WO2019148799A1 - 利用填充液体填充电枢的工艺装备和方法 - Google Patents

利用填充液体填充电枢的工艺装备和方法 Download PDF

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Publication number
WO2019148799A1
WO2019148799A1 PCT/CN2018/100453 CN2018100453W WO2019148799A1 WO 2019148799 A1 WO2019148799 A1 WO 2019148799A1 CN 2018100453 W CN2018100453 W CN 2018100453W WO 2019148799 A1 WO2019148799 A1 WO 2019148799A1
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Prior art keywords
armature
filling
positive pressure
gap
liquid
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PCT/CN2018/100453
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English (en)
French (fr)
Inventor
马盛骏
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北京金风科创风电设备有限公司
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Publication of WO2019148799A1 publication Critical patent/WO2019148799A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines

Definitions

  • the present disclosure is in the field of component liquid infiltration, and more particularly, the present invention relates to a process equipment and method for filling a liquid filled armature.
  • a wind turbine is a large-scale power generation device that converts wind energy into electrical energy.
  • the motor is a core component of the wind turbine, including a rotor and a stator, and the stator includes a stator core and windings wound around the stator core.
  • the armature 100 includes a stator core 10 and a winding 20, and a winding slot 11 is disposed on the stator core 10, and the winding 20 is embedded in the winding slot 11 and installed in the slot of the winding slot 11.
  • the wedge 30 is used to secure the winding 20 within the winding slot 11.
  • the wind turbine Since the wind turbine is placed outdoors, subjected to wind and rain, moisture and moisture can enter the stator and rotor of the generator, causing the stator core and windings to be corroded and damaged. In particular, wind turbines installed at sea are more susceptible to salt and fog.
  • the insulating film of the winding and the insulating layer such as the slot insulation in the core slot are abraded by electromagnetic vibration and mechanical vibration, and are also subjected to heat and aging. Therefore, in order to ensure the insulation performance of the stator winding, it is also necessary to encapsulate the winding and its adjacent components with an insulating resin to form a tight and firm whole.
  • the anti-corrosion treatment and the insulation treatment of the various components of the motor, especially the stator windings, are particularly critical.
  • the stator winding is usually immersed, and the pores in the stator winding are filled with a filling material such as insulating varnish or insulating glue. Dipping treatment is a common immersion treatment method for insulating the stator winding of the motor.
  • the traditional vacuum pressure varnish (VPI) process is carried out in a vacuum thermodynamic environment.
  • the varnish cannot completely wet the gap between the winding and the core, or between the core laminations.
  • Space, in these locations usually have holes or pores, and can not be completely wetted by the insulating varnish, so that the insulation treatment of the motor can not completely cover all the gap space, which has hidden dangers to the insulation of the motor.
  • the notch portion it is difficult to form a strict sealing ring on the outer circumference of the wedge, which creates a gap between the wedge and the core slot silicon wafer. The moisture and water naturally enter the groove along the debonding gap to break the insulation, which is a wind turbine. The operation brings security risks.
  • the purpose of the present disclosure is to provide a process equipment and method for filling a liquid flooding impregnated infiltrating armature, which, under the action of positive pressure, causes the filling liquid to enter the gap between the winding and the core, so that the backward liquid displaces the first incoming liquid, and makes the entry
  • the filling liquid in the gap displaces the gas originally in the gap, so that the filling liquid completely fills the gap.
  • the present disclosure provides a process equipment for filling an armature with a liquid, comprising: a casing for supporting an armature; a liquid filling device for supplying a pressurized liquid; a positive pressure filling device forming a positive pressure filling chamber between a surface having a slit opening of the armature, the positive pressure filling chamber being capable of receiving a filling liquid from the filling liquid supply device, and allowing the filling liquid to Under the action of positive pressure, it flows into the gap in the armature body of the armature through the slit.
  • a method of filling an armature with a filling liquid comprising: causing a filling liquid to permeate into a gap of an armature body of the armature under a positive pressure, wherein The filling liquid penetrates through the gap between the wedge and the core on the armature body and displaces the gas in the slit, so that the gas is driven away through the axial slit of the armature.
  • the process equipment and method provided by the embodiments of the present disclosure pass through the rotor or stator surface (convex or concave) of the motor to face the winding end between the various tissue parts (iron core) and the air interface area, the wedge and the core
  • a sealing protection system is constructed between the seepage gap and the air junction area to overcome the surface of the gas-liquid two-phase infiltrated core wedge by the insulating paint under the traditional vacuum state.
  • the dual function of liquid displacement liquid and liquid displacement gas is realized by means of seepage mechanics.
  • the traditional vacuum pressure impregnation process (ie, VPI) gas residue is solved, thereby completely eliminating voids in all gaps in the armature, preventing subsequent breathing phenomena, improving insulation strength, and making oxygen, moisture and water in the air. It is not easy to invade the inside of the slot insulation, which can delay the aging process of the insulation system, reduce the risk of the motor being exposed to moisture and water, and improve the insulation reliability of the motor.
  • Figure 1 is a partial schematic view of an armature of a wind power generator set
  • FIG. 2 is a perspective view showing an enlarged structure of a winding and an iron core of an armature of a wind power generator
  • Figure 3 is a partial cross-sectional view of a winding slot of an armature of a wind power generator
  • FIG. 4 is a schematic view of an armature in accordance with an embodiment of the present disclosure.
  • Figure 5 is a simplified schematic view of one tooth of the core of the armature shown in Figure 4.
  • Figure 6 is a partial cross-sectional view of a winding slot of the armature shown in Figure 4;
  • FIG. 7 is a schematic structural view of a process equipment for filling a liquid displacement impregnated infiltrating armature according to an embodiment of the present disclosure
  • Figure 8 is a top plan view of the process equipment shown in Figure 7;
  • FIG. 9 is a schematic diagram of an excitation device in accordance with an embodiment of the present disclosure.
  • FIG. 10 is a schematic structural view of a process equipment for filling a liquid flooded impregnated infiltrating armature according to another embodiment of the present disclosure
  • FIG. 11 is a schematic structural view of a process equipment for filling a liquid displacement impregnated infiltrating armature according to another embodiment of the present disclosure.
  • a motor armature (hereinafter referred to as an armature) 100 in a state to be immersed in paint according to an embodiment of the present disclosure is illustrated.
  • the motor to which the armature 100 is applied may be an inner stator outer rotor structure, that is, the stator is located radially inward of the rotor, including the stator core 10 and the winding 20, and the stator core 10 is provided with a winding slot 11 and a winding 20
  • the winding groove 11 is embedded in the winding groove 11, and the groove 30 is mounted in the notch of the winding groove 11 to fix the winding 20 in the winding groove 11.
  • the stator core 10 includes a plurality of teeth 12 as a radially outer surface, the winding groove 11 is opened between two adjacent teeth 12, and the wedge 30 is also mounted on two adjacent teeth. Between the 12th.
  • the winding slot 11 extends from one armature end to the other armature end along the stator axis, so that the winding slots 11 are formed through the two axial end faces of the stator.
  • the axial passage of the stator In the case where the winding 20 is mounted in the winding groove 11 and the wedge is installed in the slot, since the winding 20 cannot completely fill the winding groove 11, the winding 20 and the winding groove 11 and the wedge are formed in a large amount.
  • the slit, and at both ends of the stator core 10, the slit in the winding groove 11 communicates with the outside through the axial end opening of the winding groove 11.
  • the axial gap formed in the stator can extend axially from one armature end of the armature 100 to the other armature end.
  • the opening of the slit formed in the winding groove at the axial end of the stator is referred to as an axial slit opening 14.
  • the axial gap opening 14 described herein may include all gap openings between the core 10, the wedge 30 and the winding 20 at the end face of the armature 100, that is, as long as the gas and/or insulating varnish can be passed through
  • the slit opening from which the slit port flows out from the end face of the armature 100 may be referred to as an axial slit port 14.
  • a seepage slit 13 between the wedge 30 and the inner wall of the groove of the winding groove 11 of the stator core, hereinafter referred to as a seepage slit 13.
  • the seepage slit 13 extends in the axial direction and communicates with the outside through the axial slit opening 14.
