A unipolar magnetic pole iron core insulation and winding process

Abstract

The present invention discloses a unipolar magnetic pole core insulation and winding process, including a magnetic pole core insulation process and a magnetic pole core winding process; the magnetic pole core insulation process includes the following steps: Step (A1), insulating the pole body of the magnetic pole core, filling the notch of the pole body with a strip-shaped expansion plate, and pasting an arc-shaped insulating paper at the corner of the magnetic pole core. The present invention insulates the pole body by laying a horizontal epoxy board, a vertical epoxy board and a composite board in combination in the pole body of the magnetic pole core to form a C-shaped board groove, and pasting two L-shaped insulating papers in the C-shaped board groove. Then, by laying a square expansion plate at the extreme end of the magnetic pole core and wrapping a U-shaped adhesive insulating paper, the extreme end is insulated. The insulation process of this magnetic pole core has few processes, short cycle, low cost and is easy to operate. The insulation between windings is the self-insulation of the wire, and after the winding is wound, it is directly impregnated with paint without the process of manually wrapping insulation. Therefore, the insulation quality of the winding is stable and reliable.

Description

Technical Field

[0001] The present invention relates to a unipolar magnetic pole core insulation and winding process. Background Art

[0002] The traditional structure of the unipolar magnetic pole is as follows: the magnetic pole winding is separately wound with flat copper wire. After annealing and shaping, blank cloth is padded between every two layers of copper wire as the inter-turn insulation, and then hot-pressed and cured. The magnetic pole core is insulated by wrapping blank cloth around the periphery, and then the insulated magnetic pole winding is installed into the insulated magnetic pole core.

[0003] This winding process has many processes, a long cycle, and high costs. The inter-turn insulation of the magnetic pole winding is manually padded, which may result in misalignment and dislocation. During hot pressing, the inter-turn insulation may also shift, which may reduce the insulation effect between the turns of the magnetic pole winding. At the same time, due to the relatively thick inter-turn insulation of the magnetic pole winding, the size of the motor rotor is larger under the same power, and the energy consumption is higher. Summary of the Invention

[0004] The purpose of the present invention is to provide a unipolar magnetic pole core insulation and winding process to solve the problems in the above-mentioned background art, such as the traditional winding process having many processes, a long cycle, high costs, the inter-turn insulation of the magnetic pole winding being manually padded, resulting in misalignment and dislocation, the inter-turn insulation shifting during hot pressing, which may reduce the insulation effect between the turns of the magnetic pole winding, and at the same time, due to the relatively thick inter-turn insulation of the magnetic pole winding, the size of the motor rotor is larger under the same power, and the energy consumption is higher.

[0005] To achieve the above purpose, the present invention provides the following technical solution: a unipolar magnetic pole core insulation and winding process, including a magnetic pole core insulation process and a magnetic pole core winding process;

[0006] The magnetic pole core insulation process includes the following steps:

[0007] Step (A1): Insulate the pole body of the magnetic pole core. Use a strip-shaped expansion plate to fill the notch of the pole body, and paste a layer of arc-shaped insulating paper at the corner of the magnetic pole core.

[0008] Step (B1): Lay a layer of horizontal epoxy board on the upper and lower surfaces of the pole body of the magnetic pole core, lay a layer of vertical epoxy board on the two side edges of the outer circle of the magnetic pole core, and lay a composite board on the two side edges of the inner circle of the magnetic pole core.

[0009] Step (C1): The horizontal epoxy board, the vertical epoxy board, and the composite board are combined to form a C-shaped plate groove, and two L-shaped insulating papers are pasted in the C-shaped plate groove.

[0010] Step (D1): Insulate the extreme ends of the magnetic pole core. Lay a layer of square expansion plate at the two end faces of the extreme ends of the magnetic pole core, then wrap a layer of U-shaped adhesive insulating paper, and reinforce it with tape.

[0011] The winding process of the magnetic pole iron core includes the following steps:

[0012] Step (A2): Install the whole magnetic pole iron core on the winding machine. The starting point of the wire winding is at the bottom of the magnetic pole iron core and close to the inner circle of the magnetic pole iron core. Operate the winding machine to wind the wire layer by layer onto the magnetic pole iron core.

