WO2022085358A1 - マグネットワイヤ被覆の検査装置、マグネットワイヤ被覆の検査方法、および電気機械の製造方法 - Google Patents

マグネットワイヤ被覆の検査装置、マグネットワイヤ被覆の検査方法、および電気機械の製造方法 Download PDF

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Publication number
WO2022085358A1
WO2022085358A1 PCT/JP2021/034783 JP2021034783W WO2022085358A1 WO 2022085358 A1 WO2022085358 A1 WO 2022085358A1 JP 2021034783 W JP2021034783 W JP 2021034783W WO 2022085358 A1 WO2022085358 A1 WO 2022085358A1
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WIPO (PCT)
Prior art keywords
magnet wire
discharge
wire coating
magnet
voltage application
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2021/034783
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English (en)
French (fr)
Japanese (ja)
Inventor
貞治 高橋
旭涛 李
貴浩 三澤
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Mitsubishi Electric Corp
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Mitsubishi Electric Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mitsubishi Electric Corp filed Critical Mitsubishi Electric Corp
Priority to CN202180069897.1A priority Critical patent/CN116325031B/zh
Priority to JP2022557314A priority patent/JP7329698B2/ja
Publication of WO2022085358A1 publication Critical patent/WO2022085358A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/12—Testing dielectric strength or breakdown voltage ; Testing or monitoring effectiveness or level of insulation, e.g. of a cable or of an apparatus, for example using partial discharge measurements; Electrostatic testing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/16—Insulating conductors or cables by passing through or dipping in a liquid bath; by spraying

Definitions

  • the present application relates to a magnet wire coating inspection device, a magnet wire coating inspection method, and an electric machine manufacturing method.
  • a coil used for a stator of a motor or the like has conventionally been configured by winding a conductor wire called a magnet wire in which the surface of a wire made of copper, aluminum, or the like is coated with an organic insulator. If there is an abnormality such as a pinhole or a scratch on the magnet wire coating, the insulation performance of the magnet wire deteriorates, and a short circuit abnormality occurs during the operation of the motor.
  • the conventional insulation characteristic inspection device is arranged on the downstream side of the guaranteed voltage application unit that applies the guaranteed voltage to the traveling line and the guaranteed voltage application unit, and removes the charge charged on the traveling line by grounding the traveling line. It is provided with a grounding unit and an inspection voltage application unit which is arranged on the downstream side of the grounding unit and applies an inspection voltage lower than the guaranteed voltage to the traveling line to detect a leakage current value (for example, Patent Document 1).
  • Patent Document 1 enhances the reliability of abnormality detection of insulation characteristics by applying a guaranteed voltage to a traveling magnet wire.
  • the guaranteed voltage which is a relatively high voltage
  • spark discharge may occur and the normal magnet wire coating may be damaged.
  • the present application discloses a technique for solving the above-mentioned problems, and a magnet capable of reliably inspecting the insulation characteristics of a magnet wire before winding without damaging a normal magnet wire coating. It is an object of the present invention to provide an inspection device and an inspection method for wire coating.
  • the magnet wire coating inspection device disclosed in the present application includes a traveling path forming device for forming a traveling path by traveling the coated magnet wire at a constant speed in a linear direction before winding, and a setting point in the traveling path.
  • a discharge detection electrode that applies an AC voltage to the magnet wire to collect the discharge charge generated from the wire of the magnet wire, and a detection device that detects a discharge signal based on the discharge charge from the discharge detection electrode. It is provided with a discharge detecting device having a discharge detecting device and a discharge promoting device for promoting discharge generation from the strands of the magnet wire at a voltage application point at the setting point in the traveling path.
  • the method for inspecting the magnet wire coating disclosed in the present application is a first step of traveling the coated magnet wire at a constant speed in the linear direction before winding, and a setting point in the traveling path by the magnet wire.
  • the method for manufacturing an electric machine disclosed in the present application is to manufacture an electric machine by winding the magnet wire inspected using the magnet wire coating inspection device around an iron core.
  • the insulation characteristics of the magnet wire can be reliably inspected before winding without damaging the normal magnet wire coating.
  • the insulation characteristics of the magnet wire can be reliably inspected before winding without damaging the normal magnet wire coating.
  • FIG. 3 is a waveform diagram of the detected discharge signal according to the first embodiment.
  • FIG. It is a waveform diagram of the discharge signal after the smoothing process by Embodiment 1.
  • FIG. It is a figure which shows the structure of the traveling path forming apparatus by another example of Embodiment 1.
  • FIG. It is a figure which shows the structure of the inspection apparatus of the magnet wire coating by another example of Embodiment 1.
  • FIG. It is a figure which shows the structure of the inspection apparatus of the magnet wire coating by Embodiment 2.
  • FIG. It is a figure which shows the structure of the inspection apparatus of the magnet wire coating by Embodiment 3.
  • FIG. It is a figure which shows the structure of the heating apparatus according to Embodiment 4. It is a figure explaining the operation of the heating apparatus by Embodiment 4.
  • FIG. It is a figure which shows the structure of the heating apparatus according to Embodiment 5. It is a figure explaining the operation of the heating apparatus according to Embodiment 5.
  • Embodiment 6. It is a figure explaining the guide block of the magnet wire by Embodiment 6.
  • Embodiment 7. It is a figure explaining the guide block of the magnet wire by Embodiment 7.
  • FIG. 5 is a partially enlarged view showing a winding device and a stator core connected to the magnet wire coating inspection device according to the eighth embodiment. It is a figure which shows the structure of the stator after winding in Embodiment 8. FIG. It is a figure which shows the structure of the electric machine using the stator after winding in Embodiment 8.
  • FIG. 5 is a partially enlarged view showing a winding device and a stator core connected to the magnet wire coating inspection device according to the eighth embodiment. It is a figure which shows the structure of the stator after winding in Embodiment 8.
  • FIG. It is a figure which shows the structure of the electric machine using the stator after winding in Embodiment 8.