  • the seepage slit 13 can extend inward at an angle with respect to the radial direction. When the angle is relatively small, the seepage slit 13 can be Extending generally in the radial direction, or may be referred to as a radial gap.
  • gaps 13, 18 and 17 between the winding 20 and the winding slots 11 of the stator core 10 there are also gaps 15 between the individual core laminations 16 of the stator core 10, as shown in FIG.
  • These slits 15 are all in communication with the slits 13, 18 and 17 described above.
  • the slits 13, 15, 18, and 17 described above are various, multi-layered structure slits, and the materials constituting each slit and their respective shapes are different.
  • the armature 100 can be generally divided into an armature body 23 and two armature ends 21 and 22, and the windings at the two armature ends 21 and 22 can be referred to as winding noses.
  • the armature 100 can be axially vertical and axially horizontal when the armature 100 is subjected to a dip coating process using a filling liquid (for example, an insulating varnish or a liquid insulating medium or the like, for convenience of description, hereinafter, using an insulating varnish).
  • a filling liquid for example, an insulating varnish or a liquid insulating medium or the like, for convenience of description, hereinafter, using an insulating varnish.
  • the liquid filled flooding process equipment 200 provided by the embodiments of the present disclosure is placed and supported in any direction or in any direction.
  • FIG. 7 there is shown a schematic structural view of a process equipment 200 for filling a liquid flooded impregnated infiltrating armature or a working state diagram of a process equipment 200, for ease of showing the process equipment 200, in accordance with an embodiment of the present disclosure.
  • the armature 100 is shown only in simplified form.
  • the process equipment 200 can include a housing 210, a fill liquid supply 220, and a positive pressure fill 240.
  • the positive pressure mentioned here is relative to the negative pressure, and the positive pressure means that the pressure inside the container is greater than the normal pressure.
  • the filling liquid as long as the pressure is greater than the ambient pressure, it can seep into the gap in the armature 100 under the pressure difference. The greater the pressure, the greater the seepage force, and the easier it is to impregnate the gap in the armature 100.
  • the housing 210 is located at the outermost periphery, and its outer contour may be substantially cylindrical, and the armature 100 is placed inside the housing 210.
  • the housing 210 may be made of a high-strength material to ensure that its strength is high enough to withstand excessive pressure, and may also be provided with a heat insulating layer to prevent heat inside the housing 100 from being leaked, thereby substantially Form a sealed high pressure environment.
  • the filling liquid supply device 220 is used to produce a pressurized insulating varnish, and such insulating varnish can be delivered into the housing 210 to perform a dip coating operation on the armature 100.
  • an insulating varnish having good viscosity and fluidity can be prepared in advance, and when the ambient temperature is too low, the insulating varnish can be appropriately heated.
  • the insulating varnish has good fluidity for subsequent impregnation and wetting.
  • the fill liquid supply device 220 may generally include a heater (not shown) that performs a heating operation, a compressor (not shown) that performs a pressurization operation, and a pump 221 that pumps the varnish.
  • the heater, compressor and pump 221 can be connected in series via a conduit, and the pump 221 can also deliver high pressure insulating varnish to the housing 210 via a conduit.
  • the positive pressure filling device 240 may be disposed in the housing 210, and is internally provided with a positive pressure chamber 242, which may be substantially at the periphery of the armature body 23, capable of receiving insulating varnish from the filling liquid supply device 220. And the high pressure of the insulating varnish in the positive pressure chamber 242 is applied to the respective slits on the armature main body 23 under the positive pressure applied radially by the armature main body 23, and the multiple tissues are infiltrated while driving The gas in these gaps causes the gas to be driven out of the armature 100 along the axial gap opening 14.
  • the armature 100 is substantially under a certain degree of vacuum to extract the gas in the gap of the porous medium as much as possible.
  • the positive pressure filling device 240 may include a positive pressure closed cylinder 241, which may include a vertical annular outer cylinder and upper and lower annular partitions connected to the outer cylinder The plates 243 and 244, such that the positive pressure closed cylinder 241, together with the radial surface of the armature body 23, form a closed and annular positive pressure chamber 242.
  • the outer cylinder body can be a part of the housing 210, has high structural strength and has a certain thermal insulation capability.
  • the partition plates 243 and 244 may be aligned with the end faces of the armature ends 21 and 22 of the armature 100 such that the entire radially outer surface of the stator core 10 is in the positive pressure chamber 242 so that the insulating paint can be sufficiently contacted
  • the armature body 23 completely infiltrates the armature body 23 while the two winding noses of the armature 100 are outside of the positive pressure chamber 242.
  • the pump 221 can deliver the high temperature and high pressure insulating varnish into the positive pressure chamber 242 such that the positive pressure chamber 242 has a certain pressure or the pressure therein is higher than a predetermined value, so that the positive pressure chamber 242 is at a high temperature and a high pressure.
  • the environment is thus effective to apply a radial positive pressure to the armature body 23.
  • the pump 221 may be disposed in plurality, distributed in a plurality of circumferential positions of the armature main body 23 or at a plurality of upper and lower positions, thereby further shortening the insulating paint conveying time and saving.
  • the dip coating process takes time.
  • a plurality of diverting ducts may be provided so that the pressure in the positive pressure chamber 242 can be substantially equalized in the case where only one pump 221 is used.
  • the positive pressure chamber 242 can apply a radial positive pressure to the armature body 23, and since the pressure within the positive pressure chamber 242 is high, the value of the positive pressure is also relatively high.
  • the insulating varnish can be infiltrated inwardly into the slits 18 and 17 in the armature body 23 through the seepage slit 13 under the action of the positive pressure, and can also seep into the gap 15 between the core laminations 16.
  • the infiltrated insulating varnish drives the infiltrated insulating varnish to continue to diffuse inwardly, thereby continuously driving the insulating varnish to ooze inward, and the insulating varnish will displace the gas originally occupying each of the slits 13, 15, 17, and 18, Alternatively, the infiltration of the insulating varnish will drive off the gas, and the driven gas will flow out of the armature body 23 through the axial slit ports 14 at the upper and lower armature ends 21 and 22 of the armature 100, thereby finally insulating.
  • the lacquer completely occupies each slit in the armature main body 23, and completely fills the gap, and impregnates and wets various surfaces in the slit.
  • the solid insulating layer around the winding can be fully wetted to avoid residual gas in the gap and cause voids. Or the generation of pores, and then establish a complete sealing protection system between the wedge and the iron core and the air interface area, improve the filling rate of the insulating paint, realize the comprehensive insulation treatment of the armature, delay the corrosion aging process of the motor, and improve the motor. The service life.
  • the insulating paint is always under high pressure throughout the immersion infiltration process, and the insulating paint has no chance or possibility.
  • the gasification phenomenon occurs, so that the single-phase state or the non-phase-change state can be effectively maintained, thereby completely avoiding the problem of phase change of the insulating paint in the conventional dipping process and the damage of the two-phase flow caused by the problem (including generation) Additional gas remains in the various gaps of the armature 100, preventing the formation of voids or bubbles in the various, multi-layered tissue gaps.
  • the respective slits of the insulating varnish flowing into the armature 100 may start to infiltrate with the seepage slit 13 between the wedge 30 and the winding groove 11 as an inlet, or may infiltrate directly from the slit 15 between the core laminations 15, once When the insulating varnish penetrates into the gap, it can diffuse in the gap, including infiltration into the depth of the gap, seepage in the up and down direction or seepage in other directions, while displace the gas in the gap until it completely occupies all the gaps.
  • the positive pressure filling device 240 may further include a plurality of core holding pieces 245 which are disposed in one-to-one correspondence with the core tooth portions 12, and one core holding piece 245 is clamped from the outside.
  • a core tooth portion 12 completely blocks the radially outer surface of the core tooth portion 12, that is, blocks the gap 15 at the core tooth portion 12, and reserves a one-to-one correspondence with the groove wedge 30 region.
  • the radial flow passage is such that during the wetting process, the insulating varnish around the radial direction of the armature body 23 can only ooze inwardly from the seepage slit 13 between the wedge 30 and the winding groove 11 through the radial flow passage, where
  • the "radial direction" may be substantially in the radial direction, and the flow direction within a certain angular range at the relative radial direction may be referred to as radial flow.