[0013] Step (B2): During winding, wrap a layer of mica tape at the bend of the wire at the interlayer transition, lay a composite insulating part at the interlayer conversion where the wires cross, and lay an arc-shaped insulating paper at the corner of each layer.

[0014] Step (C2): The end point of the wire winding is also at the bottom of the magnetic pole iron core and close to the inner circle of the magnetic pole iron core. After the wire winding is completed, a magnetic pole winding is formed, and finally stop the operation of the winding machine.

[0015] Furthermore, in step (B1), the composite plate includes a thin expansion plate and a thin epoxy plate. A double-layer adhesive insulating paper is also pasted on the thin expansion plate of the composite plate. The composite plate is laid on the side of the inner circle of the magnetic pole iron core through the double-layer adhesive insulating paper.

[0016] Furthermore, in step (C1), both L-shaped insulating papers of the C-shaped plate groove are of double-layer structure, and when the two L-shaped insulating papers are joined together, they fit the C-shaped plate groove to cover it completely.

[0017] Furthermore, the thickness of the double-layer-structured L-shaped insulating paper is 0.2 - 0.3 mm.

[0018] Furthermore, in step (A2), the winding machine includes a machine body, a rotating disk, and a mounting seat. The rotating disk is connected to the machine body, and the machine body drives the rotating disk to rotate.

[0019] The mounting seat is fixed in the middle of the rotating disk for mounting the magnetic pole iron core to drive the magnetic pole iron core to rotate for winding.

[0020] Furthermore, in step (B2), the cross-sectional area of the wire is not greater than 60 mm², and the wire is wound as a single wire or a double wire parallel winding during winding.

[0021] Furthermore, when the wire is wound as a single wire, wrap a layer of mica tape in a half-overlapping manner at the bend of the last turn of the first layer and the first turn of the second layer, and the wrapping length is more than 50 mm.

[0022] When the wire is wound as a double wire parallel winding, only wrap the mica tape on the last turn of the first layer, and the wrapping method is the same as that of the single wire.

[0023] Furthermore, in step (B2), when the wire is wound to 2 - 3 layers, there is an interlayer conversion where the wires cross, and lay a composite insulating part at the crossing part.

[0024] Furthermore, the composite insulating member is insulating paper and polyester felt.

[0025] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0026] In the present invention, a C-shaped plate groove is formed by laying a horizontal epoxy board, a vertical epoxy board and a composite board on the pole body of the pole core. Two L-shaped insulating papers are pasted in the C-shaped plate groove to insulate the pole body. Then, a square expansion plate is laid on the extreme end of the pole core and wrapped with a U-shaped adhesive insulating paper to insulate the extreme end. The insulating process of the pole core has fewer processes, a short cycle, low cost and is easy to operate. The insulation between windings is the self-insulation of the wire. After the winding is wound, it is directly impregnated with paint without the process of manually wrapping insulation. Therefore, the insulation quality of the winding is stable and reliable. Moreover, since the insulation between windings is the self-insulation of the wire, the insulation thickness is generally 0.15 mm, which is much smaller than the insulation thickness of the traditional process of laying blank cloth. And the current winding process can be wound into a tower shape according to the different upper and lower space dimensions of the pole core, making the most of the size of the pole core. Therefore, by adopting this process, the size of the pole core can be reduced, and correspondingly, the size of the rotor can be reduced, and further, the size of the generator can be reduced. Description of the Drawings

[0027] Figure 1 It is a three-dimensional structural schematic diagram of the present invention when laying the strip expansion plate and the arc-shaped insulating paper;

[0028] Figure 2 It is a three-dimensional structural schematic diagram of the present invention when laying the C-shaped plate groove;

[0029] Figure 3 It is a three-dimensional structural schematic diagram of the present invention when laying the L-shaped insulating paper;

[0030] Figure 4 It is a three-dimensional structural schematic diagram of the present invention when laying the square expansion plate and the U-shaped adhesive insulating paper;

[0031] Figure 5 It is a three-dimensional structural schematic diagram of the present invention when winding the wire;

[0032] Figure 6 It is a partial cross-sectional structural schematic diagram of the present invention when the pole core is installed on the winding machine.

