FIG. A sea-shaped coil 4 is formed. Next, an insulating sheet 5 as shown in FIG.
To temporarily form the coil 4 as shown in FIG. 8 (c). Thereafter, a turtle-shaped coil 7 as shown in FIG.

Then, the winding end line of the coil row (not shown) of the tortoise-shaped coil 7 and the winding start line of the other row are connected, and this portion is insulated to form a two-row vertical winding shown in FIG. Form an electric wire array. Then, for example, a mica tape is wound around the lead wire and the entire circumference of the tortoise-shaped coil 7 for a predetermined number of times, and further, outer layer insulation is performed to form a ground insulating layer. FIG. 9 is a cross-sectional view of the tortoiseshell coil 7 before the formation of the ground insulating layer. After manufacturing a large number of these tortoise-shaped coils 7, these are housed in grooves of a stator iron core (not shown), and after connecting and insulating the lead wires, impregnated with an epoxy resin under vacuum and heat-cured to form an electromagnetic coil of a rotating machine. Is done.

[0006]

In the formation of such a conventional tortoise-shaped coil 7, when the insulating sheet 5 is inserted between the columns after the flat wire 1 is wound on the former 3, the flat wire 1 is displaced. In the case of a thin wire that is easy to work, workability is poor and a long time is required for coil production. Further, since the insulating sheet 5 inserted over the entire length in the lengthwise direction of the substantially coiled coil 4 is long, the coil R portion 8 and the loop portion 9 of the coil 7 have a rectangular shape when the coil 4 is formed into a tortoise-shaped coil 7. Because the wire 1 is twisted,
There is a disadvantage that the long insulating sheet 5 is easily damaged due to deformation and displacement. And the tortoise-shaped coil 7 of a predetermined shape was not formed.

To solve such a problem, Japanese Patent Application Laid-Open No.
No. 2332 describes a method of manufacturing a coil by winding a rectangular wire with element insulation and a flat electric wire without element insulation simultaneously in parallel into a winding form. However, when this method is applied to form an electric wire array of two vertical windings shown in FIG. 7, the rectangular electric wire with element insulation is biased to one side row, so that the rectangular electric wire is wound while being transposed. Then, as described above, it takes a long time to manufacture the coil, and conversely, the dislocation portion is liable to be damaged due to deformation and displacement at the dislocation portion.

Next, the problem of the displacement between the electric wires will be described. FIG. 6 is a cross-sectional view of the loop portion 8 of the tortoise-shaped coil. In the loop portion 8, a large gap is easily formed between the parallel electric wires 1 due to displacement or deformation of the rectangular electric wire 1. In such a case, the large gap is caused by the fact that the resin impregnated in the ground insulating layer also undergoes a viscosity decrease due to temperature characteristics in the process of curing the impregnated resin even when the epoxy resin is impregnated under vacuum pressure, so that the mica tape has a polymerized portion or a mouth. It flows out of the branch and remains as a void. When the insulating layer having the voids is formed, partial discharge occurs in the voids due to intrusion of an overvoltage or a surge, and the inter-column insulation is easily damaged.

Here, in order to prevent the generation of voids, conventionally, as a first method, a semi-cured resin filler containing an inorganic filler is buried between coil insulated wires (Japanese Utility Model Publication No. 64-124).
No. 62). As a second method, there is a method in which a small amount of a curing accelerator which reacts with the impregnated resin in the process of heat curing is put in the adhesive of the mica tape wound on the conductor. In the first method, the gap between the wires due to the corner curvature of the flat wire forming the tortoise-shaped coil is a resin-impregnated intrusion path from the outlet branch portion, and the resin is easily and quickly applied to the ground insulating layer. An important impregnation route for impregnation is filled, and impregnation is impaired. In the second method, when a large gap is formed between the parallel electric wires due to the displacement of the rectangular electric wire, the resin cannot be held only by the catalyst.

[0010] As described above, in the conventional technique, it is not possible to improve the defects caused by the displacement of the insulating sheet and the large voids generated near the insulating sheet. The present invention has been made in view of the above circumstances, eliminates the occurrence of voids that are likely to occur between the columns of the electromagnetic coil and improves the dielectric strength between the columns,
An object of the present invention is to provide an electromagnetic coil having improved insulation performance and a method for manufacturing the same.

