A synchronous motor rotor magnetic pole production process

Abstract

The present invention relates to a synchronous motor rotor magnetic pole production process, belonging to the field of motor manufacturing, and comprises the following steps: step 1, making a copper mother coil; step 2, making an inter-turn insulating gasket; step 3, making inter-turn insulation of the copper mother coil; step 4, making a magnetic pole coil; step 5, hot-packing the magnetic pole core; step 6, assembling the motor rotor magnetic pole and strengthening the insulation to the ground; step 7, varnishing and cleaning the magnetic pole. The present invention improves the appearance quality of the magnetic pole, reduces the insulation failure to the ground and inter-turn, improves the quality of the synchronous machine, and prolongs the service life of the motor by optimizing the coil manufacturing process, the magnetic pole hot-packing process, the coil set process, and the magnetic pole support plate welding structure.

Description

Technical Field

[0001] The invention relates to a synchronous motor rotor magnetic pole production process and belongs to the field of motor manufacturing. Background Art

[0002] With the continuous development of the national economy, synchronous machines are used in more and more occasions. There are three main operating modes of synchronous machines, namely, as generators, motors and compensators. Almost all generators in modern water conservancy, thermal power and nuclear power plants are synchronous generators. Synchronous motors are also widely used in power systems and industrial and mining enterprises.

[0003] The manufacturing quality of the synchronous machine rotor is the key to the entire synchronous machine production, and the synchronous machine pole manufacturing process is the key among the keys. The poor appearance of the synchronous machine poles, large insulation resistance changes, and high ground and turn-to-turn failure rates have always been prominent problems that have plagued many companies in the industry. The present invention aims to solve the above problems by improving the production process. Summary of the invention

[0004] The main purpose of the present invention is to improve the appearance quality of the magnetic pole, reduce ground and inter-turn insulation failures, improve the quality of the synchronous machine, and extend the service life of the motor by optimizing the coil manufacturing process, the magnetic pole hot wrapping process, the coil set process, and the magnetic pole support plate welding structure.

[0005] According to the technical solution provided by the present invention, a synchronous motor rotor pole production process comprises the following steps:

[0006] Step 1, making a copper mother coil: winding the copper busbar around a mold to form a copper mother coil, and shaping the copper mother coil;

[0007] Step 2, making inter-turn insulating gaskets: cutting the epoxy phenolic glass cloth into inter-turn insulating gaskets of uniform size;

[0008] Step 3, making inter-turn insulation of the copper mother coil: pad the prepared inter-turn insulation gasket between each turn of the copper mother coil and glue it;

[0009] Step 4, making the magnetic pole coil: the copper mother coil with inter-turn insulating gaskets is placed on the mold for shaping, and the copper mother coil is electrically heated to gelatinize the inter-turns to form the magnetic pole coil;

[0010] Step 5, hot packing treatment of the pole core: pasting multiple layers of epoxy phenolic glass cloth on the surface of the pole core, and then pasting multiple layers of thin film powder mica foil, and finally pasting the epoxy phenolic glass cloth again outside the thin film powder mica foil, and heating and curing treatment are performed when each layer of epoxy phenolic glass cloth and thin film powder mica foil are pasted, and the epoxy phenolic glass cloth and thin film powder mica foil are coated with quick-drying paint before pasting, and the epoxy phenolic glass cloth needs to be higher than the pole core by a certain height.

[0011] Step 6, motor rotor pole assembly and ground insulation strengthening treatment: the rotor pole assembly is to install a lower pole gasket at the lower part of the rotor core, sleeve the pole coil on the pole core, and install an insulating spacer between the pole coil and the pole core;

[0012] The gap between the pole core and the pole coil is filled with heat-expandable glass mat and epoxy glass cloth board.

[0013] After the above steps are completed, the pole gasket is installed on the pole coil, and the pole support plate is welded and fixed on the pole core;

[0014] The ground insulation strengthening treatment is to open the epoxy phenolic glass cloth that is higher than the magnetic pole core, and the opened epoxy phenolic glass cloth is folded outward to cover the magnetic pole coil;

[0015] Step 7, paint and clean the magnetic poles: paint and clean the rotor magnetic poles installed in step 6.

[0016] As a further improvement of the present invention, the opening processing method of the epoxy phenolic glass cloth in step 6 is: the opening of each layer of the epoxy phenolic glass cloth located at the bend of the coil is staggered.