  • Embodiment 9 It is a figure which shows the structure of the inspection apparatus of the magnet wire coating by Embodiment 9. It is a figure which shows the structure of the decompression device according to Embodiment 9. It is a figure which shows the structure of the decompression device by another example of Embodiment 9. It is a figure which shows the relationship between the pressure around the magnet wire and the discharge start voltage by Embodiment 9. FIG. It is a figure which shows the hardware composition of the control device in Embodiments 1-9.
  • FIG. 1 is a diagram showing a configuration of an inspection device for magnet wire coating according to the first embodiment.
  • the magnet wire coating inspection device 100 has a feeding device 3 for feeding out the coated magnet wire 2 and a winding device 4 for winding the magnet wire 2, and has a traveling path of the magnet wire 2.
  • the traveling path forming device is configured from the feeding device 3 and the winding device 4.
  • the inspection device 100 includes a discharge detection device including a discharge detection electrode 5 for detecting the discharge generated from the wire of the magnet wire 2, a detection device 10 for detecting the discharge signal, and a wire of the magnet wire 2. It is provided with a heating device 7A for heating.
  • the heating device 7A is provided as a discharge promoting device that promotes the generation of discharge from the wire of the magnet wire 2.
  • the feeding device 3 includes a feeding machine 3A and a bobbin 3B for feeding the magnet wire 2, and is arranged on the upstream side of the traveling path 1.
  • the take-up device 4 includes a take-up machine 4A and a bobbin 4B for taking up the magnet wire 2, and is arranged on the downstream side of the traveling path 1. Then, the feeding machine 3A and the winding machine 4A adjust the speed and cause the magnet wire 2 before winding to travel in the linear direction at a constant speed to form a traveling path 1.
  • the discharge detection electrode 5 detects discharge by applying an AC voltage from the AC power supply 6 to the magnet wire 2 and collecting the discharge charge generated from the wire of the magnet wire 2 at a set location in the traveling path 1. ..
  • the detection device 10 detects the discharge signal based on the discharge charge from the discharge detection electrode 5.
  • the heating device 7A is provided on at least one of the upstream side and the downstream side (in this case, only the upstream side) of the voltage application point by the discharge detection electrode 5, and heats the wire of the magnet wire 2 at the voltage application point. .. Since the heating device 7A is provided for heating the wire of the magnet wire 2 at the voltage application point, it is arranged in the vicinity of the discharge detection electrode 5 and in the vicinity thereof.
  • the inspection device 100 includes a control device 30 that monitors the discharge signal from the detection device 10 and determines an abnormality in the magnet wire coating based on the discharge signal.
  • the control device 30 includes an A / D (analog-digital) conversion unit 31, a storage unit 32, a calculation unit 33, a measurement unit 34, and a determination unit 35.
  • the discharge signal from the detection device 10 is A / D converted by the A / D conversion unit 31 at a constant sampling frequency, and then stored in the storage unit 32.
  • the calculation unit 33 takes out the discharge signal in the storage unit 32, performs a predetermined process described later, and then calculates the feature amount.
  • the determination unit 35 determines an abnormality in the magnet wire coating based on the calculated feature amount. Further, the measuring unit 34 measures the traveling time of the magnet wire 2 as needed.
  • FIG. 2 is a diagram illustrating the configuration of the magnet wire 2.
  • the magnet wire 2 is composed of a wire 21 made of copper, aluminum, or the like, and a coating 22 which is a magnet wire coating made of an organic insulator that covers the surface of the wire 21.
  • the wire 21 from which the coating 22 has been peeled off is grounded (see FIG. 1).
  • FIG. 3 is a diagram showing the configuration of the discharge detection electrode 5
  • FIG. 4 is a diagram illustrating discharge detection by the discharge detection electrode 5 and the detection device 10.
  • the discharge detection electrode 5 is arranged in an annular shape around the magnet wire 2 at the voltage application point in the traveling path 1 of the magnet wire 2, and is formed, for example, in a ring shape having a circular cross-sectional shape.
  • the discharge detection electrode 5 may be formed of a metal material such as iron, aluminum, or copper, or may be formed of a conductive rubber or a resin material having a metal material such as aluminum vapor-deposited on the surface thereof.
  • the inner diameter of the ring-shaped discharge detection electrode 5 may be matched with the outer diameter of the magnet wire 2, and the discharge detection electrode 5 may be brought into contact with the magnet wire 2.
  • the discharge detection electrode 5 may be arranged with a gap of about 10 ⁇ m to 100 ⁇ m between the coating wire 2 and the magnet wire 2 in order to avoid scratching of the coating 22 due to contact.
  • one end of the AC power supply 6 is connected to the discharge detection electrode 5, and the other end of the AC power supply 6 is grounded in the same manner as the wire 21.
  • the discharge detection electrode 5 applies an AC voltage from the AC power supply 6 to the magnet wire 2 at a set location in the traveling path 1.
  • a discharge is generated from the wire 21 at the voltage application point to the discharge detection electrode 5 via the defective portion 23 of the coating 22, and the discharge charge thereof. Is collected by the discharge detection electrode 5 and sent to the detection device 10.
  • the detection device 10 is composed of, for example, a coupling capacitor 11, a detection impedance 12, and a discharge detector 13.
  • a series circuit of the coupling capacitor 11 and the detection impedance 12 is connected in parallel to the coating 22, and an AC voltage is applied to the series circuit and the coating 22 from the AC power supply 6.
  • the discharge detector 13 detects the voltage generated across the detection impedance 12. When a discharge is generated from the strand 21 to the discharge detection electrode 5, a steep fluctuation occurs in the applied AC voltage.
  • the discharge detector 13 detects the fluctuation of the AC voltage as a voltage value generated across the detection impedance 12.
  • FIG. 5 is an equivalent circuit diagram illustrating the discharge detection shown in FIG.