  • diffusion flow begins, and diffusion also flows into the gap 15 between the core laminations. In this way, it is possible to prevent the insulating varnish that has penetrated into the slit from flowing out again through the slit 15, and also to ensure uniform distribution and wetting of the insulating varnish in the respective slits 13, 15, 17, and 18.
  • the core holding piece 245 can be tightened at both ends to be closely fitted to the radially outer surfaces of the respective core teeth 12 for reliable sealing.
  • gases displaced or driven out of the respective slits may flow outward through the axial slit ports 14 at the armature ends 21 and 22, and a portion of the insulating varnish may also be from the axial gap.
  • the mouth 14 leaks out, either during the dipping process or after driving off all the gases.
  • the process equipment 200 provided by the present disclosure may further include a recovery device 260 to recover the displaced gas and the leaked insulating varnish.
  • the recovery device 260 can be disposed at the armature ends 21 and 22.
  • the recovery unit 260 can include a recovery closure cylinder that can form a closed annular recovery chamber 264 with the end faces of the armature ends 21 and 22, and a gas converging fluid that is driven away by the insulating paint.
  • a recovery closure cylinder that can form a closed annular recovery chamber 264 with the end faces of the armature ends 21 and 22, and a gas converging fluid that is driven away by the insulating paint.
  • Recycling a portion of the closed barrel can be accomplished by the housing 210.
  • the above-mentioned partition plates 243 and 244 may be respectively used as a part of the upper and lower recovery closed cylinders.
  • the two recovery closed cylinders may further comprise vertically disposed and cylindrical partitioning cylinders 261 and 262, respectively. Both the cylinders 261 and 262 are mounted radially inward of the axial slit opening 14.
  • the recovery unit 260 may further include a gas-liquid separator 263 through which the gas and the insulating varnish recovered into the recovery chamber 264 are sent to the gas-liquid separator 263 for gas-liquid separation for recycling.
  • the recovery device 260 may also include various aftertreatment devices such as an adsorption tower.
  • the process equipment provided by the embodiments of the present disclosure may further include an excitation device 280, as shown in FIG.
  • the insulating varnish In order to induce the vibration of the winding of the armature, in conjunction with the positive pressure of the positive pressure filling device 240, the insulating varnish completely fills the gaps, further improving the fullness and filling rate of the insulating varnish.
  • the excitation device 280 can be disposed at two ends of the two armature ends 21 and 22, and induce the vibration of the winding noses at both ends, thereby vibrating all the windings, accelerating the infiltration of the insulating varnish, and promoting the insulation in the gap. The diffusion of flow and insulating varnish and assists the insulating paint to displace the gas while allowing the gas to be driven away more quickly.
  • Each of the excitation devices 280 can include an exciter 281 as a vibration generator.
  • the exciter 281 can be an electromagnetic vortex generator or an ultrasonic vibration generator.
  • the excitation device 280 can also include an annular support plate 283 disposed at the respective armature end, the annular support plate 283 can be in contact with the winding nose and can preferably be disposed at an axially outer side of the winding nose for excitation
  • the vibration generated by the 281 can be transmitted to the annular support plate 283 via the elastic energy storage element 282, causing the annular support plate 283 and the winding 20 to vibrate together at a certain frequency.
  • the winding 20 vibrates, there is a possibility that the axial direction will cause the axial position to change.
  • the annular support plate 283 can also be used as a limiting plate, on the one hand, can transmit vibration to the winding, and can also prevent the winding.
  • the axial sway maintains its axial position, and is particularly suitable for situations where the armature 100 is placed vertically within the housing 210.
  • the frequency of the electromagnetic wave generated by the electromagnetic vortex generator can be adjusted to adjust the winding.
  • the immersion infiltration operation is performed adaptively with the vibration frequency and amplitude.
  • various internal temperature and pressure sensors disposed within the positive pressure chamber 242 can also be used to detect the internal immersion condition in real time to control the immersion in real time based on the current varnish infiltration state. The temperature and pressure within the positive pressure chamber 242 are adjusted.
  • a process apparatus 300 for filling a liquid flooded impregnated infiltrating armature will now be described in detail with reference to FIG.
  • components of the process equipment 300 that are identical or similar to the process equipment 200 are denoted by the same reference numerals, and for the sake of brevity, the same components of the process equipment 300 as the process equipment 200 will not be repeated. description.
  • FIG. 10 a job state diagram of the process equipment 300 is shown.
  • the motor to which the armature 100 is applied is also an inner stator outer rotor structure.
  • Process equipment 300 may also generally include a housing 210, a fill liquid supply 220, and a positive pressure fill 340.
  • the armature 100 can be placed within the housing 210 generally axially vertically or axially horizontally or in any direction.
  • the positive pressure filling device 340 may include a positive pressure closed cylinder 341, and the positive pressure chamber 342 inside the positive pressure closed cylinder 341 may be an outer cylinder, a partition plate 243, an armature main body 23, an armature.
  • the end portion 21 and the dividing cylinder 262 are sealed, that is, the outer surface of the armature main body 23 and the lower armature end portion 21 are in the positive pressure chamber 342 to be subjected to a positive pressure.
  • the axial slot opening 14 of the armature end 21 can be within the positive pressure chamber 342.
  • the insulating varnish can penetrate not only from the seepage slit 13 in the armature main body 23 into the respective slits but also from the axial slit opening 14 at the armature end portion 21 located below.
  • the driven gas can rise upward within the gap and be driven away through the axial slit opening 14 at the upper armature end 22.
  • the recovery device 360 of the process equipment 300 may be provided with only one, which is located above the armature end 22. Similarly, the recovery device 360 can include a recovery chamber 364 that can be enclosed by the end faces of the divider plate 243, the divider barrel 261, and the armature end 22.
  • the process equipment 300 can also be provided with the above-mentioned excitation device 280 and core holding piece 245, which will not be described herein.
  • the armature end 22 can be placed in the positive pressure chamber 342 with the armature end 22 outside the positive pressure chamber 342.
  • the recovery device 360 can be disposed below the armature end 21.
  • a process equipment 400 for filling a liquid flooded impregnated infiltrated armature in accordance with another embodiment of the present disclosure will now be described in detail with reference to FIG.
  • components of the process equipment 400 that are identical or similar to the process equipment 200, 300 are denoted by the same reference numerals, and for the purpose of brevity of description, the same for the process equipment 400, the process equipment 200, 300 The parts will not be described repeatedly.
  • the motor to which the armature 100 is applied is an outer stator inner rotor structure, that is, the stator is radially outward of the rotor, and the winding groove 11 and the wedge 30 are disposed on the radially inner surface of the armature body 23. Therefore, the surface to be insulated is a radially inner surface.
  • Process equipment 400 can likewise include a housing 410, a fill liquid supply 420, and a positive pressure fill 440.
  • the armature 100 can be supported by the housing 410 generally axially vertically or axially horizontally or in any direction.
  • the housing 410 and the positive pressure filling device 440 are both disposed in the inner cavity of the armature 100, and the positive pressure chamber 442 is located radially inward of the armature main body 23, and other specific structures are similar. I will not repeat them here.
  • the positive pressure chamber 442 may take the form of the positive pressure chamber 242 in the above embodiment, that is, the positive pressure chamber 442 applies only a positive pressure to the radially inner surface of the armature body 23.
  • the insulating varnish penetrates into the respective slits in the armature 100 from the seepage slit 13 between the wedge 30 and the winding groove 11.
  • the positive pressure chamber 442 may also take the form of the positive pressure chamber 342 in the above embodiment, that is, the positive pressure chamber 442 applies to the radially inner surface of the armature body 23 and the end surface of one armature end portion 21.
  • the positive pressure acts such that the insulating varnish can penetrate into the respective slits in the armature 100 from the seepage slit 13 between the wedge 30 and the winding groove 11 and the axial slit opening 14 at the armature end 21.
  • the arrangement of the two positive pressure chambers 442 is similar to the above, and will not be described herein.
  • a method of filling a liquid flooding intrusion armature which utilizes positive pressure action to drive the insulating varnish into the armature based on engineering thermodynamics, fluid mechanics, mass transfer and multiphase flow principles.
