Generator stator assembly and insulation treatment method and mold thereof

Abstract

The present invention discloses an insulation treatment method for a generator stator assembly, wherein the stator assembly includes a stator and a single coil embedded in an iron core slot of the stator, and the insulation treatment method includes: placing a formed single coil into a prefabricated mold corresponding to the single coil, and then impregnating the mold with the single coil with an insulating material, or pouring the insulating material into the mold by pouring. The method performs insulation treatment on the single coil separately, so that the single coil is embedded in the stator iron core slot of the stator assembly after insulation treatment, so that the insulation treatment of the generator stator assembly does not need to rely on large equipment, reducing the difficulty of insulation treatment of the generator stator assembly. The present invention also discloses a generator stator assembly and a mold for insulation treatment of the generator stator assembly.

Description

Technical Field

[0001] The invention relates to the technical field of generator structures, in particular to a generator stator component and an insulation treatment method thereof, and also to a mold used in the insulation treatment method of the generator stator component. Background Art

[0002] The stator assembly of the generator mainly includes a stator core and a single coil embedded in the stator core slot. Among them, the insulation treatment method of the stator assembly is mostly: after the single coil is formed, it is wrapped with several layers of insulating tape (such as mica tape) as a whole, and then embedded in the stator core slot for vacuum pressure impregnation treatment. This treatment process uses liquid insulating material for impregnation, and the final insulation structure is formed after impregnation and curing.

[0003] It can be seen from the above insulation treatment process that the size of the generator stator assembly is limited by the size of the subsequent impregnation equipment. If the core size is large, a correspondingly large impregnation equipment is required, which not only increases the cost but also has the problem of difficulty in manufacturing. In addition, currently, the insulation tape is mostly wound around the single coil by manual work, which has a large human influence factor. Affected by the dispersion of manual work, the insulation performance of the generator stator assembly will also be dispersed.

[0004] In view of this, it is urgent to improve the existing insulation treatment method of the generator stator assembly so that the insulation treatment of the stator assembly is not limited by the size of the impregnation equipment and the difficulty of the insulation treatment is reduced. Summary of the invention

[0005] In order to solve the above technical problems, the present invention provides an insulation treatment method for a generator stator assembly, wherein the stator assembly comprises a stator and a single coil embedded in an iron core slot of the stator, and the insulation treatment method comprises:

[0006] The formed single coil (without insulation tape) is placed in a prefabricated mold corresponding to the single coil, and then the mold containing the single coil is impregnated with liquid insulation material, or the liquid insulation material is poured into the mold by pouring.

[0007] The insulation treatment method provided by the present invention performs insulation treatment on the single coils of the generator stator assembly separately. In this way, after each single coil is insulated, it can be embedded in the slot of the stator core of the generator stator assembly. There is no need to perform overall impregnation insulation treatment on the stator assembly, which avoids the use of large-sized impregnation equipment that matches the size of the stator assembly. The impregnation equipment or related casting equipment used for the insulation treatment of the single coils is relatively much smaller in size, so that the insulation treatment of the generator stator assembly does not need to rely on large equipment, reducing the difficulty of insulation treatment of the generator stator assembly.

[0008] In the insulation treatment method as described above, after the mold containing the single coil is subjected to dipping or pouring treatment, the mold is dried to solidify the insulation material.

[0009] According to the insulation treatment method described above, after the drying treatment, the mold and the single coil are separated, an insulation test is performed on the single coil after the insulation treatment, and the single coil that passes the test is embedded in the core slot of the stator.

[0010] In the insulation treatment method as described above, before placing the single coil into the mold, a release agent or an oleophobic layer is first applied to the inner surface of the mold.

[0011] In the insulation treatment method as described above, the single coil is not wrapped with an insulation tape before being placed in the mold.

[0012] In the insulation treatment method as described above, since the coil is not wrapped with an insulating tape, the liquid insulating material can be a water-based environmentally friendly insulating paint.

[0013] The present invention also provides a generator stator assembly, comprising a stator core and a single coil embedded in a slot of the stator core, wherein the single coil is a single coil impregnated with a liquid insulating material and is not wrapped with an insulating tape.