  • the capacitance C1 of the defective portion 23 due to a pinhole or a scratch in the coating 22 and the capacitance C2 of the portion between the defective portion 23 and the wire 21 are connected in series.
  • the impedance 12 is in a parallel relationship, and an AC voltage is applied.
  • the generated discharge charge is discharged to the grounding point through a closed circuit composed of the capacitances C1, C2, C4 and the detection impedance 12.
  • a discharge charge flows through the detection impedance 12
  • a voltage is generated at both ends thereof, and the discharge detector 13 detects the generated voltage. If no discharge charge flows through the detection impedance 12, no voltage is generated.
  • the voltage (voltage signal) detected by the discharge detector 13 is the discharge signal detected by the detection device 10.
  • the heating device 7A lowers the discharge start voltage to promote the generation of discharge.
  • the heating device 7A heats the wire 21 at a heat resistant temperature of the coating 22, that is, a temperature not exceeding the heat resistant temperature of the coating material.
  • FIG. 6 is a waveform diagram showing the characteristics of the discharge start voltage depending on the temperature change.
  • the coating film thickness is 2E-05 m (20 ⁇ m)
  • the temperature of the discharge detection unit between the wire 21 at the voltage application point and the discharge detection electrode 5 is increased from 25 ° C to 200 ° C at 25 ° C intervals.
  • the discharge start voltage is shown when the voltage is increased.
  • the discharge start voltage is 500 V
  • the atmospheric pressure of the discharge detection unit is 101330 Pa (1 atm). It can be seen that the discharge start voltage decreases as the temperature rises and the air density decreases.
  • FIG. 7 is a flowchart illustrating the operation of the magnet wire covering inspection device 100.
  • the feeding device 3 and the winding device 4 drive the magnet wire 2 before winding in the linear direction at a constant speed.
  • the above-mentioned travel path 1 is formed (step S1).
  • the discharge detection electrode 5 applies an AC voltage to the magnet wire 2, and the detection device 10 detects the discharge signal (step S2).
  • the detected discharge signal is transmitted to the control device 30, is A / D converted at a constant sampling frequency by the A / D conversion unit 31, and then stored in the storage unit 32.
  • the calculation unit 33 takes out the discharge signal in the storage unit 32 and performs the following processing. First, for a preset reference charge amount signal strength, for example, 100 picocoolons, a signal having a reference charge amount signal strength or less is removed from the discharge signal to remove unnecessary weak noise, discharge noise. As a result, discharge noise not related to the discharge caused by the defective portion 23 due to the pinhole or scratch in the coating 22 is removed.
  • the discharge noise to be removed includes the discharge from the surface of the normal coating 22, and the discharge caused by the environment of the inspection work place of the inspection apparatus 100, for example, the wire 21, the AC power supply 6, or the discharge detection. Discharge and the like caused by the instability of the grounding point potential of the device 13 are also included (step S3).
  • the discharge noise removal which is the process of step S3, may be performed at the same time when the discharge signal is stored in the storage unit 32 in order to reduce the calculation load of the calculation unit 33.
  • the reference charge amount signal strength may be stored in the storage unit 32 in advance, and the discharge noise, which is a signal equal to or lower than the reference charge amount signal strength, may be removed from the detected discharge signal so as not to be stored.
  • the calculation unit 33 further smoothes the discharge signal from which the discharge noise has been removed.
  • the moving average method can be applied to the smoothing process (step S4).
  • FIG. 8 is a waveform diagram of the discharge signal detected by the detection device 10
  • FIG. 9 is a waveform diagram of the discharge signal after the smoothing process.
  • FIG. 9 shows an example of moving average processing with a moving average score of 9 points.
  • the discharge signal waveform 15 shown in FIG. 8 becomes a smoothed discharge signal waveform 16 as shown in FIG. 9 after the smoothing process.
  • the smoothing process can be performed by a simple calculation.
  • step S3 and the smoothing process in step S4 can be performed at the same time. In that case, the discharge signal having a reference charge amount signal strength or less may be ignored during the smoothing process.
  • the calculation unit 33 calculates the feature amount for the discharge signal after the smoothing process.
  • the feature amount for example, the peak discharge charge amount, the discharge duration, the total discharge charge amount, etc. of the detected discharge are used, and one or more of these calculation targets may be used. May be selected and combined (step S5).
  • the determination unit 35 acquires the feature amount which is the calculation result from the calculation unit 33, determines whether or not the value is equal to or more than the preset upper limit value (step S6), and when it is equal to or more than the upper limit value, the magnet. It is determined that there is a defect portion 23 in the wire coating (step S7). In step S6, when the value of the feature amount is less than the upper limit value, it is determined that the magnet wire coating has no defect (step S8).
  • the inspection device 100 causes the coated magnet wire 2 to travel at a constant speed in the linear direction before winding (corresponding to the first step of the present application), and is set in the traveling path 1.
  • an AC voltage is applied by the discharge detection electrode 5 to collect the discharge charge generated from the wire 21 of the magnet wire 2 (corresponding to the second step of the present application), and discharge detection is performed based on the discharge charge (corresponding to the second step of the present application).
  • the heating device 7A is arranged close to the discharge detection electrode 5 to heat the wire 21 of the magnet wire 2 at the voltage application point (corresponding to the fourth step of the present application), and perform the discharge detection.
  • the voltage applied for discharge detection can be suppressed to a low voltage. That is, the defective portion 23 of the coating 22 that causes an insulation abnormality of the magnet wire 2 can be detected with high accuracy at a low voltage. As a result, the insulation characteristics of the magnet wire 2 can be reliably inspected before winding without damaging the normal magnet wire coating.
  • the inspection device 100 calculates a feature amount based on the detected discharge signal, and determines an abnormality in the magnet wire coating based on the feature amount (corresponding to the fifth step of the present application). Therefore, the inspection of the insulation characteristics of the magnet wire 2 can be easily performed with high accuracy.
  • the inspection device 100 is provided with a control device 30 that monitors the detected discharge signal and determines an abnormality.