  • the space inside the casing 210 can be evacuated before the insulating varnish is conveyed into the positive pressure chamber 242, so that the armature 100 is substantially under a certain degree of vacuum, and the residue is reduced as much as possible.
  • the gas in the gap in the armature is delivered into the positive pressure chamber 242 such that the high pressure and high pressure state is reached within the positive pressure chamber 242.
  • the positive pressure exerted on the armature surface by the high temperature and high pressure environment in the positive pressure chamber 242 causes the insulating varnish to seep into the gap in the armature body 23.
  • the insulating varnish can be infiltrated through the gap between the wedge 30 and the core 10 on the armature main body 23 and displace the gas originally remaining in the slit, so that the gas is discharged axially outward through the axial slit opening 14 From the armature body. Once the insulating varnish penetrates into the gap, it can spread in the gap, filling the entire gap and driving out all the gases.
  • the insulating varnish In the vacuum state, in cooperation with the positive pressure in the positive pressure chamber 242, the insulating varnish is in a high pressure state throughout the immersion and wetting process, and no gasification phenomenon occurs, so that it does not seep into the respective gaps of the armature 100. A phase change occurs, thereby maintaining a single-phase state, avoiding various problems caused by the two-phase flow of the insulating varnish, and preventing the formation of voids or bubbles in a plurality of layers of the multilayer structure.
  • the immersion and wetting process for the armature 100 may last for several hours or even longer, ensuring that the insulating varnish can completely seep into the various tissue gaps in the armature 100, ensuring The gases in these gaps are all displaced or driven away.
  • the radially outer surface of the core tooth portion 12 of the armature 100 may also be blocked prior to delivery of the insulating varnish to prevent the insulating varnish from penetrating through the gap 15 between the core laminations 16 at the tooth portion 12, such that The insulating varnish can only penetrate through the seepage slit 13 between the wedge 30 and the winding groove 11 of the core 10.
  • the winding vibration of the armature 100 can be induced to promote the seepage of the insulating varnish toward the slit and the gas drive away, for example, the winding nose at the upper and lower ends of the armature 100 can be vibrated, thereby Driving the entire winding in the winding slot 11 to vibrate, on the one hand, the insulating paint penetrates smoothly from the gap, and also contributes to the diffusion flow of the insulating paint in the gap, and improves the infiltration of the insulating paint into the surface and material in the gap. Therefore, the filling rate and fullness of the insulating varnish can be further improved to avoid the generation of voids.
  • the winding when inducing winding vibration, can also be limited to prevent axial turbulence of the winding.
  • the process equipment provided by the present disclosure may further include other parts, such as a control system or the like, so that the insulating varnish infiltration process can be controlled in real time according to various monitoring signals.
  • the secondary varnish can also be performed, so that the insulating varnish can completely cover the outer surface of the armature 100, cover the armature end and the winding nose to achieve comprehensive insulation. deal with.
  • the insulating varnish enters the winding slot from the gap between the armature end and the iron core, enters the gap in the winding slot from the iron core and the wedge wedge, enters the winding