[0014] The single coil of the generator stator assembly is a single coil that has been impregnated with a liquid insulating material, which is consistent with the principle of the insulation treatment method of the generator stator assembly mentioned above and has the same technical effect.

[0015] The present invention also provides a mold for insulation treatment of a generator stator assembly, wherein the stator assembly includes a stator and a single coil embedded in an iron core slot of the stator, and the mold includes a first mold portion having a first cavity and a second mold portion having a second cavity. When the two are butt-jointed, the first cavity and the second cavity are connected to form a mold cavity, and the shape of the mold cavity is adapted to the single coil; the mold also has two through-hole portions connected to the mold cavity.

[0016] In the mold as described above, the single coil is a concentrated winding coil, including two parallel straight sections and two curved sections, the curved sections connecting the corresponding ends of the two straight sections, and the two straight sections and the two curved sections form a ring structure; the single coil also includes two lead wires, and the two lead wires extend toward the same side along the length direction of the two straight sections respectively;

[0017] The first mold part includes a first annular body having an annular groove, and the second mold part includes a second annular body having an annular groove. When the first annular body and the second annular body are in a docking state, the annular grooves of the two are connected to form the mold cavity that is compatible with the annular structure of the single coil; the mold also includes an insert that is compatible with the shape of the curved segment at the end of the mold, the outer peripheral walls of the first annular body and the second annular body have slots for the inserts to be inserted, and the inserts are provided with two sockets for the lead wires to pass through, and the outer peripheral wall of the mold has a notch that is connected to the socket at a position corresponding to the socket.

[0018] In the mold as described above, the single coil is a distributed winding coil, the single coil is a closed ring structure, and one end of the single coil has two lead wires extending outward;

[0019] The first mold part comprises a first body having a first through groove and a first cover body, wherein the first cover body is used to block the notch of the first through groove to form a first through hole;

[0020] The second mold part comprises a second body having a second through groove and a second cover body, wherein the second cover body is used to block the notch of the second through groove to form a second through hole;

[0021] The two ends of the first mold part are respectively used to butt with the two ends of the second mold part, and when the first mold part and the second mold part are butt-jointed, the first through hole and the second through hole are connected to form the mold cavity;

[0022] The outer peripheral wall of the mold has a notch for the lead wire to pass through. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is a flow chart of an insulation treatment method for a generator stator assembly in a specific embodiment;

[0024] Figure 2 is a schematic cross-sectional view of a single coil of a generator stator assembly in a specific embodiment;

[0025] Figure 3 It is a structural schematic diagram of a concentrated winding coil in a specific embodiment;

[0026] Figure 4 For Figure 3 A schematic structural diagram of a mold corresponding to the concentrated winding coil shown;

[0027] Figure 5 for Figure 4 An exploded view of the mold shown;

[0028] Figure 6 for Figure 4A schematic structural diagram of a first mold portion of the mold shown;

[0029] Figure 7 for Figure 4 A schematic structural diagram of the second mold part of the mold shown;

[0030] Figure 8 for Figure 4 A schematic diagram of the structure of the insert of the mold shown;

[0031] Fig. 9 for Figure 8 A top view of the insert shown;

[0032] Fig.10 It is a structural schematic diagram of a distributed winding coil in a specific embodiment;

[0033] Fig.11 For Fig.10 A schematic structural diagram of a mold corresponding to the distributed winding coil shown;

[0034] Fig.12 for Fig.11 A schematic structural diagram of the first mold of the mold shown;

[0035] Fig.13 for Fig.11 A schematic diagram of the specific structure of the second mold of the mold shown;

[0036] Fig.14 for Fig.11 Schematic diagram of the structure of the cover plate of the mold shown.

[0037] Description of reference numerals:

[0038] A single coil 100, a conductor 110, inter-turn insulation 120, and an insulating material 130;

[0039] Concentrated winding coil 200, straight section 210, curved section 220, lead wire 230;

[0040] A first mold 300, a first mold portion 310, a first annular groove 311, a second mold portion 320, a second annular groove 321, an insert 330, a socket 331, a notch 340, and a pipe fitting 350;

[0041] Distributed winding coil 400;

[0042] The second mold 500 , the first mold body 510 , the first body 511 , the first through hole 512 , the second mold body 520 , the cover body 530 , the cover body 531 , the folded edge 532 , and the connecting pipe 550 . DETAILED DESCRIPTION

[0043] In order to enable those skilled in the art to better understand the solution of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0044] For ease of understanding and concise description, the following text will explain the generator stator assembly and its insulation treatment method, as well as the mold used for insulation treatment, and the beneficial effects will not be repeated.