  • the control device 30 is provided separately from the inspection device 100 and the discharge signal is provided. May be received.
  • the feeding device 3 and the winding device 4 shown in the above embodiment may be configured by placing the bobbins 3B and 4B on the turntable 19 as shown in FIG. 10, respectively.
  • the inspection device 100 in which the heating device 7A is provided only on the upstream side of the voltage application point by the discharge detection electrode 5 is shown, but as shown in FIG. 11, the discharge is performed on the upstream side and the downstream side, respectively.
  • Heating devices 7A and 7B that serve as acceleration devices may be provided.
  • the temperature stability at the voltage application point by the discharge detection electrode 5 can be ensured, and the inspection accuracy by the inspection device 100 is improved.
  • the heating devices 7A and 7B are provided to heat the wire 21 of the magnet wire 2 at the voltage application point, they are arranged in the vicinity of the discharge detection electrode 5 and in the vicinity thereof. Further, each of the heating devices 7A and 7B heats the wire 21 at a heat resistant temperature of the coating 22 of the magnet wire 2, that is, a temperature not exceeding the heat resistant temperature of the coating material.
  • FIG. 12 is a diagram showing a configuration of an inspection device for magnet wire coating according to the second embodiment.
  • the magnet wire coating inspection device 100A according to the second embodiment includes the magnet wire coating inspection device 100 according to the first embodiment, thermometers 41A and 41B as temperature measuring units, and a temperature display device. 42A and 42B are provided.
  • the thermometer 41A is arranged between the heating device 7A and the discharge detection electrode 5 in the vicinity of the downstream side of the heating device 7A
  • the thermometer 41B is arranged with the heating device 7B and the discharge detection electrode 5 in the vicinity of the upstream side of the heating device 7B. Place between.
  • the temperature of the magnet wire 2 measured by the thermometers 41A and 41B is displayed on the temperature display devices 42A and 42B.
  • Other configurations and operations are the same as those in the first embodiment.
  • thermometers 41A and 41B and the temperature display devices 42A and 42B are provided, the operator of the inspection device 100A can be urged to adjust the outputs of the heating devices 7A and 7B. Specifically, when the operator visually confirms the temperature display of the temperature display devices 42A and 42B and the temperature of the magnet wire 2 rises to near the heat resistant temperature of the coating material, the heat resistant temperature of the coating material is not exceeded. Make adjustments such as lowering the output of the heating devices 7A and 7B. As a result, it is possible to prevent the coating 22 of the magnet wire 2 from being damaged, and the insulation characteristics of the magnet wire 2 can be inspected more reliably.
  • thermometers 41A and 41B are arranged between the heating devices 7A and 7B and the discharge detection electrode 5, respectively, but the present invention is not limited to this.
  • the thermometer 41A may be arranged in the vicinity of the upstream side of the heating device 7A, and the thermometer 41B may be arranged in the vicinity of the downstream side of the heating device 7B.
  • the heating device 7A includes the thermometer 41A and the temperature display device 42A, and the heating device 7B is a thermometer. It may be provided with 41B and a temperature display device 42B.
  • alarm devices 43A and 43B may be provided instead of the temperature display devices 42A and 42B.
  • the alarm devices 43A and 43B issue an alarm.
  • the operator is urged to adjust the outputs of the heating devices 7A and 7B, and the same effect can be obtained.
  • thermometers 41A and 41B used in the second embodiment are formed by attaching a thermocouple 45 to a ring-shaped metal thin film 44 such as iron, copper, or aluminum by soldering or the like, as shown in FIG. 14, for example. You may use the one that has been used. In that case, the inner diameter of the ring formed by the metal thin film 44 may be matched with the outer diameter of the magnet wire 2 so that the metal thin film 44 and the magnet wire 2 are brought into contact with each other.
  • FIG. 15 is a diagram showing a configuration of an inspection device for magnet wire coating according to the third embodiment.
  • the magnet wire coating inspection device 100B according to the third embodiment has the same thermometers 41A and 41B as those of the second embodiment in the magnet wire coating inspection device 100 according to the first embodiment.
  • the control device 30 includes a temperature adjusting unit 36 that controls the heating devices 7A and 7B to adjust the temperature.
  • the temperature signal of the magnet wire 2 which is the output of each thermometer 41A and 41B is transmitted to the control device 30, and is A / D converted by the A / D conversion unit 31 at a constant sampling frequency, and then the temperature adjustment unit. It is input to 36.
  • the temperature adjusting unit 36 adjusts the outputs of the heating devices 7A and 7B so that the temperature of the magnet wire 2 is within a preset range.
  • the preset range is set so that the discharge is effectively detected at a temperature not exceeding the heat resistant temperature of the coating material.
  • Other configurations and operations are the same as those in the first embodiment.
  • the heating devices 7A and 7B can be automatically adjusted to maintain the magnet wire 2 at a desired temperature, and damage to the coating 22 of the magnet wire 2 can be easily and reliably prevented, and the air density can be increased by heating.
  • the discharge detection accuracy can be improved by lowering the accuracy to high. Therefore, the insulation characteristics of the magnet wire 2 can be inspected more reliably.
  • the temperature signal of the magnet wire 2 transmitted to the control device 30 may be stored not only in the temperature adjusting unit 36 but also in the storage unit 32 after the A / D conversion.
  • the operator can read out the signal information at any time and utilize it as a quality record at the time of inspection. For example, the operator confirms the correlation between the discharge detection frequency and the temperature transition of the magnet wire 2 based on the read signal information, and the set traveling speed of the magnet wire 2, or the output conditions of the heating devices 7A and 7B, etc. Can be confirmed if is appropriate.
  • FIG. 16 is a diagram showing the configuration of the heating device
  • FIG. 17 is a diagram showing the operation of the heating device.