[0033] In the figure: 1. Pole core; 101. Pole body; 102. Extreme end; 103. Outer circle; 104. Inner circle; 2. Strip expansion plate; 3. Arc-shaped insulating paper; 4. Horizontal epoxy board; 5. Vertical epoxy board; 6. Composite board; 7. L-shaped insulating paper; 8. Square expansion plate; 9. U-shaped adhesive insulating paper; 10. Winding machine; 1001. Machine body; 1002. Rotating disk; 1003. Mounting seat; 11. Winding. Detailed Embodiments

[0034] Next, in combination with the accompanying drawings in the embodiments of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0035] Please refer to Figure 1-6 , the present invention provides a technical solution: a monopolar magnetic pole core insulation and winding process, including a magnetic pole core insulation process and a magnetic pole core winding process;

[0036] The magnetic pole core insulation process includes the following steps:

[0037] Step (A1), insulate the pole body 101 of the magnetic pole core 1, use a strip-shaped expansion plate 2 to fill the notch of the pole body 101, and paste a layer of arc-shaped insulating paper 3 at the corner of the magnetic pole core 1, as Figure 1 shown. Specifically, when implementing, paste the arc-shaped insulating paper 3 without glue at the corner of the magnetic pole core 1 with double-sided tape;

[0038] Step (B1), lay a layer of horizontal epoxy board 4 on the upper and lower surfaces of the pole body 101 of the magnetic pole core, and lay a layer of vertical epoxy board 5 on the two side edges of the outer circle 103 of the magnetic pole core, and lay a composite board 6 on the two side edges of the inner circle 104 of the magnetic pole core, as Figure 2 shown;

[0039] In step (B1), the composite board 6 includes a layer of thin expansion board and a layer of thin epoxy board. A double-layer adhesive insulating paper is also pasted on the thin expansion board of the composite board 6. The composite board 6 is laid on the side edge of the inner circle 104 of the magnetic pole core through the double-layer adhesive insulating paper;

[0040] Specifically, when implementing, first paste two layers of adhesive insulating paper on the side edge of the inner circle 104 of the magnetic pole core, and then pad a layer of thin expansion board and a layer of thin epoxy board;

[0041] Step (C1), the horizontal epoxy board 4, the vertical epoxy board 5 and the composite board 6 combine to form a C-shaped board groove, and paste two L-shaped insulating papers 7 in the C-shaped board groove, as Figure 3 shown;

[0042] In step (C1), both of the two L-shaped insulating papers 7 in the C-shaped board groove are double-layer structures, and when the two L-shaped insulating papers 7 are joined together, they fit the C-shaped board groove to cover it completely and are fixed with imide tape;

[0043] Among them, the thickness of the double-layer structure L-shaped insulating paper 7 is 0.2 - 0.3 mm;

[0044] Step (D1), the pole end 102 of the pole core 1 is insulated, a layer of square expansion board 8 is laid on the two end surfaces of the pole core pole end 102, and then wrapped with a layer of U-shaped adhesive insulating paper 9, and reinforced with tape, the tape is imide tape, such as Figure 4 As shown;

[0045] The magnetic pole core winding process includes the following steps:

[0046] Step (A2), the pole core 1 is integrally mounted on the winding machine 10, the starting point of the wire winding is located at the bottom of the pole core 1 and close to the inner circle 104 of the pole core, and the winding machine 10 is operated to wind the wire layer by layer onto the pole core 1;

[0047] In step (A2), the winding machine 10 includes a machine body 1001, a rotating disk 1002 and a mounting seat 1003, the rotating disk 1002 is connected to the machine body 1001, and the rotating disk 1002 is driven to rotate by the machine body 1001;

[0048] The mounting seat 1003 is fixed in the middle of the rotating disk 1002 for mounting the pole core 1 to drive the pole core 1 to rotate and wind. Figure 6 As shown;

[0049] Step (B2), during the winding process, a layer of mica tape is wrapped at the bend of the interlayer transition conductor, and a composite insulation member is laid at the interlayer transition where the conductors cross, and a layer of arc-shaped insulation paper is laid at the corner of each layer. During the winding process, a wooden knocking stick or a nylon wedge can be used to align the conductors, and gaps between adjacent conductors are avoided as much as possible to prevent the loss of insulating paint until the pole winding is completed;