[0045] Please refer to Figure 1 and Figure 2 , Figure 1 is a flow chart of an insulation treatment method for a generator stator assembly in a specific embodiment; Figure 2 It is a cross-sectional schematic diagram of a single coil of a generator stator assembly in a specific embodiment.

[0046] The generator stator assembly mainly includes a stator and a single coil 100 embedded in the iron core slot of the stator. The insulation treatment of the generator stator assembly is mainly to ensure the insulation of the single coil 100.

[0047] In this embodiment, the insulation treatment method of the generator stator assembly includes the steps of:

[0048] S1. Making a single coil and prefabricating a mold corresponding to the single coil;

[0049] The manufacturing method of the single coil 100 is roughly the same as the existing one. The wire 110 containing the inter-turn insulation 120 is wound to form the single coil 100. The winding method is determined according to the requirements of the generator stator assembly, wherein the inter-turn insulation 120 between the wires 110 of the single coil 100 can be selected as needed.

[0050] The "single coil" here does not imply the winding method of the coil, etc. It only refers to the smallest unit of coil wound in the core slot.

[0051] The mold corresponds to the shape and structure of the single coil 100 .

[0052] S2. Place the formed single coil into a corresponding mold, and then impregnate the mold containing the single coil with a liquid insulating material, or pour the liquid insulating material into the mold by pouring to impregnate the single coil.

[0053] As described above, the insulation treatment method of the generator stator assembly is to perform insulation treatment on the single coil 100 separately after the single coil 100 is manufactured. In this way, after each single coil 100 is insulated, it can be embedded in the stator core slot of the generator stator assembly. There is no need to perform overall impregnation insulation treatment on the stator assembly, which avoids the use of larger-sized impregnation equipment that matches the size of the stator assembly. The impregnation equipment or related casting equipment used for the insulation treatment of the single coil 100 is relatively much smaller, so that the insulation treatment of the generator stator assembly does not need to rely on large equipment, reducing the difficulty of insulation treatment of the generator stator assembly.

[0054] After the above insulation treatment method is adopted, the cross-sectional structure of the single coil 100 embedded in the iron core slot of the stator is as follows: Figure 2 As shown, the outer periphery of the single coil 100 is covered with an insulating material 130 .

[0055] In the specific solution, since the coil surface is not wrapped with insulating tape, the insulating material used for the impregnation or casting treatment can be an oil-based impregnation resin or a water-based environmentally friendly impregnation resin (paint) that is currently widely used in large motors, making the manufacturing process of the stator assembly more environmentally friendly.

[0056] In step S1, after the single coil 100 is wound and formed, it will enter the subsequent separate insulation processing step, so there is no need to wrap the single coil 100 with insulation tape as in the prior art, that is, in this embodiment, in step S1, after the single coil 100 is formed, it is not wrapped with insulation tape. In this way, the manual wrapping process is omitted, the dispersion effect caused by it is avoided, and the insulation performance of the subsequent generator stator assembly can be ensured to be more consistent.

[0057] In a specific solution, after the above step S2, the following is further included:

[0058] Step S3, drying the mold with the single coil 100 after the insulation treatment to solidify the insulation material.

[0059] Specifically, a drying device, such as a baking oven, may be used for drying. The drying temperature may be set according to actual needs and is not limited here.

[0060] Step S4, separating the mold and the single coil 100, and performing an insulation test on the single coil 100, and embedding the single coil 100 that passes the test into the core slot of the stator.

[0061] The insulation test of the single coil 100 may be performed in the conventional way, which will not be described in detail.

[0062] In a specific solution, in order to facilitate the separation of the single coil 100 from the mold, between the aforementioned steps S1 and S2, that is, before the single coil 100 is placed into the mold, a step S11 is further included: applying a release agent or an oleophobic layer on the inner surface of the mold.

[0063] The material of the release agent or the oleophobic layer may be any existing mature material, as long as it is convenient for the subsequent separation of the single coil 100 and the mold.

