A method for manufacturing stator coils of a high-voltage motor

Abstract

This invention discloses a method for manufacturing a high-voltage motor stator coil, comprising the following steps: installing two semi-circular winding dies on a winding machine to wind a racetrack-shaped coil, and fixing the straight edges with adhesive tape; placing the racetrack-shaped coil on a pre-wrapping special tape wrapping machine, adjusting and calibrating its position, and then partially wrapping it with two layers of mica tape as pre-wrapping insulation to ground; completing the pre-wrapping of the racetrack-shaped coil on an expanding machine according to the drawing requirements; placing the expanded coil on a regular tape wrapping machine to complete the wrapping of the remaining insulation to ground, thus completing the manufacturing of a single high-voltage motor stator coil. This invention eliminates the need for the initial wrapping and removal of white cloth tape, shortening the production cycle and saving material and labor costs; it also eliminates the need for the inter-turn gluing process, reducing energy consumption and environmental pollution.

Description

Technical Field

[0001] This invention relates to the field of motor manufacturing, and in particular to a method for manufacturing a high-voltage motor stator coil. Background Technology

[0002] In recent years, with the vigorous development of my country's economy, the application fields of high-voltage motors have become increasingly broad. Currently, the high-voltage motor market is mainly dominated by motors with rated voltages of 6kV and 10kV. Higher rated voltages inevitably bring certain difficulties to motor manufacturing, especially the manufacturing of stator coils. Stator coil manufacturing mainly involves two processes: multi-adhesive molding and low-adhesive vacuum pressure impregnation (VPI). Nowadays, most motor manufacturers have phased out the multi-adhesive molding process, which is space-consuming, has a long manufacturing cycle, requires many molds, has low production efficiency, and high energy consumption, and instead adopt the low-adhesive VPI process. Motor coil windings using low-adhesive VPI technology have advantages such as good electrical performance, high mechanical strength, good thermal conductivity, and good weather resistance. Compared with multi-adhesive molding, the insulation thickness of the low-adhesive VPI insulation structure for motors of the same voltage level can be thinner, which can greatly improve motor efficiency and material utilization, while also simplifying the production process and shortening the manufacturing cycle.

[0003] Currently, the low-adhesion VPI process for high-voltage motor stator coils mainly includes the following steps: 1. Winding the shuttle-shaped coil; 2. Initial wrapping with white cloth tape; 3. Expansion; 4. Inter-turn curing; 5. Removing the white cloth tape; 6. Wrapping the main insulation; 7. Wire embedding; 8. Vacuum pressure impregnation; 9. Baking and curing. The low-adhesion VPI process is clearly more advanced than the multi-adhesion molding process, but it also has the following problems: Problem 1: Step 2, wrapping with white cloth tape, is to protect the coil during step 3 (expansion) and step 4 (inter-turn curing). Step 5, removing the white cloth tape, is necessary before step 6 (wrapping the main insulation), wasting both time and materials. Problem 2: Step 4, inter-turn curing, uses the adhesive within the electromagnetic wire insulation layer to bond the straight edges together under high temperature, preventing loosening in subsequent steps. This step consumes a lot of electricity, is physically demanding, and the adhesive releases harmful substances during the curing process, causing environmental pollution. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides a low-cost, short-cycle, high-efficiency, low-energy-consumption, and environmentally friendly method for manufacturing high-voltage motor stator coils.

[0005] The technical solution of this invention to solve the above-mentioned technical problems is: a method for manufacturing a high-voltage motor stator coil, comprising the following steps:

[0006] Step 1: Install two semi-circular winding dies on the winding machine, wind a racetrack-shaped coil, and fix the straight sides with adhesive tape;

[0007] Step 2: Place the racetrack-shaped coil on the pre-wrapping special wrapping machine, adjust the calibration position, and then half-overlap two layers of mica tape as pre-wrapping insulation to ground;

[0008] Step 3: Complete the pre-wrapped racetrack-shaped coil and expand it on the expansion machine according to the drawing requirements;

[0009] Step 4: After expansion, the coil is placed on a regular wrapping machine to complete the wrapping of the remaining insulation to ground, thus completing the production of a single high-voltage motor stator coil.