[0050] In step (B2), the cross-section of the wire is not greater than 60 mm². Considering factors such as clearance and tolerance, the cross-section size of each wire needs to be increased by 0.25 mm on a theoretical basis, and the wire is wound in a single-wire or double-wire manner;

[0051] When the conductor is wound in a single wire, a layer of mica tape is wrapped in a semi-folded manner at the bend of the last turn of the first layer and the first turn of the second layer, and the length of the wrapping is more than 50mm;

[0052] When the conductor is wound in pairs, only the last turn of the first layer is wrapped with mica tape, and the wrapping method is the same as that of a single wire;

[0053] For the pole core of the four-pole rotor, the first turn of the last layer should be wrapped with a layer of mica tape half-folded at the bend of the conductor, and the last turn of the last layer should also be wrapped with mica tape as above;

[0054] Rotor pole width <200mm: The conductor realizes inter-layer angle conversion in the core pole body.

[0055] The width of the rotor magnetic pole > 200 mm: The wire realizes the interlayer angle conversion jointly at the extreme end and the pole body of the iron core. The first layer is at the extreme end, and the second layer is at the pole body.

[0056] The wedge-shaped gap formed by the angle conversion during winding should be filled with an expansion plate insulating material to the last layer. The transition between winding layers needs to be realized at the extreme end of the iron core. The gap below the transition is filled with an expansion plate. The length of the filling material is about 25 mm. Place the binding tape at the gap of the transition to facilitate binding the winding and making it transition smoothly. If necessary, expansion plate spacer wedges can be placed between each layer on the surface of the coil to facilitate the transition of the interlayer winding.

[0057] In step (B2), when the wire is wound to 2 - 3 layers, there is an interlayer conversion where the wires cross. Lay a composite insulating part at the crossing part. At the same time, after the turn of the wire is wound and formed, the winding machine needs to be reversed to make the wire return to the state before winding to confirm whether the insulation at this conversion is damaged. If it is found that the insulating paint or insulating paper of the wire is damaged, a new composite insulation needs to be replaced. At the same time, half - lap a layer of imide tape at the damaged part of the wire, and then continue winding and check the insulated part during the return. Repeat this process until there is no damage at the composite insulating part.

[0058] The composite insulating part is insulating paper and polyester felt.

[0059] In step (C2), the end point of the wire winding is also at the bottom of the magnetic pole iron core 1 and close to the inner circle 104 of the magnetic pole iron core. After the wire winding is completed, a magnetic pole winding 11 is formed, as Figure 5 shown, and finally stop the operation of the winding machine 10.

[0060] In steps (A2) - (C2), both the starting point and the end point of the wire winding are at the bottom of the magnetic pole iron core 1, that is, the number of winding layers is even. When the magnetic pole iron core 1 is installed on the winding machine 10, place the starting point of the wire at the bottom of the magnetic pole iron core 1 and close to the inner circle 104, and fix the wire to the mounting seat 1003 of the winding machine 10 through bolts. After the winding is completed, the end point of the wire is also at the bottom of the magnetic pole iron core 1 and close to the inner circle 104, and then fix the end point of the wire to the mounting seat 1003 of the winding machine 10 through bolts.

[0061] In summary, the insulation process of the magnetic pole core has fewer processes, a shorter cycle, lower costs, and is easy to operate. The insulation between windings is the self-insulation of the wire, and after the winding is wound, it is directly impregnated with paint without the process of manually wrapping insulation. Therefore, the insulation quality of the winding is stable and reliable. Moreover, since the insulation between windings is the self-insulation of the wire, the insulation thickness is generally 0.15 mm, which is much smaller than the insulation thickness of the traditional process of laying base cloth. And the current winding process can be wound into a tower shape according to the different upper and lower space dimensions of the magnetic pole core, making the most of the size of the magnetic pole core. Therefore, by adopting this process, the size of the magnetic pole core can be reduced, and correspondingly, the size of the rotor can be reduced, and further, the size of the generator can be reduced.