  • each heating device 7A, 7B includes a heating wire coil 46 formed by forming a heating wire such as a nichrome wire into a coil shape, and a DC power supply 47. Then, as shown in FIG. 17, the magnet wire 2 is run so as to pass through the heating wire coil 46 to which the DC voltage is applied from the DC power supply 47. A direct current flows through the heating wire coil 46, and the heat conduction 48 due to the heat generated by the resistance can raise the temperature of the magnet wire 2.
  • the output adjustment of the heating devices 7A and 7B can be realized by adjusting the output voltage of the DC power supply 47.
  • the inner diameter of the heating wire coil 46 may be matched with the outer diameter of the magnet wire 2 so that the heating wire coil 46 and the magnet wire 2 may be brought into contact with each other.
  • the inner diameter of the heating wire coil 46 may be formed larger than the outer diameter of the magnet wire 2 with a margin of about 10 ⁇ m to 100 ⁇ m.
  • FIG. 18 is a diagram showing the configuration of the heating device
  • FIG. 19 is a diagram showing the operation of the heating device.
  • each of the heating devices 7A and 7B is configured by using an induction heating coil including a conductor coil 49 in which a conductor is formed into a coil and a high frequency power supply 50.
  • the magnet wire 2 is run so as to pass through the conducting wire coil 49, which is an induction heating coil to which a high frequency voltage is applied from the high frequency power supply 50.
  • a temperature setting device 51 connected to the high frequency power supply 50 may be provided.
  • Optimal heating efficiency can be obtained by adjusting the oscillation frequency of the high-frequency power supply 50 to be variable.
  • the optimum oscillation frequency is determined in advance for each wire diameter of the strand 21 by an experiment or the like, and stored in the temperature setting device 51. Then, when inspecting the insulation characteristics, the wire diameter of the wire 21 of the magnet wire 2 to be inspected is input to the temperature setting device 51, the temperature setting device 51 extracts the optimum oscillation frequency, and the high frequency power supply 50 is used. Adjust the oscillation frequency of. Alternatively, the operator may set the optimum oscillation frequency determined in advance according to the wire diameter of the strand 21.
  • the temperature adjusting unit 36 can adjust the output of the heating devices 7A and 7B by adjusting the high frequency power output from the high frequency power supply 50 to the conducting coil 49.
  • the temperature adjusting unit 36 may be configured to also serve as the temperature setting device 51.
  • the inner diameter of the conducting wire coil 49 which is an induction heating coil, may be matched with the outer diameter of the magnet wire 2 so that the conducting wire coil 49 and the magnet wire 2 are brought into contact with each other.
  • the inner diameter of the conducting wire coil 49 may be formed larger than the outer diameter of the magnet wire 2 with a margin of about 10 ⁇ m to 100 ⁇ m.
  • FIG. 20 is a diagram illustrating a guide block of a magnet wire according to a sixth embodiment.
  • an AC voltage is applied by the discharge detection electrode 5 while heating the wire 21 of the magnet wire 2 at the set location in the traveling path 1.
  • the discharge generated by the defective portion 23 of the coating 22 is detected.
  • Instability of the traveling path 1 is a factor that hinders highly accurate discharge detection.
  • the contact state or distance between the magnet wire 2 and the discharge detection electrode 5 may fluctuate due to slight meandering or slight vibration of the traveling path 1.
  • the guide block 60 is arranged as.
  • the guide block 60 stabilizes the travel path 1 by the magnet wire 2, and includes a feeding device 3, a winding device 4, and a guide block 60 to form a traveling path forming device.
  • the guide block 60 can be similarly applied to the above-described first to fifth embodiments.
  • the guide block 60 made of a resin material having a substantially cubic shape is provided with a through hole 61 for passing the magnet wire 2 and a groove 62 for accommodating the discharge detection electrode 5, and as shown in FIG. 20B, discharge detection is provided.
  • the electrode 5 is stored in the groove 62, and as shown in FIG. 20C, the magnet wire 2 is run so as to pass through the through hole 61.
  • the through hole 61 penetrates two surfaces facing each other across the circular surface of the discharge detection electrode 5, and the center point coincides with the center point of the discharge detection electrode 5 and is about 10 ⁇ m to 100 ⁇ m larger than the outer diameter of the magnet wire 2. Formed by diameter. Further, the magnet wire 2 enters the guide block 60 from the entrance of the through hole 61 on the upstream end surface of the guide block 60, approaches the discharge detection electrode 5, and is in a stable contact state with the discharge detection electrode 5 or at an appropriate distance. It passes through the voltage application point while maintaining the above speed, and exits from the through hole 61 outlet on the downstream end surface of the guide block 60 to the outside of the guide block 60.
  • the magnet wire 2 is guided by the guide block 60 to stabilize the traveling path 1, so that a high-strength discharge can be stably detected.
  • the feature amount of the discharge signal can be calculated with high accuracy by the calculation unit 33, and the accuracy of discharge detection is improved.
  • the guide block 60 is made of a resin material, it is possible to prevent the magnet wire 2 from being damaged by scratching.
  • a fluororesin such as PTFE (Poly Terra Fluoro Ethylene) having a low coefficient of friction is suitable.
  • the guide block 60 can also be formed of a metal material such as iron, aluminum, or copper. In that case, the run path 1 of the magnet wire 2 is formed instead of storing the discharge detection electrode 5 in the guide block 60.
  • the guide block 60 itself provided with the through hole 61 is used as a discharge detection electrode. Also in this case, the through hole 61 is adjusted to have a diameter larger than the outer diameter of the magnet wire 2 by about 10 ⁇ m to 100 ⁇ m.
  • the guide block 60 may be held on a gantry in the traveling path 1 (not shown).
  • the guide structure for guiding the magnet wire 2 is described above as long as the magnet wire 2 is guided to pass through the voltage application point while maintaining a stable contact state with the discharge detection electrode 5 or an appropriate distance. It is not limited to that shown in the sixth embodiment.
  • Embodiment 7 is a diagram illustrating a guide block of a magnet wire according to a seventh embodiment.