[0064] In this embodiment, the mold for the insulation treatment of the generator stator assembly includes a first mold part having a first cavity and a second mold part having a second cavity. When the two are connected, the first cavity and the second cavity can be connected to form a mold cavity, and the shape of the mold cavity is adapted to the manufactured single coil; wherein, the mold is divided into two parts to facilitate the assembly of the single coil and the mold. Specifically, two through-holes connected to the mold cavity are provided on the mold to facilitate the entry of the insulating material into the mold during dipping or pouring, and to maintain air pressure balance during the insulation treatment.

[0065] For the generator stator assembly, common single coils 100 are in two forms: concentrated winding and distributed winding. The molds corresponding to the two types of coils are described below.

[0066] Please refer to Figures 3 to 9 , Figure 3 It is a structural schematic diagram of a concentrated winding coil in a specific embodiment; Figure 4 For Figure 3 A schematic structural diagram of a mold corresponding to the concentrated winding coil shown; Figure 5 for Figure 4 An exploded view of the mold shown; Figure 6 for Figure 4 A schematic structural diagram of a first mold portion of the mold shown; Figure 7 for Figure 4 A schematic structural diagram of the second mold part of the mold shown; Figure 8 for Figure 4 A schematic diagram of the structure of the insert of the mold shown; Fig. 9 for Figure 8 A top view of the insert shown.

[0067] Figure 3The structure of a concentrated winding coil 200 in an example is shown. The concentrated winding coil 200 has a runway-shaped structure, mainly including two parallel straight sections 210 and two curved sections 220. The curved sections 220 are used to connect the corresponding ends of the two straight sections 210. The concentrated winding coil 200 also includes two lead wires 230. The two lead wires 230 extend toward the same side along the length direction of the two straight sections 210. For the concentrated winding coil 200, the two lead wires 230 are respectively located at the upper and lower sides of the winding, where the upper and lower sides are based on the vertical direction to the annular surface of the winding.

[0068] The concentrated winding coil 200 has a certain thickness in the up and down directions. The first mold 300 corresponding to the concentrated winding coil 200 includes a first mold part 310 and a second mold part 320. The first mold part 310 includes a first annular body having a first annular groove 311, and the second mold part 320 includes a second annular body having a second annular groove 321. When the first mold part 310 and the second mold part 320 are docked, the notch directions of the first annular groove 311 and the second annular groove 321 are opposite. In the docked state, the first annular groove 311 and the second annular groove 321 are connected to form a mold cavity, and the shape of the mold cavity is adapted to the concentrated winding coil 200.

[0069] Obviously, the first annular groove 311 is the aforementioned first cavity, and the second annular groove 321 is the aforementioned second cavity.

[0070] In a specific configuration, the first mold part 310 and the second mold part 320 may be configured to be substantially equal in the thickness direction.

[0071] It can be understood that in order to form the first annular groove 311 and the second annular groove 321 , the first annular body and the second annular body both have an annular inner circumferential wall and an annular outer circumferential wall.

[0072] The first mold 300 also includes an inserting piece 330, which is matched with the shape of the curved section at the end of the first mold, and the outer peripheral wall of the same end of the first annular body and the second annular body has a slot for inserting the inserting piece 330, and the inserting piece 330 is provided with two sockets 331 for the lead wires 230 of the concentrated winding coil 200 to pass through, and the outer peripheral walls of the first annular body and the second annular body are provided with notches 340 corresponding to the positions of the sockets 331, so that during assembly, the lead wires 230 passing through the inserting piece 330 can extend out of the first mold 300. Obviously, the notch 340 matches the shape of the lead wires 230.

[0073] When assembling the concentrated winding coil 200 and the first mold 300, the concentrated winding coil 200 can be first placed in the first annular groove 311 of the first mold part 310, and then the insert 330 is passed through the two lead wires 230 of the concentrated winding coil 200 and inserted into the outer wall of the first mold part 310, and then the second mold part 320 is buckled with the first mold part 310.

[0074] In the illustrated scheme, two pipes 350 are connected to the peripheral wall of the first mold part 310 and communicate with the mold cavity thereof. When used, one pipe 350 can be used as an inlet for the insulating material to enter the mold, and the other pipe 350 plays a role in air pressure balance. It can be understood that the two pipes 350 are the two through-hole parts mentioned above.