[0010] In the above-mentioned method for manufacturing the stator coil of a high-voltage motor, in step 1, the adhesive tape used is polyester adhesive tape or polyimide adhesive tape, and the radius R of the semi-circular winding mold is greater than 90mm.

[0011] In the above-mentioned method for manufacturing the stator coil of a high-voltage motor, in step 2, the end clamping device and the straight edge clamping device of the pre-wrapping special tape machine are in the same plane, and the operation path of the wrapped wire head is in-plane movement; adjust the calibration position to ensure that the clamping devices at both ends of the racetrack-shaped coil are at the midpoint of the semi-circular winding mold, and half-overlap two times with less adhesive mica tape as the pre-wrapped main insulation, the wrapping position of the pre-wrapped main insulation is at the midpoint of the straight edge of the racetrack-shaped coil, and the wrapping length is the length L of the straight edge of the finished coil plus the length x, where x takes different values ​​according to different coil models, and the value range is from 100mm to 200mm.

[0012] In the above-mentioned method for manufacturing the stator coil of a high-voltage motor, in step 3, the expansion machine is equipped with four clamping mechanisms for clamping the racetrack-shaped coil. The surface of the clamping mechanism in contact with the racetrack-shaped coil is made of polytetrafluoroethylene, and a felt pad is placed at the contact position between the clamping mechanism and the racetrack-shaped coil.

[0013] In the above-mentioned method for manufacturing the stator coil of a high-voltage motor, in step 4, the end clamping device of the ordinary wrapping machine is higher than the plane where the straight side clamping device is located, and the operation path of the wrapping head is not on the same plane; after completing the wrapping of the remaining main insulation, the main insulation of the motor with rated voltage of 6kV or 10kV is half-stacked with 4 to 10 layers of low-adhesion mica tape. Two layers have been completed in step 3, and the remaining 2 to 8 layers are completed in this step, and the inter-turn and ground withstand voltage tests are performed; thus, the manufacturing of a single high-voltage motor stator coil is completed.

[0014] The beneficial effects of this invention are as follows:

[0015] 1. This invention eliminates the need for the initial wrapping and removal of the white cloth strip, thus shortening the production cycle and saving material and labor costs.

[0016] 2. This invention eliminates the need for the inter-turn gelling process, which reduces both energy consumption and environmental pollution.

[0017] 3. The coil produced by this invention does not have inter-turn gelation. During the insulation impregnation process, the insulating resin can penetrate more easily, which can improve the coil dielectric loss value and thus improve the life of the coil and motor.

[0018] 4. This invention does not limit parameters such as coil size and electromagnetic wire gauge, and has wide applicability. Attached Figure Description

[0019] Figure 1 This is a flowchart of the present invention.

[0020] Figure 2 This is a schematic diagram of a runway-shaped coil structure.

[0021] Figure 3 This is a schematic diagram of the finished coil structure. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0023] like Figures 1-3 As shown, a method for manufacturing a high-voltage motor stator coil includes the following steps:

[0024] Step 1: Install two semi-circular winding dies on the winding machine, wind the racetrack-shaped coil 1, and fix the straight edges with adhesive tape to ensure a tight and secure fit. The adhesive tape used should be polyester or polyimide tape, and the radius R of the semi-circular winding die should be greater than 90mm to provide sufficient operating space for the next step.

[0025] Step 2: Place the racetrack-shaped coil 1 on a pre-wrapping machine. The end clamping device and the straight-side clamping device of the pre-wrapping machine are in the same plane, and the operation path of the wrapped wire end is in-plane movement. Adjust the calibration position to ensure that the clamping devices at both ends of the racetrack-shaped coil 1 are at the midpoint 2 of the semi-circular winding mold. Half-overlap and wrap with a small amount of adhesive mica tape twice as the pre-wrapped main insulation. The wrapping position of the pre-wrapped main insulation is at the midpoint 3 of the straight side of the racetrack-shaped coil 1. The wrapping length is the length L of the straight side 5 of the finished coil 4 plus the length x. x takes different values ​​depending on the coil model, ranging from 100mm to 200mm.