  • the gap between the solid insulation layer wound around the electromagnetic wire, including the entry into the core lamination, is carried out in a vacuum thermodynamic environment; during the dipping process, the insulating varnish maintains the liquid single-phase state and remains under positive pressure.
  • the non-phase change of the insulator enters the solid insulation layer of the armature winding, enters the gap between the winding and the core, and the liquid in the gap drives the gas in the gap, impregnates and infiltrates the solid surface, and the liquid that enters continuously drives the first entry.
  • the liquid continuously immerses and infiltrates the gap and the solid surface continuously.
  • the electromagnetic eddy current generator is used to induce the vibration of the winding, and promote the flow, displacement and diffusion of the liquid insulating paint in the gap. At the same time, it can also promote the infiltration of the electromagnetic wire and the peripheral liquid insulating varnish, reduce the contact angle, and fill and wrap the peripheral gap space.
  • the object to which the embodiments of the present disclosure are directed may be a motor stator or other component requiring insulation treatment, impregnation and filling of the liquid insulating material for a particular structure, and limited to the armature or stator described above.
  • the sealing protection system is constructed to overcome the surface of the gas-liquid two-phase infiltrated core wedge by the insulating paint under the traditional vacuum condition, which causes the gas-liquid two phases to enter various gaps.
  • the dual function of liquid displacement liquid and liquid displacement gas is realized by means of seepage mechanics.
  • the traditional vacuum pressure impregnation process (ie, VPI) gas residue is solved, thereby completely eliminating voids in all gaps in the armature, preventing subsequent breathing phenomena, improving insulation strength, and making oxygen, moisture and water in the air. It is not easy to invade the inside of the slot insulation, which can delay the aging process of the insulation system, reduce the risk of the motor being exposed to moisture and water, and improve the insulation reliability of the motor.

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Abstract

本公开公开了一种利用填充液体填充电枢的工艺装备和方法，所述工艺装备包括：壳体，用于支撑电枢；填充液体供应装置，用于供应增压后的填充液体；正压填充装置，在与所述电枢的具有缝隙口的表面之间形成正压填充腔室，所述正压填充腔室能够从所述填充液体供应装置接收填充液体，并且使填充液体在正压力作用下通过所述缝隙口渗流到所述电枢的电枢主体中的缝隙内。本公开所提供的工艺装备能够使填充液体完全充满缝隙，提高绝液体在电枢中的填充率。

Description

利用填充液体填充电枢的工艺装备和方法 技术领域
本公开属于部件液体浸润领域，具体地说，本公开涉及一种填充液体填充电枢的工艺装备和方法。
背景技术
风力发电机组是一种将风能转化为电能的大型发电装置。电机作为风力发电机组的核心部件，包括转子和定子，定子包括定子铁芯以及缠绕在定子铁芯上的绕组。如图1-3所示，电枢100包括定子铁芯10和绕组20，在定子铁芯10上设置有绕组槽11，绕组20嵌入在绕组槽11内，并在绕组槽11的槽口安装槽楔30来将绕组20固定在绕组槽11内。
由于风力发电机组设置在户外，经受风吹雨淋，水汽和湿气会进入发电机定子和转子内部，导致定子铁芯以及绕组受到腐蚀而损坏。尤其是，安装在海上的风力发电机，更容易受到盐雾的侵袭腐蚀。除此之外，发电机在运行过程中，绕组的绝缘膜以及铁芯槽内的槽绝缘等绝缘层会由于受到电磁振动和机械振动的冲击而磨损，同时还会经受发热而老化。因此，为了保证定子绕组的绝缘性能，还需要将绕组与其相邻部件用绝缘树脂包封形成紧密坚固的整体。
因此，在制造发电机的过程中，电机各个部件，尤其是定子绕组的防腐处理和绝缘处理特别关键。
为了提高定子绕组的防腐性能和绝缘性能，通常对定子绕组采用浸渍处理，用绝缘漆或绝缘胶等填充材料填充定子绕组中的孔隙。浸漆处理是对电机定子绕组进行绝缘处理的一种常用的浸渍处理方式。
然而，传统的真空加压浸漆(VPI)工艺，是在真空热力学状态环境内进行的，在浸漆过程中，绝缘漆不能完全地浸润绕组与铁芯的缝隙，或者铁芯叠片之间的空间，在这些位置通常存在空穴或气孔，而不能被绝缘漆完全浸润，使得电机的绝缘处理并不能完全覆盖所有的缝隙空间，这对电机的绝缘产生隐患。在槽口部分，难以在槽楔外周形成严格的密封圈，造成槽楔与 铁芯槽口硅片之间形成缝隙，潮气和水自然会沿着脱粘缝隙进入槽内破坏绝缘，为风力发电机组的运行带来安全隐患。
发明内容
本公开的目的在于提供一种填充液体驱替浸渍浸润电枢的工艺装备和方法，在正压力作用下使填充液体进入绕组与铁芯缝隙，使后进液体驱替先进入的液体，并且使进入缝隙内的填充液体驱替原先处于缝隙内的气体，从而使填充液体完全充满缝隙。
为了实现上述目的，本公开提供了一种利用液体填充电枢的工艺装备，包括：壳体，所述壳体用于支撑电枢；填充液体供应装置，用与供应增压后的填充液体；正压填充装置，在与所述电枢的具有缝隙口的表面之间形成正压填充腔室，所述正压填充腔室能够从所述填充液体供应装置接收填充液体，并且使填充液体在正压力作用下通过所述缝隙口渗流到所述电枢的电枢主体中的缝隙内。
根据本公开的另一实施例，还提供了一种利用填充液体填充电枢的方法，所述方法包括：在正压力作用下，使填充液体渗流到电枢的电枢主体的缝隙中，其中，填充液体通过所述电枢主体上的槽楔与铁芯之间的缝隙渗入并驱替缝隙内的气体，使得气体通过所述电枢的轴向缝隙口而被驱离。
本公开的实施例所提供的工艺装备和方法通过电机转子或定子表面(凸面或凹面)柱状腔体内面向绕组端部多种组织部件(铁芯)与空气交接区域之间，槽楔与铁芯间的渗流缝隙和空气交接区域之间构筑密封防护体系，克服绝缘漆在传统真空状态下导致气液两相进入各种缝隙和气液两相浸润铁芯槽楔的表面。借助渗流力学实现液体驱替液体、液体驱替气体的双重功能。解决了传统的真空压力浸渍工艺(即，VPI)气体残留，从而完全地剔除了电枢内的所有缝隙的空穴，阻止后续呼吸现象发生，提高绝缘强度，使空气中的氧、潮气和水等不易侵入槽绝缘内部，可延缓绝缘体系老化过程，降低电机受潮气和水侵入存留其中的风险，提高电机绝缘可靠性。