[0075] In actual configuration, the specific configuration positions of the two pipe fittings 350 can be set at other positions of the first mold 300 according to specific circumstances.

[0076] Please refer to Figures 10 to 14 , Fig.10 It is a structural schematic diagram of a distributed winding coil in a specific embodiment; Fig.11 For Fig.10 A schematic structural diagram of a mold corresponding to the distributed winding coil shown; Fig.12 for Fig.11 A schematic structural diagram of the first mold of the mold shown; Fig.13 for Fig.11 A schematic diagram of the specific structure of the second mold of the mold shown; Fig.14 for Fig.11 and Fig.12 Schematic diagram of the structure of the cover plate of the mold shown.

[0077] Fig.10 The specific shape structure of the distributed winding coil 400 in an example is shown. The distributed winding coil 400 is a closed ring structure. In actual application, it is set according to needs, and its specific ring form is not limited to that shown in the figure. In actual setting, one end of the distributed winding coil 400 also has two lead wires extending outward (not shown in the figure).

[0078] Generally, the thickness of the distributed winding coil 400 in the direction perpendicular to its annular surface is relatively small, so it is inconvenient for its corresponding mold to be divided into two parts in the thickness direction.

[0079] In this embodiment, the second mold 500 corresponding to the distributed winding coil 400 includes a first mold body 510 and a second mold body 520, which are connected to form a ring structure corresponding to the distributed winding coil 400, that is, the first mold body 510 and the second mold body 520 are respectively part of the formed ring structure.

[0080] The first mold body 510 includes a first main body 511 having a through slot and a cover body 530 , wherein the cover body 530 is used to block the notch of the through slot, so that the first mold body 510 formed after the cover body 530 is assembled with the first main body 511 has a first through hole 512 .

[0081] The second mold body 520 is similar in composition to the first mold body 510 , and includes a second body 521 having a through slot and a cover body 530 . The cover body 530 blocks the opening of the through slot to form a second through hole.

[0082] Obviously, the first through hole is the aforementioned first cavity, and the second through hole 512 is the aforementioned second cavity.

[0083] After the two ends of the first mold body 510 are respectively connected with the two ends of the second mold body 520, the first through hole of the first mold body 510 is connected with the second through hole of the second mold body 520 to form a mold cavity of the second mold 500, and the shape of the mold cavity is adapted to the distributed winding coil 400.

[0084] During assembly, part of the distributed winding coil 400 can be first embedded in the through groove of the first body 511, and then the cover body 530 can be matched with the first body 511. After that, the remaining part of the distributed winding coil 400 can be embedded in the second body of the second mold body 520, and then another cover body 530 can be matched with the second body. In this way, the distributed winding coil 400 can be loaded into the second mold 500; or the distributed winding coil 400 can be first embedded in the first body 511 and the second body, and then the corresponding cover bodies 530 can be assembled on the first body 511 and the second body respectively.

[0085] In the illustrated embodiment, for ease of manufacturing, the first mold body 510 and the second mold body 520 are substantially symmetrically arranged along the longitudinal center line of the first mold 500 .

[0086] In a specific embodiment, the cover 530 includes a cover body 531 and folded edges 532 bent toward the same side along both sides of the cover body 531 . The peripheral walls of the first body 511 and the second body have slots corresponding to the folded edges 532 to facilitate the installation of the cover 530 .

[0087] like Fig.14 As shown, specifically, the cover body 531 is not provided with folded edges 532 near the two ends, so that a slot for the lead wires of the distributed winding coil 400 to extend out can be formed between the ends of the cover body 531 and the body of the mold body.

[0088] In the illustrated solution, two connecting pipes 550 communicating with the through grooves of the first mold body 510 are inserted on the peripheral wall thereof. It can be understood that the two connecting pipes 550 are the two through-hole portions mentioned above.

[0089] The mold structure provided in this embodiment can be used for both dipping and pouring. In actual applications, the dipping method or pouring method is selected according to the needs to perform insulation treatment on the single coil.