[0011]

An electromagnetic coil according to the present invention is an electromagnetic coil formed by winding an insulated wire in at least two rows in a row, insulating between the columns and performing resin impregnation insulation treatment. A first coil formed by winding an insulated wire and a second coil formed by winding an inter-column insulating tape around the entire circumference or a part of the first coil are arranged in the other row. According to such an electromagnetic coil, the coil with the inter-column insulating tape has a small tape thickness and does not shift even when being formed into a predetermined shape. Insulation performance can be secured. Further, when the rotating electric machine is used, the flat electric wires at the coil end portion do not spread. Since the tape can be wound by a machine, the insulating operation can be performed in a short time and the coil can be manufactured at a low cost. Alternatively, in the case of the tortoiseshell coil used in the rotating electric machine, the short-time AC breakdown voltage of the vertical interlayer insulation of the voltage class of 3 kV is increased to 1.4 times the breakdown voltage as compared with the related art.

[0012] In the second aspect, the inter-column insulating tape is an electromagnetic coil formed by adhering a film and a non-woven fabric to the mica paper, and the use of the non-woven fabric shortens the resin impregnation in the resin impregnating insulation process.

According to a third aspect of the present invention, the inter-column insulating tape is wrapped around a half of the tape width. Since the inter-column insulating mica tape is a tape narrower than the conventional long insulating sheet, the tape is narrow due to the coil deformation at the R part and the loop part when forming the second coil into a turtle-shaped coil. With a small amount of movement, the tape can be followed, and the tape is not displaced with the synergistic action of lap winding at 1/2 of the tape width. Insulation performance can be secured.

According to a fourth aspect of the present invention, the inter-column insulating tape is formed of a first tape in which a film is attached to mica paper and a second tape in which a nonwoven fabric or a glass substrate is attached to mica paper. The first tape and the second tape are wound by a double winding method. Then, it becomes easy to impregnate the thermosetting resin in the varnish impregnation process after storing the tortoise-shaped coil in the stator slot, and it is possible to use an inexpensive material. In other words, if the mica tape between columns is used as a film-based mica tape, the price will be low, but there will be almost no gaps between the tapes when the tape is wound and there will be almost no gap between the tapes. Can be solved by this configuration.

According to a fifth aspect of the present invention, the first coil and the second coil are connected to a power source side by a stator core of a rotating electric machine.
An electromagnetic coil which is housed in the pole electromagnetic coil storage slot, and in the other pole slot, a coil formed by aligning and winding only the first coil in two vertical rows. Then, when a high surge voltage from the power supply is applied, the high voltage applied between the columns can be protected with the insulated mica tape between columns, and other coils do not need to be wound around the tape, which lowers the price of the entire device. .

According to a sixth aspect of the present invention, there is provided a method of manufacturing an electromagnetic coil in which insulated wires are formed by winding at least two rows in a row and insulating between the columns and formed by resin-impregnated insulation treatment. A first coil having a predetermined shape is formed by molding and processing the first coil wound by winding, and a second coil wound by forming an inter-column insulating tape around the entire circumference or a part of the first coil. Forming a second coil having substantially the same shape as the first coil, and arranging the first coil and the second coil in two vertical rows and performing resin impregnation and insulation treatment. It is a manufacturing method of.
According to such a manufacturing method, the same operation and effect as described in claim 1 can be obtained.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG.
3 to FIG. 3, the same components as those of the related art will be described using the same reference numerals. Examples of the application of an electromagnetic coil wound in two rows in a vertical direction are, as in the prior art, a plurality of rectangular wires insulated on the surface used for a high-voltage electric motor of a rotating electric machine in parallel in the width direction or a single wire. Are wound in a predetermined number of times to form a mold-wound coil, and this mold-wound coil is formed into a turtle-shape coil by a molding machine.

FIG. 1 shows a process of manufacturing a tortoise-shaped coil by single-row winding in a first embodiment of the present invention. FIG. 1 (a)
Is a winding form 3 on which a drum 1a and a substantially oval shaped coil can be formed.
In the winding state diagram of the rectangular electric wire 1 according to the above, one drum 1a accommodating the wound rectangular electric wire 1 is arranged, and the rectangular electric wire 1 released from the drum 1a is wound around the former 3 a predetermined number of times. Then, the winding form 3 is dismantled to form a first type winding coil 24 having a substantially oval coil shape as shown in FIG. next,
The tape 2 is applied to the linear portion and the curved portion of the first type winding coil 24.
6 is wound and fixed to prevent the flat rectangular electric wire 1 on which the layers are formed from collapsing. Subsequently, as shown in FIG. 1 (c), an inter-column insulating mica tape 20, which is an inter-column insulating tape described later, is applied to the entire circumference of the first type wound coil 24 or a part thereof, and the half of the tape width.
To form a second-type wound coil 24a.