[0026] Step 3: Complete the pre-wrapped racetrack-shaped coil 1 and expand it on the expansion machine according to the drawing requirements. The expansion machine is equipped with four clamping mechanisms for clamping the racetrack-shaped coil 1. Sufficient protection measures should be taken for the contact parts between the clamping mechanisms and the racetrack-shaped coil 1 to prevent mechanical damage to the mica layer of the racetrack-shaped coil 1. The protection method can be that the surface of the contact position between the clamping mechanism and the racetrack-shaped coil 1 is made of polytetrafluoroethylene, or that felt is placed at the contact position between the clamping mechanism and the racetrack-shaped coil 1. After expansion, inspect the coil dimensions.

[0027] Step 4: After expansion, the coil is placed on a standard wrapping machine. The end clamping device of the standard wrapping machine is higher than the plane where the straight edge clamping device is located, and the operation path of the wrapping head is not on the same plane. Complete the wrapping of the remaining main insulation. The main insulation of a 6kV or 10kV motor is usually half-stacked with 4 to 10 layers of low-adhesion mica tape. Two layers were completed in step 3. This step completes the remaining 2 to 8 layers, and performs inter-turn and ground withstand voltage tests. The fabrication of a single high-voltage motor stator coil is now complete.

Claims

1. A method of manufacturing a high voltage motor stator coil, characterized by, It comprises the following steps: Step 1: install two semi-circular structure winding molds on a winding machine, wind a racetrack-shaped coil, and fix the straight line edge with adhesive tape; Step 2: place the racetrack-shaped coil on a pre-pack special taping machine, adjust the calibration position, and then semi-lap pack two layers of mica tape as the pre-pack ground insulation; the midpoint position of the straight line edge of the racetrack-shaped coil is pre-packed with two layers of mica tape with less glue, the packing length is the length L of the straight line edge of the finished coil plus the expansion length X of 100mm to 200mm, and the pre-pack insulation and the subsequent main insulation form a continuous whole insulation structure; the end clamping device and the straight line edge clamping device of the pre-pack special taping machine are in the same plane, and the operation path of the wire head is in-plane movement; Step 3: complete the pre-pack racetrack-shaped coil, and complete the expansion on the expansion machine according to the drawing requirements; the expansion machine is provided with four clamping mechanisms for clamping the racetrack-shaped coil, the surface of the contact position of the clamping mechanism and the racetrack-shaped coil is made of polytetrafluoroethylene material, and the contact position of the clamping mechanism and the racetrack-shaped coil is padded with felt; Step 4: place the expanded coil on a general taping machine to complete the remaining ground insulation packing, i.e. the production of a single high-voltage motor stator coil.

2. The method of manufacturing a high voltage machine stator coil according to claim 1, wherein, In step 1, the adhesive tape used is polyester adhesive tape or polyimide adhesive tape, and the radius R of the semi-circular structure winding mold is greater than 90mm.

3. The method of claim 1, wherein the step of winding the wire around the core is performed by a winding machine. In step 2, the calibration position is adjusted to ensure that the end clamping devices of the racetrack-shaped coil are at the midpoint position of the semi-circular structure winding mold, and the two times of semi-lap packing of the mica tape with less glue are used as the pre-pack main insulation, the pre-pack main insulation packing position is the midpoint position of the straight line edge of the racetrack-shaped coil, and the packing length is the length L of the straight line edge of the finished coil plus the length x, x takes different values according to different types of coils, and the value range is 100mm to 200mm.

4. The method of making a high voltage machine stator coil according to claim 1, wherein, In step 4, the end clamping device of the general taping machine is higher than the plane where the straight line edge clamping device is located, and the operation path of the wire head is not in the same plane; the remaining main insulation is packed, the main insulation of the motor with a rated voltage of 6kV or 10kV is semi-lap packed 4 to 10 times with mica tape with less glue, 2 times have been completed in step 3, the remaining 2 to 8 times are completed in this step, and the turn-to-turn and ground withstand voltage test is performed; thus, the production of a single high-voltage motor stator coil is completed.

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