[0090] The above is a detailed introduction to the generator stator assembly and its insulation treatment method and mold provided by the present invention. This article uses specific examples to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only used to help understand the method and core idea of ​​the present invention. It should be pointed out that for ordinary technicians in this technical field, without departing from the principle of the present invention, the present invention can also be improved and modified in a number of ways, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A mold for insulating a stator assembly of a generator, wherein the stator assembly comprises a stator and a single coil embedded in an iron core slot of the stator, characterized in that: The mold comprises a first mold part having a first cavity and a second mold part having a second cavity. When the two are butted, the first cavity and the second cavity are connected to form a mold cavity. The shape of the mold cavity is adapted to the single coil. The first mold part and the second mold part are arranged in a thickness direction. The mold also has two through-hole parts connected to the mold cavity, one of which is used for the entrance of the insulating material into the mold, and the other is used for balancing the air pressure. The single coil is a concentrated winding coil, comprising two parallel straight sections and two curved sections, wherein the curved sections connect the corresponding ends of the two straight sections, and the two straight sections and the two curved sections form a ring structure; the single coil also comprises two lead wires, and the two lead wires extend toward the same side along the length direction of the two straight sections respectively; The first mold part includes a first annular body having an annular groove, and the second mold part includes a second annular body having an annular groove. When the first annular body and the second annular body are in a docking state, the annular grooves of the two are connected to form the mold cavity that is compatible with the annular structure of the single coil; the mold also includes an insert that is compatible with the shape of the curved segment at the end of the mold, the outer peripheral walls of the first annular body and the second annular body have slots for the inserts to be inserted, and the inserts are provided with two sockets for the lead wires to pass through, and the outer peripheral wall of the mold has a notch that is connected to the socket at a position corresponding to the socket.

2. A mold for an insulation treatment method of a generator stator assembly, wherein the stator assembly comprises a stator and a single coil embedded in an iron core slot of the stator, characterized in that: The mold comprises a first mold part having a first cavity and a second mold part having a second cavity. When the two are butted, the first cavity and the second cavity are connected to form a mold cavity. The shape of the mold cavity is adapted to the single coil. The first mold part and the second mold part are substantially symmetrically arranged along the longitudinal center line of the mold. The mold is also provided with two through-hole parts connected to the mold cavity, one of which is used for the entrance of the insulating material into the mold, and the other is used for balancing the air pressure. The single coil is a distributed winding coil, the single coil is a closed ring structure, and one end of the single coil has two lead wires extending outwards; The first mold part comprises a first body having a first through groove and a first cover body, wherein the first cover body is used to block the notch of the first through groove to form a first through hole; The second mold part comprises a second body having a second through groove and a second cover body, wherein the second cover body is used to block the notch of the second through groove to form a second through hole; The two ends of the first mold part are respectively used to butt with the two ends of the second mold part, and when the first mold part and the second mold part are butt-jointed, the first through hole and the second through hole are connected to form the mold cavity; The outer peripheral wall of the mold has a notch for the lead wire to pass through.

3. A method for insulating a stator assembly of a generator, wherein the stator assembly comprises a stator and a single coil embedded in an iron core slot of the stator, characterized in that: The insulation treatment method is performed by the mold according to claim 1 or 2, and the insulation treatment method comprises: The formed single coil is placed in a prefabricated mold corresponding to the single coil, and the mold containing the single coil is impregnated with an insulating material, or the insulating material is poured into the mold by pouring, so that the outer periphery of the single coil is covered with the insulating material; After the mold containing the single coil is impregnated or cast, the mold is dried to solidify the insulating material; After the drying process, the mold and the single coil are separated, an insulation test is performed on the single coil after the insulation process, and the single coil that passes the test is embedded in the iron core slot of the stator.

4. The insulation treatment method according to claim 3, characterized in that: Before placing the single coil into the mold, a release agent or an oleophobic layer is applied to the inner surface of the mold.

5. The insulation treatment method according to claim 3, characterized in that: Before the single coil is placed in the mold, the single coil is not wrapped with insulating tape.

6. The insulation treatment method according to claim 3, characterized in that: The insulating material is specifically water-based environmentally friendly paint.

7. A generator stator assembly, comprising a stator core and a single coil embedded in a core slot of the stator core, characterized in that: The single coil is a single coil treated by the insulation treatment method according to any one of claims 3 to 6, and the single coil is not wrapped with an insulation tape.

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