  • the distance between the heating devices 7A and 7B and the discharge detection electrode 5 is a factor that hinders the highly accurate discharge detection by the magnet wire coating inspection device 100 and is different from the factor shown in the sixth embodiment. There is variation. If the distance between the heating devices 7A and 7B and the discharge detection electrode 5 varies, the temperature of the magnet wire 2 at the voltage application point becomes stable even if the heating devices 7A and 7B heat the magnet wire 2 with a constant output. However, the amount of discharge varies due to the decrease in air density, and the accuracy of discharge detection deteriorates.
  • the magnet wire 2 as shown in FIG. 21A is provided in the traveling path 1.
  • a guide block 60A is arranged as a guide portion for guiding.
  • a traveling path forming device is configured by including a feeding device 3, a winding device 4, and a guide block 60A. Further, the guide block 60A can be applied to the inspection device 100 shown in the first embodiment.
  • a through hole 61 for passing the magnet wire 2 a groove 62 for accommodating the discharge detection electrode 5, and a groove for accommodating the heating devices 7A and 7B, respectively.
  • 63A and 63B are provided in the guide block 60A made of a highly heat-resistant resin material having a substantially rectangular parallelepiped shape.
  • the grooves 63A and 63B for the heating devices 7A and 7B are provided parallel to the groove 62 for the discharge detection electrode 5 and equidistant on both sides of the groove 62 as the center.
  • the heating wire coil 46 according to the fourth embodiment or the conducting wire coil 49 according to the fifth embodiment is stored in the grooves 63A and 63B.
  • the heating wire coil 46 is connected to the DC power supply 47, and the conductor coil 49 is connected to the high frequency power supply 50.
  • the discharge detection electrode 5 is stored in the groove 62
  • the heating devices 7A and 7B are stored in the grooves 63A and 63B, respectively
  • the magnet wire 2 is inserted into the through hole 61 as shown in FIG. 21C. Run so that it passes through the inside.
  • the guide block 60A is provided with a plurality of (in this case, three) grooves 62, 63A, 63B for accommodating the discharge detection electrode 5 and the heating devices 7A, 7B, respectively.
  • the discharge detection electrode 5 and the heating devices 7A and 7B are stored in the three grooves 62, 63A and 63B, respectively, so that the center points of the heating devices 7A and 7B coincide with the center points of the discharge detection electrodes 5. Fix in each fixed position. Therefore, the distance between the heating devices 7A and 7B and the discharge detection electrode 5 is constant and does not vary.
  • the through hole 61 penetrates two opposite surfaces with the circular surface of the discharge detection electrode 5 interposed therebetween, and the center point coincides with the center point of the discharge detection electrode 5, and is about 10 ⁇ m to 100 ⁇ m from the outer diameter of the magnet wire 2. Formed with a large diameter.
  • the magnet wire 2 enters the guide block 60A from the entrance of the through hole 61 on the upstream end surface of the guide block 60A, passes through the coil of the heating device 7A, approaches the discharge detection electrode 5, and is stable with the discharge detection electrode 5. It passes through the voltage application point in a good contact state or at an appropriate distance, passes through the coil of the heating device 7B, and goes out of the guide block 60A from the through hole 61 outlet on the downstream end surface of the guide block 60A.
  • the magnet wire 2 is guided by the guide block 60A to stabilize the traveling path 1, and the distance between the heating devices 7A and 7B and the discharge detection electrode 5 is constant. Therefore, the temperature of the magnet wire 2 at the voltage application point can be stabilized, and the discharge due to the decrease in air density can be stably detected with high intensity under the condition of constant temperature. As a result, the feature amount of the discharge signal can be calculated with high accuracy by the calculation unit 33, and the accuracy of discharge detection is improved.
  • the guide block 60A is made of a highly heat-resistant resin material, it is possible to prevent the magnet wire 2 from being damaged by scratching, and it also has heat resistance to heating by the heating devices 7A and 7B.
  • a fluororesin such as PTFE having a heat-resistant temperature of 200 ° C. or higher is suitable.
  • FIG. 22 is a diagram illustrating a guide block of a magnet wire according to another example of the seventh embodiment. This guide block 60B can be applied to the inspection devices 100A and 100B shown in the second and third embodiments.
  • a through hole 61 for passing the magnet wire 2 a groove 62 for accommodating the discharge detection electrode 5, and a groove for accommodating the heating devices 7A and 7B, respectively.
  • 63A and 63B and grooves 64A and 64B for accommodating thermometers 41A and 41B are provided, respectively.
  • the grooves 63A and 63B for the heating devices 7A and 7B are provided parallel to the groove 62 for the discharge detection electrode 5 and equidistant on both sides of the groove 62 as the center.
  • the grooves 64A and 64B for the thermometers 41A and 41B are located between the grooves 63A and 63B and the groove 62, respectively, parallel to the groove 62 and equidistant on both sides of the groove 62 as the center. It is provided in.
  • the discharge detection electrode 5 is stored in the groove 62
  • the heating devices 7A and 7B are stored in the grooves 63A and 63B, respectively
  • the thermometers 41A and 41B are stored in the grooves 64A and 64B, respectively.
  • the magnet wire 2 is run so as to pass through the through hole 61.
  • the guide block 60B further provided with the grooves 64A and 64B for the thermometers 41A and 41B, the distance between the temperature measurement position of the magnet wire 2 and the discharge detection electrode 5 can be made constant, and the heating device 7A , The accuracy of the output adjustment of 7B is improved, which further improves the accuracy of discharge detection.
  • FIG. 23 is a diagram showing a configuration of an inspection device for magnet wire coating according to the eighth embodiment.
  • FIG. 24 is a partially enlarged view showing a winding device and a stator core connected to an inspection device for magnet wire coating.
  • the point A in FIG. 23 is connected to the point A in FIG. 24.
  • the magnet wire coating inspection device 100C is applied to the winding process of a stator which is an armature of a rotary electric machine or a linear motion machine.