附图说明
图1是风力发电机组的电枢的局部示意图；
图2是风力发电机组的电枢的绕组与铁芯的放大结构立体图；
图3是风力发电机组的电枢的一个绕组槽的局部截面图；
图4是根据本公开的实施例的电枢的示意图；
图5是图4所示的电枢的铁芯的一个齿的简化示意图；
图6是图4所示的电枢的一个绕组槽的局部截面图；
图7是根据本公开的实施例的填充液体驱替浸渍浸润电枢的工艺装备的结构示意图；
图8是图7所示的工艺装备的俯视示意图；
图9是根据本公开的实施例的激振装置的示意图；
图10是根据本公开的另一实施例的填充液体驱替浸渍浸润电枢的工艺装备的结构示意图；
图11是根据本公开的另一实施例的填充液体驱替浸渍浸润电枢的工艺装备的结构示意图。
附图标记说明：
100：电机电枢，10：定子铁芯，11：绕组槽，20：绕组，21、22：电枢端部，23：电枢主体，30：槽楔，12：铁芯齿部；13：渗流缝隙，14：轴向缝隙口，15、17、18：缝隙，16：铁芯叠片，200、300、400：工艺装备，210、410：壳体，220：填充液体供应装置，221：泵，240、340、440：正压填充装置，241、341：正压封闭筒体，242、342、442：正压腔室，243、244：分隔板，245：铁芯夹持片，260、360：回收装置，261、262：分隔筒，263：气液分离器，264、364：回收腔室，280：激振装置，281：激振器，282：弹性储能元件，283：环形支撑板。
具体实施方式
为了使本领域技术人员能够更好的理解本公开，下面结合附图对本公开的具体实施例进行详细描述。
参照图1至图7，示出了根据本公开的实施例的处于待浸漆状态的电机电枢(以下简称电枢)100。该电枢100所应用到的电机可为内定子外转子结构，即，定子处于转子的径向内侧，包括定子铁芯10和绕组20，在定子铁芯10上设置有绕组槽11，绕组20嵌入在绕组槽11内，并在绕组槽11的槽口安装槽楔30来将绕组20固定在绕组槽11内。
如图4所示，定子铁芯10包括作为径向外表面的多个齿部12，绕组槽 11开设在相邻两个齿部12之间，而槽楔30也安装在相邻两个齿部12之间。
如图2所示，对于定子而言，绕组槽11沿着定子轴向从一个电枢端部延伸到另一个电枢端部，从而贯穿定子的两个轴向端面，绕组槽11形成了贯穿定子的轴向通道。在绕组20安装于绕组槽11中并且槽楔安装在槽口中的情况下，由于绕组20无法完全密实地填充绕组槽11，因此，在绕组20与绕组槽11以及槽楔之间，形成有大量缝隙，并且在定子铁芯10的两个端部处，绕组槽11中的缝隙通过绕组槽11的轴向端部开口与外部连通。因此，公开形成在定子中的轴向缝隙可从电枢100的一个电枢端部沿轴向延伸到另一个电枢端部处。在下面的描述，将形成在绕组槽内的缝隙在定子轴向端部处的开口称为轴向缝隙口14。这里所述的轴向缝隙口14可包括铁芯10、槽楔30和绕组20之间的处于电枢100端面处的所有缝隙口，也即，只要能够使气体和/或绝缘漆能够通过该缝隙口从电枢100的端面流出的缝隙口都可以称为轴向缝隙口14。
如图3所示，对于每个绕组槽11而言，在槽口处，在槽楔30与定子铁芯的绕组槽11的槽口内壁之间具有缝隙13，在下文中称为渗流缝隙13。渗流缝隙13在轴向上延伸，并通过轴向缝隙口14与外部连通。另外，在槽楔30和铁芯10上的绕组槽的开口处呈梯形或三角形时，渗流缝隙13可相对于径向成一定角度地向内延伸，在该角度相对较小时，渗流缝隙13可大体上沿径向延伸，或者可称为径向缝隙。
如图6所示，在定子铁芯10上缠绕绕组20时，会事先在绕组20上缠绕上多层柔软的固体绝缘层，在将绕组20嵌装在绕组槽11内之后，绕组20与绕组槽11的内壁之间具有缝隙18，并且多层绝缘层彼此之间也存在一定的缝隙17。以上所述的各个缝隙13、18和17均彼此连通，并且会充满气体。
除了绕组20与定子铁芯10的绕组槽11之间的各个缝隙13、18和17之间，在定子铁芯10的各个铁芯叠片16之间也存在缝隙15，如图5所示，这些缝隙15都与上述缝隙13、18和17连通。上述这些缝隙13、15、18和17为多种、多层组织缝隙，构成各个缝隙的材料及其各自的形状均有所不同。
电枢100可大体上分成电枢主体23和两个电枢端部21和22，在两个电枢端部21和22处的绕组可称为绕组鼻部。
在利用填充液体(例如，绝缘漆或者液体绝缘介质等，为了便于描述，在下文中，使用绝缘漆代表)对电枢100进行浸漆工艺时，电枢100可轴向 竖直地、轴向水平地或沿着任何方向放置和支撑在本公开实施例所提供的填充液体驱替浸润的工艺装备200中。
参照图7，图7示出了根据本公开的实施例的填充液体驱替浸渍浸润电枢的工艺装备200的结构示意图或者工艺装备200的作业状态图，为了便于示出工艺装备200，其内的电枢100仅以简化的形式示出。
工艺装备200可包括壳体210、填充液体供应装置220和正压填充装置240。这里提到的正压是相对于负压而言的，正压是指容器内的压力大于常压。对于填充液体而言，只要压力大于环境压力，就能够在压差的作用下渗流到电枢100中的缝隙内，压力越大，渗流动力越大，越容易浸渍浸润电枢100中的缝隙。
壳体210位于最外围，其外轮廓可大体上呈圆柱状，电枢100放置在壳体210内。该壳体210可由高强度材质制成，以确保其强度足够高而能够承受过高的压力，并且还可设置有绝热层，能够防止壳体100内的热量外泄，从而在其内部大体上形成密封的高压环境。
填充液体供应装置220用来产生增压后的绝缘漆，并且可将这样的绝缘漆输送到壳体210内，以对电枢100进行浸漆操作。在将绝缘漆输送到壳体210内之前，可事先调配出具有良好的粘稠度和流动性的绝缘漆，在环境温度过低时，还可通过对于绝缘漆进行适度的加热的方式来使绝缘漆具有较好的流动性，以便于后续的浸渍和浸润。为此，填充液体供应装置220可大体上包括执行加热操作的加热器(未示出)、执行增压操作的压缩机(未示出)和泵送绝缘漆的泵221。加热器、压缩机和泵221可通过管道依次连接，并且泵221也可通过管道将高压的绝缘漆输送到壳体210内。
正压填充装置240可设置在壳体210内，其内部设置有正压腔室242，该正压腔室242可大体上处于电枢主体23的周边，能够从填充液体供应装置220接收绝缘漆，并且使绝缘漆在正压腔室242内的高压强对电枢主体23沿径向施加的正压力作用下渗流到电枢主体23上的上述各个缝隙中并对多重组织进行浸润，同时驱替这些缝隙内的气体，使得气体沿着轴向缝隙口14而被驱离出电枢100。需要说明的是，在进行绝缘漆浸渍、浸润之前，最好事先对壳体210内部进行抽真空，使电枢100大体上处于一定的真空度下，以尽可能地将多孔介质缝隙内气体抽出。
具体地说，正压填充装置240可包括正压封闭筒体241，该正压封闭筒 体241可包括竖直的环状外缸体以及与外缸体相连接的上下两个环形的分隔板243和244，从而正压封闭筒体241可与电枢主体23的径向表面一起形成密闭的且呈环形的正压腔室242。其中，外缸体可以是壳体210的一部分，具有较高的结构强度且具有一定的绝热能力。
分隔板243和244可与电枢100的电枢端部21和22的端面对齐，从而使得定子铁芯10的整个径向外表面都处于正压腔室242内，以便绝缘漆能够充分接触电枢主体23并完全浸润电枢主体23，而电枢100的两个绕组鼻部处于正压腔室242之外。
泵221可将高温高压的绝缘漆输送到正压腔室242内，使得正压腔室242内具有一定的压力，或者使得其内的压力高于预定值，使得正压腔室242处于高温高压环境，从而可有效地对电枢主体23施加径向的正压力。
为了使正压腔室242内的压力各处均衡，泵221可以设置多个，分布在电枢主体23的多个周向位置或者上下多个位置，这样还可以进一步缩短绝缘漆输送时间，节省浸漆工艺耗时。另外，还可以设置多条分流管道，从而可在仅使用一个泵221的情况下，也可以大体上使正压腔室242内的压力各处均衡。
如上所述，正压腔室242可对电枢主体23施加径向的正压力，由于正压腔室242内的压强较高，因此该正压力的值也相对较高。绝缘漆能够在正压力的驱使作用下，通过渗流缝隙13向内渗流到电枢主体23上的缝隙18和17内，并且还能够渗流到铁芯叠片16之间的缝隙15中。后渗入的绝缘漆驱使先渗入的绝缘漆继续向内扩散流动，从而能够连续不断地驱使绝缘漆向内渗流，并且绝缘漆会驱替原先占据各个缝隙13、15、17和18内的气体，或者说绝缘漆的渗入会驱赶气体，这些被驱赶的气体会通过电枢100的上下两个电枢端部21和22处的轴向缝隙口14而从电枢主体23内流出，从而最终绝缘漆完全占据电枢主体23内的各个缝隙，进而完全充满缝隙，并浸渍、浸润缝隙内的各种表面，例如，可充分浸润绕组周围的固体绝缘层，避免在缝隙内残留气体而导致空穴或气孔的产生，进而对槽楔与铁芯和空气交接区域之间构建彻底的密封防护体系，提高绝缘漆的填充率，实现对电枢全面的绝缘处理，延缓电机的腐蚀老化进程，提高电机的使用寿命。
在上述绝缘漆驱替绝缘漆和气体的过程中，因为在正压填充装置240所施加的正压力协同作用下，绝缘漆在整个浸渍浸润过程中始终处于高压状态， 绝缘漆没有机会或不可能出现气化现象，从而可有效地保持单相状态或者非相变状态，从而可完全避免传统的浸漆工艺中绝缘漆发生相变问题及其所引起的两相流的危害等问题(包括产生额外的气体残留在电枢100的各种缝隙内)，阻止多种、多层组织缝隙的空穴或气泡的形成。