[0017] As a further improvement of the present invention, in step 1, the copper mother coil is subjected to oxygen-free annealing before the shaping process, and impurities on the surface of the copper mother coil are cleaned after the annealing.

[0018] As a further improvement of the present invention, the shaping process includes grinding the areas where the thickness of the copper mother coil corners is inconsistent.

[0019] As a further improvement of the present invention, in step 5, the height of the epoxy phenolic glass cloth above the surface of the magnetic pole core is two-thirds of the width of the copper busbar.

[0020] As a further improvement of the present invention, in step 6, epoxy glass cloth board and thermal expansion felt are used to fill the space between the magnetic pole coil and the insulating spacer.

[0021] As a further improvement of the present invention, in step 6, the gap between the inner frame of the pole support plate and the pole core is no more than 1 mm.

[0022] The beneficial effects of the invention are:

[0023] By optimizing the coil manufacturing process, pole hot wrapping process, coil set process, and pole support plate welding structure, the appearance quality of the pole can be improved, the ground and inter-turn insulation failures can be reduced, the quality of the synchronous machine can be improved, and the service life of the motor can be extended. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1It is an assembly step diagram of the present invention.

[0025] Figure 2 Schematic diagram of the magnetic pole coil of the present invention.

[0026] Figure 3 Schematic diagram of magnetic poles of the present invention.

[0027] Figure 4 It is a schematic diagram of the magnetic pole support plate of the present invention.

[0028] Figure 5 The figure is a diagram showing the coordination of the magnetic pole core, magnetic pole coil, epoxy glass blank cloth and inter-turn insulating spacer of the present invention.

[0029] Figure 6 Schematic diagram of the first layer of epoxy glass cloth.

[0030] Figure 7 Schematic diagram of the second layer of epoxy glass cloth.

[0031] Explanation of the reference numerals: 1. copper busbar; 2. copper bus coil; 3. inter-turn insulating gasket; 4. pole core; 5. lower pole gasket; 6. pole coil; 7. pole support plate; 8. epoxy glass blank cloth; 9. heat-expandable glass felt; 10. epoxy glass cloth board; 11. thin film powder mica foil; 12. insulating spacer; 13. upper pole gasket; 81. first layer connection port; 82. notch; 83. staggered notch; 84. second layer connection port. DETAILED DESCRIPTION

[0032] The present invention will be further described below with reference to the embodiments in the accompanying drawings:

[0033] As shown in the figure, the motor rotor pole of the present invention includes the following steps:

[0034] Step 1, making a copper mother coil: winding a copper busbar around a mold to form a copper mother coil 2, and shaping the copper mother coil, wherein the wound copper mother coil is subjected to oxygen-free annealing and softening before being shaped;

[0035] The copper busbar 1 is wound according to the drawing requirements to form a copper mother coil 2, and the copper mother coil 2 is subjected to oxygen-free annealing to reduce the hardness, and the impurities on the surface of the copper busbar 1 are cleaned after annealing. Due to process reasons, the thickness of the copper busbar 1 at the corner position will increase during winding, resulting in changes in the height at the corner, and proper grinding and trimming are required to ensure that the thickness of the copper mother coil 2 is consistent in the final formation.

[0036] Use the mold to limit and pressurize the copper mother coil 2 after winding to shape it, ensure that the copper mother coil 2 has a neat appearance, consistent height, and the inner and outer frame sizes meet the requirements of the drawing. Use alcohol to wipe the surface of the copper busbar 2, and use a clean plastic bag to cover the cleaned copper mother coil 2 to prevent foreign matter from entering.

[0037] Step 2, making the inter-turn insulating gasket 3: cutting the epoxy phenolic glass blank cloth 8 into the inter-turn insulating gasket 3 of the same size;

[0038] According to the requirements of the drawings, the inner and outer frame widths and lengths of the inter-turn insulating gasket 3 are set in the CNC cutting machine. After the setting is completed, the first inter-turn insulating gasket 3 is cut for trial, and the inner and outer frame widths and lengths are measured to see if they meet the requirements. Adjustments are made according to actual needs and batch cutting is then carried out.