The inter-column insulating mica tape 20 is a film mica tape attached to a non-woven fabric, and the structure thereof is as shown in FIG.
And the thickness of the tape to which the nonwoven fabric 12 is attached is 0.05 to 0.1
mm. The film 11 is made of, for example, polyester, P having a thickness of 0.025 to 0.05 mm.
It is made of a material such as PS or PEN. The non-woven fabric 12 is preferably in the form of a felt in which fibers are entangled.
It is made of a material such as polyester or aromatic polyamide fiber weighing 15-80 g / m and weighing 15-80 g / m.

Next, the first type coil 24 and the second type coil 24a are arranged in two vertical rows, and are molded to produce a tortoise-shaped coil 22 having a predetermined shape. Then, the first pattern wound coil 24 becomes the first coil 34 (substantially the same shape as in FIG. 1D without winding 20 tapes), and the second pattern wound coil 24a becomes the second coil 3.
4a (FIG. 1D). The sectional shape of the tortoiseshell coil 22 is as shown in FIG. And the turtle-shaped coil 22
Is stored in a slot of a stator (not shown). continue,
A winding end line of a coil row (not shown) of the tortoise-shaped coil 22 and a winding start line of the other row are connected to insulate this portion to form a conventional two-row winding wire arrangement shown in FIG. Subsequent work is the same as in the related art.

The second coil 34a thus formed
Is a tape 20 because the wound inter-column insulating mica tape 20 on the surface is as thin as about 0.05 to 0.1 mm.
The thickness is almost the same as that of the unwound first coil 34. Since the inter-column insulating mica tape 20 is a tape having a width smaller than that of the conventional long insulating sheet 5, the R m when forming the second coil 34 a into a tortoise-shaped coil is reduced.
Since the tape 20 has a small width, it can follow the coil deformation in the section 8 and the loop section 9 with a small movement amount, and can be reliably moved without a displacement by a half of the tape width with a synergistic effect of lap winding. In each of the layers, the inter-column insulating mica tape 20 exists between any layers, so that stable inter-column insulating performance can be ensured. Further, the rectangular electric wires 1 having the layer located at the coil end portion do not spread, and do not become voids after resin impregnation. The tape 20 is made of the nonwoven fabric 12
The resin can be impregnated in a short time by the resin impregnation process. Since the winding of the tape 20 can be performed by a machine, the insulating operation can be performed in a short time, and the coil can be manufactured at low cost. This turtle-shaped coil 2
With respect to No. 2, the result of obtaining the short-time AC breakdown voltage of the vertical interlayer insulation of the voltage class of 3 kV shows that the breakdown voltage is 1.4 times higher than that of the related art as shown in FIG.

(Other Embodiments) In the first embodiment, a method of manufacturing a tortoise-shaped coil by winding one row in a vertical direction has been described. However, a rectangular wire 1 is arranged in two rows to form a substantially oval-shaped coil. May be separated into a vertical method, and a second coil 34a may be formed by winding the inter-column insulating mica tape 20 on one of the substantially oval shaped coils, and the other may be used as the first coil 34 to form a tortoiseshell coil. (Shown in FIG. 4).

As shown in FIG. 6, an insulating tape between columns is attached to the surface of the mold-wound coil, a first tape 14 in which a film is attached to mica paper, and a nonwoven fabric or a glass substrate is attached to mica paper. The first tape 14 and the second tape 15 are formed with a second tape 15 and are wound in a two-roll method. Then, it becomes easy to impregnate the thermosetting resin in the varnish impregnation process after storing the tortoise-shaped coil in the stator slot, and it is possible to use an inexpensive material.
In other words, if the inter-column insulating mica tape 20 is a mica tape of a film base, the price is low, but there is almost no gap between the overlapped tapes when the tape is wound, and the impregnating property of the resin is poor, and the impregnation is long. Time can be solved by the above method.