  • This embodiment 8 can be applied to each of the above embodiments 1 to 7, but here, the one applied to the above embodiment 3 is illustrated, and only the different parts will be described.
  • the inspection device 100C does not include a winding device 4 for winding the magnet wire 2, and sends the magnet wire 2 to the winding device 70 installed on the downstream side of the traveling path 1.
  • the magnet wire 2 is wound around the stator core 72 by the nozzle 71 of the winding device 70.
  • the inspection device 100C includes an output unit 37 inside the control device 30 and a display device 38 for displaying output information to the outside.
  • the output unit 37 displays desired output information, for example, a waveform image of the detected discharge signal on the display device 38 together with the determination result of the determination unit 35. At this time, the integrated number of the discharge signals determined to have the defective portion 23 on the magnet wire coating may also be displayed.
  • the inspection device 100C inspects the magnet wire 2 before winding by discharge detection, and the winding device 70 winds the magnet wire 2 around the stator core 72 continuously in this inspection. .. Then, in a series of steps, the operator can check the detection state of the defective portion 23, which is an insulation abnormality of the magnet wire coating, on the display device 38 at any time.
  • the winding work on the stator core 72 is continuously performed regardless of the presence or absence of the defective portion 23. Further, before the measurement is completed by the measurement unit 34, the running of the magnet wire 2 may be stopped due to the stop of the winding device 70 or the like.
  • the measuring unit 34 detects whether or not the magnet wire 2 is traveling, and if it detects that the traveling stop is detected, the measurement of the traveling time is interrupted. Then, when the winding device 70 resumes winding and the traveling of the magnet wire 2 resumes, the measurement by the measuring unit 34 also resumes.
  • stator core 72 around which the magnet wire 2 having an insulation defect is wound around the coating 22 is specified by the inspection device 100C. Then, the specified stator core 72 or the stator including the stator core 72 is not discharged to the subsequent steps. These are distinguished from non-defective products by means of transfer such as a conveyor for paying out defective products and a trolley. Further, these defective stator cores may be individually inspected again by a known method such as a surge voltage application (impulse voltage application) test.
  • surge voltage application impulse voltage application
  • FIG. 25 is a diagram showing the configuration of the stator after winding. As shown in the figure, after the stator core 72 around which the winding coil 73 wound by the magnet wire 2 is wound is circularly formed, the frame 74 is attached to form the stator 75.
  • FIG. 26 is a diagram showing a configuration of an electric machine using a stator after winding.
  • the rotary electric machine 90 which is an electric machine, includes a stator 75 and a rotor 91 formed as described above.
  • the rotary electric machine 90 is manufactured by using a stator core 72 whose coating 22 of the wound magnet wire 2 is confirmed to have no insulation defect by the magnet wire coating inspection device 100C. As a result, a highly reliable rotary electric machine 90 using the magnet wire 2 having good insulation characteristics can be obtained.
  • a rotary electric machine 90 is shown as an example of an electric machine, but it may be a linear motion machine, and the iron core around which the magnet wire 2 is wound is not limited to the stator core 72.
  • the magnet wire after the inspection is confirmed to have no insulation defect. 2 can be wound around an iron core to manufacture an electric machine. Similarly, in that case, a highly reliable electric machine using the magnet wire 2 having good insulation characteristics can be obtained.
  • FIG. 27 is a diagram showing a configuration of an inspection device for magnet wire coating according to the ninth embodiment.
  • the magnet wire coating inspection device 100D is applied to the winding process of the stator, which is an armature of a rotary electric machine or a linear motion machine, as in the eighth embodiment, and is a point in FIG. 27.
  • A is connected to the point A in FIG. 24 shown in the eighth embodiment.
  • the inspection device 100D includes a feeding device 3 having a feeding machine 3A and a bobbin 3B for feeding the magnet wire 2 on the upstream side of the traveling path 1 of the magnet wire 2, but the winding device 4 for winding the magnet wire 2 is provided.
  • the magnet wire 2 is sent to the winding device 70 installed on the downstream side of the traveling path 1.
  • the magnet wire 2 is wound around the stator core 72 by the nozzle 71 of the winding device 70.
  • the magnet wire coating inspection device 100D is provided at a voltage application point in the traveling path 1 and a discharge detection device composed of the discharge detection electrode 5 and the detection device 10 to reduce the pressure around the magnet wire 2.
  • a decompression device 9 is provided.
  • the discharge detection electrode 5 and the detection device 10 operate in the same manner as in the first embodiment.
  • the decompression device 9 is provided as a discharge promotion device that promotes the generation of discharge from the wire of the magnet wire 2, and decompresses the inside of the decompression tank 8 arranged so as to surround the magnet wire 2 at the voltage application point and the inside of the decompression tank 8. It is equipped with a decompression pump 8A.
  • the inspection device 100D includes a control device 30 that monitors the discharge signal from the detection device 10 and determines an abnormality in the magnet wire coating based on the discharge signal, and a display device 38 that displays output information to the outside.
  • the control device 30 includes an A / D (analog-to-digital) conversion unit 31, a storage unit 32, a calculation unit 33, a measurement unit 34, a determination unit 35, and an output unit 37, as in the eighth embodiment.
  • a pressure adjusting unit 39 for controlling the depressurizing device 9 to adjust the pressure is provided.
  • FIG. 28 is a diagram showing the configuration of the decompression device 9.
  • the decompression device 9 includes a decompression tank 8 formed into a substantially cubic body by an insulating resin panel such as acrylic resin, and a decompression pump 8A for depressurizing the inside of the decompression tank 8.
  • the resin panels on the two facing surfaces of the pressure reducing tank 8 are provided with through holes 65A and 65B having the same diameter of about 1 mm in order to allow the magnet wire 2 to pass perpendicularly to the two surfaces.
  • the through holes 65A and 65B are arranged so that the center lines perpendicular to the opening surface coincide with each other through the centers of the through holes 65A and 65B.