[0039] A CNC cutting machine is used to cut the inter-turn insulating gasket 3 instead of the original manual cutting. The inter-turn insulating gasket 3 after cutting has better appearance consistency than the original manual cutting, and the inner and outer frame width and length dimensions of the inter-turn insulating gasket 3 are highly accurate, which can effectively reduce the inter-turn short circuit problem caused by the displacement of the inter-turn insulating gasket 3 during the inter-turn insulation and inter-turn gelling process, and effectively improve the molding appearance of the pole coil 6.

[0040] Step 3, making inter-turn insulation of the copper mother coil: pad the prepared inter-turn insulation gasket 3 between each turn of the copper mother coil 2, and glue it;

[0041] The inter-turn insulation production site of the magnetic pole coil 6 needs to be kept clean and tidy. Place the copper mother coil 2 on a clean operating table, count the number of inter-turn insulation gaskets 3 according to the requirements of the drawing, lay the inter-turn insulation gaskets 3 flat between each wire turn of the copper mother coil 2, and apply epoxy adhesive between each layer of inter-turn insulation gaskets 3 and between the inter-turn insulation gaskets and each wire turn of the copper mother coil 2 to prevent the inter-turn insulation gaskets from shifting during subsequent operations.

[0042] Step 4, making the magnetic pole coil: the copper mother coil 2 with the inter-turn insulating gasket 3 is placed on the mold for shaping, and the copper mother coil 2 is electrically heated to gelatinize the inter-turns to form the magnetic pole coil 6;

[0043] First, place the copper mother coil 2 with inter-turn insulation paper in the inter-turn glue mold, and then place it on the work surface of the press. Add an epoxy glass cloth board of appropriate specifications between the inter-turn glue mold and the coil for protection to facilitate demoulding after inter-turn glue.

[0044] The coil is powered on for heating, and the heat is transferred to the inter-turn insulating gasket 3. After the inter-turn insulating gasket 3 is glued out, the heating is stopped, and the copper mother coil 2 is pressurized and solidified to form a magnetic pole coil 6.

[0045] After the inter-turn glueing is completed, pay attention to check whether the curing of the inter-turn insulating gasket 3 meets the requirements and clean it. After the inter-turn glueing, the turns of the pole coil 6 should not be loose. Clean the excess glue between the turns and the excess part of the inter-turn insulating gasket 3. Pay attention to avoid damaging the inter-turn insulation and copper busbar 1 during the cleaning process to avoid inter-turn short circuit problems.

[0046] Step 5, hot stamping of the magnetic pole core;

[0047] The pole core 4 is laminated according to the requirements of the drawings. The pole core 4 needs to be ironed after it is made. Before ironing the pole core 4, check whether there are burrs and sharp corners on the core surface and polish and clean it. The pull rod countersunk hole position on the pole core 4 is coated with epoxy putty and polished after curing. Use alcohol to wipe the surface of the pole core 4 to avoid insulation to the ground caused by burrs and sharp corners piercing the ironing bag. The epoxy phenolic glass cloth 8 coated with quick-drying paint is pasted on the surface of the pole core 4. Use an electric iron to heat the epoxy phenolic glass cloth 8. The seeping glue will firmly bond the epoxy phenolic glass cloth 8 to the surface of the pole core 4. The overlapping joints of each layer of epoxy phenolic glass cloth 8 are staggered. When hot-wrapping, pay attention to squeeze out the air between each layer of epoxy phenolic glass cloth 8 as much as possible. After hot-wrapping, the epoxy phenolic glass cloth 8 forms a smooth whole. First, hot-wrap the epoxy phenolic glass cloth 8 according to the number of layers required by the drawing, and then use quick-drying paint to stick the film powder mica foil 11, and finally hot-wrap the remaining epoxy phenolic glass cloth 8 according to the number of layers required by the drawing. Pay special attention to the fact that the epoxy phenolic glass cloth 8 should be higher than the surface of the magnetic pole core 4 by about 2 / 3 of the width of the copper busbar 1. When hot-wrapping, the protruding part cannot touch the electric iron to keep the original soft state of the epoxy phenolic glass cloth 8.