Further, in a rotating electrical machine in which a two-row winding and a tortoise-shaped coil having inter-row insulation are housed, the number of turns is doubled by connecting the wires between the two rows, so that a high surge from the power source is obtained. Insulation between columns is provided for high surge voltage between columns when voltage is applied. In this case, a high surge voltage is applied to several coils of one pole connected to the power supply, and a large surge voltage is not applied to other poles. Accordingly, only the first pole of the coil connected to the power supply side has the inter-column insulating mica tape 20.
Is wound. Then, when a high surge voltage from the power supply is applied, the high voltage applied between the columns is reduced to the insulated mica tape 2 between columns.
0, and the other coil does not need to be wound with 20 tapes, so that the price of the entire device is reduced.

[0025]

As described above, according to the electromagnetic coil of the present invention, the coil with the inter-column insulating tape has a small tape thickness and does not shift even when it is formed into a predetermined shape. The presence of the tape ensures a stable inter-column insulation performance. Further, when used in a rotating electric machine, the flat rectangular wires at the coil end do not spread. Furthermore, since the tape is made of a nonwoven fabric, the resin can be impregnated in a short time by the resin impregnation process. Since the tape can be wound by a machine, the insulating operation can be performed in a short time and the coil can be manufactured at a low cost. Alternatively, for a turtle-shaped coil used in a rotating electric machine, the voltage class 3
The short-time AC breakdown voltage of the vertical interlayer insulation of kV is increased by 1.4 times as compared with the conventional case.

[Brief description of the drawings]

FIG. 1 is a manufacturing process diagram of an electromagnetic coil showing one embodiment of the present invention;

FIG. 2 is a partial longitudinal sectional view of an electromagnetic coil;

FIG. 3 is a short-time AC breakdown voltage diagram between columns of electromagnetic coils,

FIG. 4 is a diagram corresponding to FIG. 1 showing a second embodiment,

FIG. 5 is a cross-sectional view of the inter-column insulating tape of the present invention;

FIG. 6 is a diagram corresponding to FIG. 1 showing a third embodiment,

FIG. 7 is a diagram showing a type of electric wire arrangement of an electromagnetic coil;

FIG. 8 is a diagram corresponding to FIG.

FIG. 9 is a diagram corresponding to FIG. 2 of the related art.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Flat wire, 3 ... winding type, 11 ... Film, 12 ... Nonwoven fabric, 13 ... Mica paper, 14 ... 1st tape, 15 ... 2nd tape, 20 ... Insulating tape between columns (insulating mica tape between columns), 22: Tortoiseshell coil, 24: First-type wound coil, 24a: Second-type wound coil, 34: First coil, 34a: Second coil.

Claims (6)

[Claims] 1. An electromagnetic coil formed by winding an insulated wire in at least two rows in an insulated manner and insulating between the columns and resin-impregnated insulation treatment, wherein one row includes a first coil formed by winding the insulated wire. An electromagnetic coil, wherein a second coil formed by winding an inter-column insulating tape around the entire circumference or a part of the first coil is arranged in the other row. 2. The electromagnetic coil according to claim 1, wherein the inter-column insulating tape is formed by adhering a film and a nonwoven fabric to mica paper. 3. The method of claim 1, wherein the inter-column insulating tape is one-third of the tape width.
3. The electromagnetic coil according to claim 1, wherein the electromagnetic coil is wound twice. 4. The inter-column insulating tape is formed of a first tape in which a film is attached to mica paper laminated, and a second tape in which a nonwoven fabric or a glass substrate is adhered to mica paper laminated. 2. The electromagnetic coil according to claim 1, wherein the second tape is wound in a two-roll winding system. 5. The first coil and the second coil are housed in an electromagnetic coil housing slot for the nearest one pole on the power supply side by a stator core of a rotating electric machine, and only the first coil is housed in the other pole slots. The electromagnetic coil according to claim 1, wherein a coil formed by winding in two vertical rows is housed. 6. A method of manufacturing an electromagnetic coil in which insulated wires are formed by arranging and winding insulated wires in at least two vertical rows, insulating between the columns, and performing resin impregnation and insulation treatment. A first coil having a predetermined shape is formed by forming a first coil and a second coil formed by winding an inter-column insulating tape around the entire circumference or a part of the first coil. To form a second coil having substantially the same shape as the first coil.
A method for producing an electromagnetic coil, comprising: arranging a resin in a row and performing resin impregnation insulation treatment.