绝缘漆渗流到电枢100中的各个缝隙可以以槽楔30与绕组槽11之间的渗流缝隙13为入口开始渗入，还可以直接从铁芯叠片15之间的缝隙15向内渗入，一旦绝缘漆渗入到缝隙内，便可以在缝隙内扩散流动，包括向缝隙的深处渗入、上下方向地渗流或者沿其他方向的渗流，同时驱替缝隙内的气体，直到完全占据所有的缝隙为止。
另外，如图8所示，正压填充装置240还可包括多个铁芯夹持片245，其与铁芯齿部12一一对应地设置，一个铁芯夹持片245从外侧夹持住一个铁芯齿部12，完全地封堵住铁芯齿部12的径向外表面，也即封堵铁芯齿部12处的缝隙15，而预留出与槽楔30区域一一对应的径向渗流通道，使得在浸润过程中，处于电枢主体23的径向周围的绝缘漆只能够通过径向渗流通道从槽楔30与绕组槽11之间的渗流缝隙13向内渗流，此处的“径向”可以是大体上处于径向方向，在相对径向处在一定角度范围内的流向都可称为径向流动。同样，一旦绝缘漆渗入到缝隙17、18内之后便开始扩散流动，并且还扩散渗流到铁芯叠片之间的缝隙15。这样，可以避免已经渗入到缝隙内的绝缘漆经由缝隙15再次流出，并且还能够确保绝缘漆在各个缝隙13、15、17和18内均匀地分布和浸润。
铁芯夹持片245可在两个端部处进行收紧，使其严密地贴合到各个铁芯齿部12的径向外表面，实现可靠地封堵。
如上所述，从各个缝隙内被驱替或驱离出来的气体可通过电枢端部21和22处的轴向缝隙口14而向外流出，另外还会有部分绝缘漆也从轴向缝隙口14泄露出来，不论是在浸漆期间还是在驱离出所有的气体之后。在通过其他的检测装置检测到从轴向缝隙口14流出的流体仅是绝缘漆而不再包含气体时，可大体上判定电枢100的浸渍完成。
本公开所提供的工艺装备200还可包括回收装置260，以回收被驱替出来的气体以及泄露出来的绝缘漆。
如图7所示，在本实施例中，回收装置260可设置在电枢端部21和22处。具体地说，回收装置260可包括回收封闭筒体，该回收封闭筒体可与电 枢端部21和22的端面一起形成封闭的环形的回收腔室264，被绝缘漆驱离出来的气体汇流到回收腔室264内。回收封闭筒体的一部分可由壳体210来实现。上述的分隔板243和244可分别作为上下两个回收封闭筒体的一部分，另外，两个回收封闭筒体还可分别包括竖直地设置且呈圆筒状的分隔筒261和262，分隔筒261和262都安装在轴向缝隙口14的径向内侧。
回收装置260还可包括气液分离器263，被回收到回收腔室264内的气体和绝缘漆通过管道被输送到气液分离器263内进行气液分离，以进行再循环利用。回收装置260还可包括吸附塔等各种后处理装置。
由于绕组20在各自的绕组槽11内安装地相对紧些，缝隙13、17和18的尺寸相对较小，并且各处缝隙的大小也不完全相等，有些地方的缝隙较大些，而有些地方的缝隙较小些。为了使绝缘漆能够更顺利地渗流到缝隙内，并且更快且更彻底地浸润和填充各个缝隙，本公开的实施例所提供的工艺装备还可包括激振装置280，如图9所示，以诱发电枢的绕组振动，协同正压填充装置240的正压力作用，促使绝缘漆完全充满各个缝隙，进一步提高绝缘漆的充满度和填充率。
激振装置280可设置两个，分别位于两个电枢端部21和22处，并诱发两端的绕组鼻部振动，从而使所有的绕组振动，加速绝缘漆的浸润，促进绝缘在缝隙内的流动和绝缘漆的扩散，并协助绝缘漆驱替气体，同时使气体更快地被驱离出来。
每个激振装置280均可包括激振器281，其作为振动发生器，例如，激振器281可以是电磁涡流发生器或者超声波振动发生器。激振装置280还可包括设置在各自的电枢端部处的环形支撑板283，环形支撑板283可与绕组鼻部接触，并且可优选地设置在绕组鼻部的轴向外侧处，激振器281产生的振动可经由弹性储能元件282传递到环形支撑板283，带动环形支撑板283以及绕组20一起以一定的频率振动。在绕组20振动时，有可能在轴向上会发生窜动导致其轴向位置发生变化，因此，环形支撑板283还可以作为限位板使用，一方面能够向绕组传递振动，还可以防止绕组轴向窜动保持其轴向位置，尤其适用于电枢100在壳体210内竖直放置的情况。
通过在正压填充装置240的协同作用的情况下诱发绕组振动，不仅能够促使绝缘漆向缝隙内的渗流以及绝缘漆的扩散流动，还能够促使绕组的被固体绝缘层包裹的电磁线与外围绝缘漆的浸润，降低绝缘漆与绕组之间的接触 角，使绝缘漆完全填充绕组槽内的缝隙并包裹处于绕组槽内的绕组。另外，绕组振动在一定程度上还有助于绝缘漆的沉降。
另外，在电枢浸漆的不同时期或阶段，根据绝缘漆的黏度、正压腔室242内的温度和压强等各种因素，可通过调节电磁涡流发生器所产生的电磁波的频率来调节绕组的振动频率和幅度而适配地执行浸渍浸润操作。
在对电枢100进行浸漆期间，还可以通过设置在正压腔室242内的各种温度和压力传感器来实时地检测内部的浸漆状况，以便基于当前的绝缘漆浸润状态来实时控制和调节正压腔室242内的温度和压强。
下面参照图10对根据本公开的另一实施例的填充液体驱替浸渍浸润电枢的工艺装备300进行具体描述。其中，在下面的描述中，工艺装备300的与工艺装备200相同或相似的部件使用相同的标号指示，并且出于简洁的目的，对于工艺装备300的与工艺装备200相同的部件将不再重复描述。
在图10中，示出了工艺装备300的作业状态图。在本实施例中，电枢100所应用到的电机同样为内定子外转子结构。
工艺装备300同样可大体上包括壳体210、填充液体供应装置220和正压填充装置340。电枢100可大体上轴向竖直地或轴向水平地或沿任何方向放置在壳体210内。
下面将主要描述正压填充装置340。在本实施例中，正压填充装置340可包括正压封闭筒体341，正压封闭筒体341内部的正压腔室342可由外缸体、分隔板243、电枢主体23、电枢端部21和分隔筒262密封而成，即，电枢主体23和处于下方的电枢端部21的外表面处于正压腔室342内而承受正压力作用。当然，电枢端部21的轴向缝隙口14可处于正压腔室342内。
在进行浸润时，绝缘漆不仅可以从电枢主体23上的渗流缝隙13处渗入到各个缝隙内，还可以从位于下方的电枢端部21处的轴向缝隙口14渗入。被驱离的气体可在缝隙内向上升，并通过处于上方的电枢端部22处的轴向缝隙口14处被驱离出来。
工艺装备300的回收装置360可仅设置一个，其位于电枢端部22上方。类似地，回收装置360可包括回收腔室364，该回收腔室364可由分隔板243、分隔筒261和电枢端部22的端面封闭而成。
该工艺装备300同样可设置有上述的激振装置280和铁芯夹持片245，在此不再赘述。
另外，除了以上设置方式以外，还可以将电枢端部22置于正压腔室342内，而使电枢端部22处于正压腔室342之外。在这种情况下，回收装置360可设置在电枢端部21下方。
下面参照图11对根据本公开的另一实施例的填充液体驱替浸渍浸润电枢的工艺装备400进行具体描述。其中，在下面的描述中，工艺装备400的与工艺装备200、300相同或相似的部件使用相同的标号指示，并且出于使描述简洁的目的，对于工艺装备400的与工艺装备200、300相同的部件将不再重复描述。
在本实施例中，电枢100所应用到的电机为外定子内转子结构，即，定子处于转子的径向外侧，绕组槽11和槽楔30设置在电枢主体23的径向内表面上，因而需要进行绝缘化处理的表面为径向内表面。
工艺装备400可同样包括壳体410、填充液体供应装置420和正压填充装置440。电枢100可大体上轴向竖直地或轴向水平地或沿任何方向由壳体410支撑。与上述工艺装备200和300不同的是，壳体410和正压填充装置440均布置在电枢100内腔中，正压腔室442处于电枢主体23的径向内侧，其他具体结构类似，在此不再赘述。
另外，在工艺装备400中，正压腔室442可以采用上述实施例中的正压腔室242的形式，即，正压腔室442仅对电枢主体23的径向内表面施加正压力作用，绝缘漆从槽楔30与绕组槽11之间的渗流缝隙13开始渗入到电枢100内的各个缝隙内。或者，正压腔室442也可以采用上述实施例中的正压腔室342的形式，即，正压腔室442对电枢主体23的径向内表面和一个电枢端部21的端面施加正压力作用，使得绝缘漆可从槽楔30与绕组槽11之间的渗流缝隙13以及电枢端部21处的轴向缝隙口14处开始渗入到电枢100内的各个缝隙内。这两个正压腔室442的布置与上述类似，在此不再赘述。
根据本公开的实施例，还提供了一种填充液体驱替浸润电枢的方法，该方法基于工程热力学、流体力学、传质学和多相流原理利用正压力作用驱使绝缘漆填充电枢内的各个缝隙并驱替气体，使得绝缘漆能够充满缝隙。
在本实施例中，在将绝缘漆输送到正压腔室242内之前，可对壳体210内的空间进行抽真空，使得电枢100大体上处于一定的真空度下，尽可能地减少残留在电枢内缝隙中的气体。接下来，将绝缘漆输送到正压腔室242内，使得正压腔室242内达到高温高压状态。
利用正压腔室242内的高温高压环境对电枢表面施加的正压力作用，使绝缘漆渗流到电枢主体23上的缝隙中。绝缘漆可通过电枢主体23上的槽楔30与铁芯10之间的缝隙渗入并驱替原先残留在缝隙内的气体，使得气体通过轴向缝隙口14沿轴向向外排出而被驱离电枢主体。一旦绝缘漆渗入到缝隙内，便可在缝隙内扩散流动，从而充满整个缝隙并驱赶出所有的气体。