[0048] Step 6: Assembling the motor rotor poles and strengthening the insulation to the ground;

[0049] The rotor pole assembly is to install a lower pole gasket 5 at the lower part of the rotor core 4, sleeve the pole coil 6 on the pole core 4, and install an insulating spacer 12 between the pole coil 6 and the pole core 4;

[0050] The ground insulation strengthening treatment is to open the epoxy phenolic glass cloth 8 higher than the magnetic pole core 4, and the opened epoxy phenolic glass cloth 8 is folded outward to cover the magnetic pole coil 6; the opening processing method is as follows Figures 5 to 7 As shown, it is a schematic diagram of the first layer processing opening and the second layer processing opening of the epoxy phenolic glass blank cloth 8. Figure 6 The first layer of epoxy phenolic glass blank cloth 8 has a first layer connection port 81, and the three corners are cut into notches 82, and then pressed down, as shown in FIG. Figure 7As shown, the second layer of epoxy phenolic glass cloth 8 has a second layer connection port 84. When winding the cloth, the second layer connection port 84 should be staggered with the first layer connection port 84, and then the staggered notches 83 are cut at the turning point of the second layer of cloth, and the staggered notches 83 are arranged to avoid the notches 82. At this point, the exposed magnetic pole coil 6 at the notch 82 of the first layer can be covered by the second layer of cloth, and then the third layer of cloth is cut in the same way, and the second layer connection port 84 is covered by the staggered notches of the third layer (the reason is that the notches 82 opened in the first layer overlap with the second layer connection port 84, and both are exposed structures, so the third layer of staggered notches are needed to cover them). Therefore, the epoxy phenolic glass cloth 8 requires at least three layers.

[0051] The gap between the pole core 4 and the pole coil 6 is sealed with a thermally expandable glass mat 9 and an epoxy glass cloth sheet 10 .

[0052] The rotor pole assembly is to install a lower pole gasket 5 at the lower part of the rotor core 4, put the pole coil 6 on the pole core 4, install an insulating spacer 12 between the pole coil 6 and the pole core 4, and use thermal expansion felt 9 and epoxy glass cloth board 10 to tightly fill the space between the pole coil 6 and the pole core 4 and between the pole coil 6 and the insulating spacer 12. When the pole is cured, the thermal expansion felt 9 will expand due to heat, which will make the pole coil 6 and the pole core 4 more firmly fixed to ensure that there is no loosening, strengthen the protection of inter-turn insulation and ground insulation, strengthen the varnishing effect, and improve the electrical performance of the pole.

[0053] After completing the above work, cut the epoxy phenolic glass cloth 8 that is higher than the magnetic pole core 4 at the corner, fold it back and put it on the magnetic pole coil 6. Note that each layer of the epoxy phenolic glass cloth 8 is cut at an offset position to ensure that the openings of the epoxy phenolic glass cloth 8 at this part are overlapped after being folded outwards, and no missing space is formed. On the one hand, it prevents foreign matter from falling into the coil turns after production, and on the other hand, it reduces the insulation damage caused by heat transfer during welding;

[0054] Install the pole gasket 13, place the pole support plate 7, and note that the gap between the inner frame of the pole support plate 7 and the pole core 4 is not greater than 1mm. The welding position of the inner frame of the pole support plate 7 is provided with a 10×45° chamfer. Before use, it is necessary to check that the inner frame size of the pole support plate 7 meets the requirements and the placement position is correct to ensure that the gap between the pole core 4 and any position of the inner frame of the pole support plate 7 is not greater than 0.5mm. The above design of the pole support plate 7 can ensure that the welding position is strong, the welding heat input is small, and the weld metal will not flow and damage the insulation to the ground and between turns. Use tooling to fix the pole support plate to ensure that the surface of the pole support plate 7 is highly consistent with the surface of the pole core 4. Use argon arc welding. During welding, welding wire can be appropriately filled to ensure that the pole support plate 7 and the pole core 4 are firmly welded.

[0055] Use a pressure welding tool, borrow the threaded holes of the pole body itself, and use bolts to reversely tighten. During the welding process, ensure that the pole coil 6 is welded in a tightened state to ensure the flatness of the pole mounting surface after welding.

[0056] By folding the epoxy phenolic glass cloth 8 for protection, changing the clearance between the pole support plate 7 and the pole core 4, and improving the fixing process of the pole support plate 7, it is ensured that the welding process will not cause damage to the ground insulation and turn-to-turn insulation, thereby improving the quality of pole manufacturing and extending the service life of the motor.