[0062] Although the embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A unipolar magnetic pole core insulation and winding process, characterized in that, It includes the insulation process of the pole core and the winding process of the pole core; The insulation process of the pole core includes the following steps: Step (A1), insulating the pole body of the pole core. Use a strip-shaped expansion plate to fill the notch of the pole body, and paste a layer of arc-shaped insulating paper at the corner of the pole core; Step (B1), lay a layer of horizontal epoxy board on the upper and lower surfaces of the pole body of the pole core, lay a layer of vertical epoxy board on the two side edges of the outer circle of the pole core, and lay a composite board on the two side edges of the inner circle of the pole core; Step (C1), the horizontal epoxy board, the vertical epoxy board and the composite board are combined to form a C-shaped plate groove, and paste two L-shaped insulating papers in the C-shaped plate groove; Step (D1), insulating the extreme end of the pole core. Lay a layer of square expansion plate on the two end faces of the extreme end of the pole core, then wrap a layer of U-shaped adhesive insulating paper, and reinforce it with tape; The winding process of the pole core includes the following steps: Step (A2), install the whole pole core on the winding machine. The starting point of the wire winding is at the bottom of the pole core and close to the inner circle of the pole core. Operate the winding machine to wind the wire layer by layer onto the pole core; Step (B2), during winding, wrap a layer of mica tape at the bend of the interlayer transition wire, lay a composite insulating part at the interlayer conversion where the wires cross, and lay a layer of arc-shaped insulating paper at the corner of each layer; Step (C2), the end point of the wire winding is also at the bottom of the pole core and close to the inner circle of the pole core. After the wire winding is completed, a pole winding is formed, and finally stop the operation of the winding machine.

2. The single-pole magnetic pole iron core insulation and winding process according to claim 1, characterized in that: In step (B1), the composite board includes a layer of thin expansion plate and a layer of thin epoxy board. A double-layer adhesive insulating paper is also pasted on the thin expansion plate of the composite board. The composite board is laid on the side of the inner circle of the pole core through the double-layer adhesive insulating paper.

3. A unipolar magnetic pole core insulation and winding process according to claim 1, characterized in that: In step (C1), both of the two L-shaped insulating papers in the C-shaped plate groove are of double-layer structure, and when the two L-shaped insulating papers are joined together, they fit the C-shaped plate groove to cover it completely.

4. A unipolar magnetic pole core insulation and winding process according to claim 3, characterized in that: The thickness of the double-layer structured L-shaped insulating paper is 0.2 - 0.3 mm.

5. A unipolar magnetic pole core insulation and winding process according to claim 1, characterized in that: In step (A2), the winding machine includes a machine body, a rotating disk and a mounting seat. The rotating disk is connected to the machine body, and the machine body drives the rotating disk to rotate; The mounting seat is fixed in the middle of the rotating disk for installing the pole core to drive the pole core to rotate for winding.

6. A single-pole magnetic pole core insulation and winding process according to claim 1, characterized in that: In step (B2), the cross-sectional area of the wire is not more than 60 mm², and the wire is wound as single-wire winding or double-wire parallel winding when winding.

7. A unipolar magnetic pole core insulation and winding process according to claim 6, characterized in that: When the wire is wound as single-wire winding, wrap a layer of mica tape in a half-overlapping manner at the bend of the last turn of the first layer and the first turn of the second layer of the wire, and the wrapped length is more than 50 mm; When the wire is wound as double-wire parallel winding, only wrap the mica tape on the last turn of the first layer, and the wrapping method is the same as that of single-wire winding.

8. A unipolar magnetic pole core insulation and winding process according to claim 1, characterized in that: In step (B2), when the wire is wound to 2 - 3 layers, there is an interlayer conversion where the wires cross, and lay a composite insulating part at the crossing part.

9. A unipolar magnetic pole core insulation and winding process according to claim 8, characterized in that: The composite insulating part is insulating paper and polyester felt.

10. A single-pole magnetic pole core insulation and winding process according to claim 1, characterized in that: In steps (A2) - (C2), the starting point and the end point of the wire winding are both at the bottom of the pole core, that is, the number of winding layers is an even number.

Images