在真空状态下协同正压腔室242内的正压力作用，绝缘漆在整个浸渍浸润过程期间均处于高压状态，不会出现气化现象，从而在向电枢100的各个缝隙内渗流时不会发生相变，从而始终维持单相状态，避免了绝缘漆发生两相流时引发的各种问题，阻止多种、多层组织缝隙的空穴或气泡的形成。
另外，需要注意的是，在上述方法中，对电枢100的浸渍浸润工艺可能会持续数小时时间，甚至更长，确保绝缘漆能够完全渗流到电枢100中的多种组织缝隙内，保证这些缝隙内的气体全部被驱替或驱离。
在输送绝缘漆之前，还可以将电枢100的铁芯齿部12的径向外表面封堵住，以防止绝缘漆经由齿部12处的铁芯叠片16之间的缝隙15渗入，使得绝缘漆仅能够通过槽楔30与铁芯10的绕组槽11之间的渗流缝隙13渗入。
另外，还可以在浸漆过程中，诱发电枢100的绕组振动，促进绝缘漆朝向缝隙的渗流以及气体的驱离，例如，可使电枢100的上下两端处的绕组鼻部振动，从而带动处于绕组槽11内的整个绕组振动起来，一方面使绝缘漆顺利从缝隙渗入，并且还有助于绝缘漆在缝隙内的扩散流动，并提高绝缘漆在缝隙内对各个表面和材料的浸润，从而可进一步提高绝缘漆的填充率和充满度，避免空穴的产生。
另外，在诱发绕组振动时，还可以对绕组进行限位，以防止绕组发生轴向窜动。
除了以上具体的描述以外，本公开所提供的工艺装备还可包括其他部分，例如，控制系统等，从而可根据各种监测信号来实时地控制绝缘漆浸润过程。
在对电枢100执行一次浸漆之后，还可以执行二次浸漆，使得绝缘漆能够完全包覆电枢100的外表面，包覆电枢端部以及绕组鼻部，以实现全面的绝缘化处理。
通过本公开所提供的填充液体驱替浸润的工艺装备和方法，绝缘漆从电枢端部与铁芯的缝隙进入绕组槽内、从铁芯与槽楔之间进入绕组槽内缝隙、进入绕组电磁线外缠绕的固体绝缘层间隙、包括进入铁芯叠片片间，都是在 真空热力学状态环境内进行的；在浸漆过程中，绝缘漆保持液体单相状态，在正压力作用下保持绝缘体非相变进入电枢绕组固体绝缘层间、进入绕组与铁芯缝隙，进入缝隙的液体驱替缝隙中的气体，浸渍、浸润固体表面，并且后进入的液体连续不断地驱替先进入的液体，对缝隙和固体表面进行连续不断地重复浸渍、浸润。
另外，还协同电磁涡流发生器诱发绕组振动，促进缝隙内绝缘漆流动、驱替和液体绝缘漆扩散。同时，还可促进电磁线与外围液体绝缘漆浸润，能够降低接触角，填充并包裹其外围缝隙空间。
本公开的实施例针对的对象可以是电机定子或者是其他需要绝缘化处理的零部件，针对特定结构实施液体绝缘材料的浸润和填充，并限于以上所述的电枢或定子。
虽然上面以铁心齿部形成在电枢的外表面为例描述了本公开的实施例，但是，在铁心齿部形成在电枢的内表面的情况下，根据本公开实施例的工作装备以及工艺方法也同样适用。
籍于电机转子或定子表面(凸面或凹面)柱状腔体内面向绕组端部多种组织部件(铁芯)与空气交接区域之间，槽楔与铁芯之间的渗流缝隙和空气交接区域之间构筑密封防护体系，克服绝缘漆在传统真空状态下导致气液两相进入各种缝隙和气液两相浸润铁芯槽楔的表面。借助渗流力学实现液体驱替液体、液体驱替气体的双重功能。解决了传统的真空压力浸渍工艺(即，VPI)气体残留，从而完全地剔除了电枢内的所有缝隙的空穴，阻止后续呼吸现象发生，提高绝缘强度，使空气中的氧、潮气和水等不易侵入槽绝缘内部，可延缓绝缘体系老化过程，降低电机受潮气和水侵入存留其中的风险，提高电机绝缘可靠性。
上面对本公开的具体实施方式进行了详细描述，虽然已表示和描述了一些实施例，但本领域技术人员应该理解，在不脱离由权利要求及其等同物限定其范围的本公开的原理和精神的情况下，可以对这些实施例进行修改和完善，这些修改和完善也应在本公开的保护范围内。

Claims (16)

  1. 一种利用填充液体填充电枢的工艺装备，其特征在于，所述工艺装备包括：
    壳体(210，410)，用于支撑电枢(100)；
    填充液体供应装置(220)，用于供应增压后的填充液体；
    正压填充装置(240，340，440)，在与所述电枢(100)的具有缝隙口的表面之间形成正压填充腔室(242，342，442)，所述正压填充腔室(242，342，442)能够从所述填充液体供应装置(220)接收填充液体，并且使填充液体在正压力作用下通过所述缝隙口渗流到所述电枢(100)的电枢主体(23)中的缝隙内。
  2. 根据权利要求1所述的工艺装备，其特征在于，所述正压填充装置(240，340，440)包括：
    正压封闭筒体(241，341)，所述正压腔室(242，342，442)形成在所述正压封闭筒体(241，341)与所述电枢主体(23)的周向表面之间，为环形密闭腔室，填充液体被输送到所述正压腔室(242，342，442)内，所述正压腔室(242，342，442)内的压力大于环境压力，从而填充液体通过径向缝隙口渗流到所述电枢主体(23)中的缝隙内。
  3. 根据权利要求2所述的工艺装备，其特征在于，所述正压腔室(242，342，442)形成在所述正压封闭筒体(241，341)与所述电枢主体(23)的周向表面以及所述电枢(100)的第一电枢端部的外表面之间，且所述第一电枢端部处的轴向缝隙口(14)位于所述正压腔室(242，342，442)内，使得填充液体还能够通过所述轴向缝隙口(14)渗流到所述电枢主体(23)中的缝隙内，移除的气体或溢流的填充液体通过所述电枢的第二电枢端部处的轴向缝隙口(14)流出。
  4. 根据权利要求3所述的工艺装备，其特征在于，所述电枢(100)沿轴向竖直放置，所述第一电枢端部为所述电枢(100)的处于下方的电枢端部(21)。
  5. 根据权利要求1所述的工艺装备，其特征在于，所述电枢主体(23)包括多个铁芯齿部(12)，所述正压填充装置(240，340，440)还包括多个铁芯夹持片(245)，以覆盖所述电枢(100)的各个铁芯齿部(12)的径向外 表面，使得填充液体仅通过所述槽楔(30)与所述铁芯齿部(12)之间的径向渗流缝隙(13)渗流到所述电枢主体(23)的缝隙中。
  6. 根据权利要求1所述的工艺装备，其特征在于，所述工艺装备还包括回收装置(260，360)，用于回收从所述电枢(100)的轴向缝隙口(14)流出的填充液体。
  7. 根据权利要求6所述的工艺装备，其特征在于，所述回收装置(260，360)包括：
    回收封闭筒体，设置在所述电枢(100)的第二电枢端部(22)处，所述回收封闭筒体与所述第二电枢端部(22)形成环形的密闭的回收腔室(264，364)，所述第二电枢端部(22)处的轴向缝隙口(14)处于所述回收腔室(264，364)内；
    气液分离器(263)，将回收的填充液体进行气液分离处理。
  8. 根据权利要求1所述的工艺装备，其特征在于，所述工艺装备还包括激振装置(280)，分别设置在所述电枢(100)的第一电枢端部(21)和第二电枢端部(22)处，用于诱发所述电枢(100)的绕组鼻部振动。
  9. 根据权利要求8所述的工艺装备，其特征在于，所述激振装置(280)包括：
    环形支撑板(283)，分别设置在所述第一电枢端部(21)和所述第二电枢端部(22)处并接触所述绕组鼻部；
    激振器(281)，产生振动；
    弹性储能元件(282)，能够将所述激振器(281)产生的振动传递到所述环形支撑板(283)。
  10. 根据权利要求8所述的工艺装备，其特征在于，所述激振器(281)为电磁涡流发生器或者超声波振动发生器。
  11. 根据权利要求1所述的工艺装备，其特征在于，所述填充液体供应装置(220)包括：
    压缩机，将填充液体增压至预定压力值；
    泵(221)，将增压后的填充液体输送至所述正压填充装置(240，340，440)。
  12. 一种利用填充液体填充电枢的方法，其特征在于，所述方法包括：
    在正压力作用下，使填充液体渗流到电枢的电枢主体(23)的缝隙中， 其中，填充液体通过所述电枢主体(23)上的槽楔(30)与铁芯(10)之间的缝隙渗入并驱替缝隙内的气体，使得所述气体通过所述电枢(100)的轴向缝隙口(14)而被驱离。
  13. 根据权利要求12所述的方法，其特征在于，所述方法还包括：封堵所述电枢(100)的铁芯(10)的各个铁芯齿部(12)的径向外表面，使得填充液体仅通过所述槽楔(30)与所述铁芯(10)之间的渗流缝隙(13)渗流到所述电枢(100)中。
  14. 根据权利要求12所述的方法，其特征在于，所述方法还包括：从所述电枢(100)的两个电枢端部(21，22)处诱发所述电枢(100)的绕组振动，便于填充液体朝向缝隙内渗流以及驱离气体。
  15. 如权利要求12-14中任一项权利要求所述的方法，其特征在于，所述方法还包括如下步骤：在将填充液体供应到所述电枢(100)之前，将所述电枢(100)放置在密闭壳体(210，410)内，并对所述壳体(210，410)内部抽真空。
  16. 根据权利要求15所述的方法，其特征在于，所述填充液体在渗流到缝隙内的过程中始终处于单相的液体状态。
PCT/CN2018/100453 2018-01-31 2018-08-14 利用填充液体填充电枢的工艺装备和方法 WO2019148799A1 (zh)

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