  • a pressure gauge 68 for measuring the pressure in the pressure reducing tank 8 is provided.
  • the inner diameter sides of the through holes 65A and 65B may be covered with a rubber material such as silicon rubber.
  • the discharge detection electrode 5 is arranged in an annular shape around the magnet wire 2 at the voltage application point inside the decompression tank 8 in the traveling path 1 of the magnet wire 2, and is connected to the AC power supply 6 via the voltage application unit 6A. Will be done.
  • the discharge detection electrode 5 is gripped and fixed by the grip portion 66 so that the center line of the discharge detection electrode 5 coincides with the center lines of the through holes 65A and 65B.
  • the magnet wire 2 enters the pressure reducing tank 8 through the through hole 65A on the upstream end surface of the pressure reducing tank 8, approaches the discharge detection electrode 5, and maintains a stable contact state with the discharge detection electrode 5 or an appropriate distance.
  • the decompression pump 8A decompresses the inside of the decompression tank 8 to a predetermined pressure while the magnet wire 2 travels in the decompression tank 8.
  • a guide roller 67 may be provided in the decompression tank 8 for guiding the magnet wire 2 to stabilize the running of the magnet wire 2. Further, it is desirable that the resin panel forming the pressure reducing tank 8 is transparent so that the traveling state of the magnet wire 2 can be visually confirmed.
  • the output of the pressure gauge 68 is a signal indicating the pressure in the pressure reducing tank 8, is transmitted to the control device 30, is A / D converted at a constant sampling frequency by the A / D conversion unit 31, and then pressure is adjusted. It is input to the unit 39.
  • the pressure adjusting unit 39 adjusts the output of the decompression pump 8A so that the pressure in the decompression tank 8 is within a preset range.
  • the voltage applied by the discharge detection electrode 5 can be suppressed to a low voltage, and the voltage generated by the discharge ⁇ V can be observed at a low voltage. That is, the defective portion 23 of the coating 22 that causes an insulation abnormality of the magnet wire 2 can be detected with high accuracy at a low voltage. This allows the insulation properties of the magnet wire to be reliably inspected prior to winding without damaging the normal magnet wire coating.
  • FIG. 30 is a diagram showing the relationship between the pressure around the magnet wire and the discharge start voltage.
  • the pressure in the decompression tank 8 is changed in the range of 0.002 Mpa to 0.1 Mpa by the decompression pump 8A, and the discharge start voltage is measured from the wire 21 through the defective portion 23 of the coating 22.
  • the horizontal axis of FIG. 30 indicates the ambient pressure of the magnet wire 2, that is, the pressure in the pressure reducing tank 8.
  • the vertical axis shows the discharge start voltage ratio obtained by dividing the discharge start voltage at each ambient pressure by the discharge start voltage at 0.1 MPa (atmospheric pressure).
  • the discharge start voltage can be lowered by reducing the ambient pressure of the magnet wire 2 to 0.1 Mpa or less, which is a pressure range that does not exceed the discharge start voltage under atmospheric pressure.
  • the pressure adjustment range by the decompression device 9 is 0.005 Mpa to 0.1 Mpa. It is desirable to set it to the range.
  • the inspection device 100D inspects the magnet wire 2 before winding by discharge detection, and the winding device 70 continuously performs the inspection by the magnet wire. 2 is wound around the stator core 72. Then, in a series of steps, the operator can check the detection state of the defective portion 23, which is an insulation abnormality of the magnet wire coating, on the display device 38 at any time.
  • the measuring unit 34 operates as a timer for measuring the traveling time of the magnet wire 2. Further, the calculation unit 33 calculates the time T until the defective portion 23 of the magnet wire coating reaches the stator core 72 in the winding, and the measurement unit 34 acquires the time information (T). Then, the stator core 72 that is in the process of winding when the measurement unit 34 completes the measurement is specified, that is, the stator core 72 having the defective portion 23 of the magnet wire coating is specified. The winding work on the stator core 72 is continuously performed regardless of the presence or absence of the defective portion 23.
  • stator core 72 around which the magnet wire 2 having an insulation defect is wound around the coating 22 is specified by the inspection device 100D. Then, the specified stator core 72 or the stator including the stator core 72 is not discharged to the subsequent steps.
  • the rotating electric machine 90 is manufactured by manufacturing the rotary electric machine 90 by using the stator core 72 whose coating 22 of the wound magnet wire 2 is confirmed to have no insulation defect by the magnet wire coating inspection device 100D. A highly reliable rotary electric machine 90 using the good magnet wire 2 can be obtained.
  • the control device 30 used in each of the above embodiments 1 to 9 can be realized by including, for example, a processor 80 and a storage device 81 having a hardware configuration as shown in FIG. 26.
  • the storage device 81 includes a volatile storage device (not shown) such as a RAM (Random Access Memory) and a non-volatile auxiliary storage device (not shown) such as an HDD (Hard Disk Drive) or SSD (Solid State Drive). It is equipped with.
  • a non-volatile auxiliary storage device a flash memory may be used instead of the HDD.
  • the processor 80 executes the control program input from the storage device 81.
  • the storage device 81 includes an auxiliary storage device and a volatile storage device.
  • the control program 82 is input to the processor 80 from the auxiliary storage device via the volatile storage device.
  • the processor 80 outputs data 83 such as calculation results to the volatile storage device of the storage device 81, and stores these data 83 in the auxiliary storage device via the volatile storage device as needed.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Testing Relating To Insulation (AREA)
PCT/JP2021/034783 2020-10-19 2021-09-22 マグネットワイヤ被覆の検査装置、マグネットワイヤ被覆の検査方法、および電気機械の製造方法 Ceased WO2022085358A1 (ja)

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JP2022557314A JP7329698B2 (ja) 2020-10-19 2021-09-22 マグネットワイヤ被覆の検査装置、マグネットワイヤ被覆の検査方法、および電気機械の製造方法

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