[0057] Step 7, paint and clean the rotor poles installed in step 6;

[0058] Before dipping in paint, use compressed air to blow away all dust and debris on the surface of the magnetic pole workpiece to be dipped. After dipping in paint, clean the paint nodules on the surface of the magnetic pole. Be careful not to damage the magnetic pole insulation and copper wire. At the same time, check whether there is any foreign matter adhering to the surface of the magnetic pole, and no insulating paint can remain in the threaded holes of the pole body. After dipping in paint, the threaded holes of the magnetic pole need to be processed with wire rewinding. After the above work is completed, conduct an electrical performance inspection, and it can be used if it passes the inspection.

Claims

1. A synchronous motor rotor pole production process, It is characterized in that The following steps are involved: Step 1, making a copper mother coil: winding a copper mother wire (1) around a mold to form a copper mother coil (2), and performing shaping processing on the copper mother coil (2); Step 2, making inter-turn insulating spacers (3): cutting the epoxy phenolic glass cloth into inter-turn insulating spacers (3) of uniform size; Step 3, making inter-turn insulation of the copper mother coil: padding the prepared inter-turn insulation gasket (3) between each turn of the copper mother coil (2), and gluing them; Step 4, making the magnetic pole coil: the copper mother coil (2) with the inter-turn insulating gasket (3) is placed on the mold for shaping, and the copper mother coil (2) is electrically heated to gelatinize the inter-turns to form the magnetic pole coil (6); Step 5, hot packing treatment of the magnetic pole core (4): a plurality of layers of epoxy phenolic glass cloth (8) are pasted on the surface of the magnetic pole core (4), and then a plurality of layers of thin film powder mica foil (11) are pasted, and finally the epoxy phenolic glass cloth (8) is pasted again outside the thin film powder mica foil (11), and each layer of epoxy phenolic glass cloth (8) and thin film powder mica foil (11) is subjected to heat curing treatment when pasted, and the epoxy phenolic glass cloth (8) and thin film powder mica foil (11) are coated with quick-drying paint before pasting, wherein the epoxy phenolic glass cloth (8) needs to be higher than the magnetic pole core (4) by a certain height; Step 6, motor rotor magnetic pole assembly and ground insulation strengthening treatment: the rotor magnetic pole assembly is to install a lower magnetic pole gasket (5) at the bottom of the magnetic pole core (4), put the magnetic pole coil (6) on the magnetic pole core (4), and install an insulating spacer (12) between the magnetic pole coil (6) and the magnetic pole core (4); The gap between the magnetic pole core (4) and the magnetic pole coil (6) is plugged with a thermal expansion felt (9) and an epoxy glass cloth plate (10); After the above steps are completed, the pole gasket (13) is installed on the pole coil (6), and the pole support plate (7) is welded and fixed on the pole core (4); The ground insulation strengthening treatment is to open the epoxy phenolic glass cloth (8) that is higher than the magnetic pole core (4), and the opened epoxy phenolic glass cloth (8) is folded outward to cover the magnetic pole coil (6); Step 7, paint and clean the magnetic poles: paint and clean the rotor magnetic poles installed in step 6.

2. A synchronous motor rotor pole production process as claimed in claim 1, It is characterized in that The opening processing method of the epoxy phenolic glass cloth (8) in step 6 is as follows: the opening of each layer of the epoxy phenolic glass cloth (8) located at the turning point of the magnetic pole coil (6) is staggered.

3. A synchronous motor rotor pole production process as claimed in claim 1, It is characterized in that In the step 1, the copper mother coil (2) is subjected to oxygen-free annealing before the shaping process, and impurities on the surface of the copper mother coil (2) are cleaned after the annealing.

4. A synchronous motor rotor pole production process as claimed in claim 3, It is characterized in that The shaping process comprises grinding the areas of the copper mother coil (2) where the thickness is inconsistent at the corners.

5. A synchronous motor rotor pole production process as claimed in claim 1, It is characterized in that In the step 5, the height of the epoxy phenolic glass cloth (8) above the surface of the magnetic pole core (4) is two-thirds of the width of the copper busbar (1).

6. A synchronous motor rotor pole production process as claimed in claim 1, It is characterized in that In step 6, epoxy glass cloth board (10) and thermal expansion felt (9) are used to fill the space between the magnetic pole coil (6) and the insulating spacer (12).

7. A synchronous motor rotor pole production process as claimed in claim 1, It is characterized in that In step 6, the gap between the inner frame of the magnetic pole support plate (7) and the magnetic pole core is no greater than 1 mm.

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