Method for detecting insulation defects of an electromagnetic wire covering, detection system and manufacturing method of an electric machine, electric machine

Abstract

An insulating defect detection method for a magnetic wire covering layer has the following steps: a traveling step (S01) of making a magnetic wire (2) travel in a wire direction; a first discharge detection step (S02) of applying an alternating voltage to a measurement point on the traveling magnetic wire (2) and detecting a first discharge; a second discharge detection step (S03) of applying an alternating voltage to the measurement point on the magnetic wire after the first discharge is detected and detecting a second discharge; and a determination step (S04-S06) of comparing the first discharge and the second discharge and determining whether the magnetic wire covering layer has an insulating defect.

Description

Technical Field

[0001] This application relates to a method and system for detecting insulation defects in a magnet wire coating, and a method for manufacturing an electric machine. Background Technology

[0002] The stator of the motor uses coils wound with electromagnetic wire. When the sheath of the electromagnetic wire develops a pinhole or is damaged, abnormal current flows through it during operation, causing the winding wire to be abnormally heated, which may lead to burnout.

[0003] To address this problem, the following method is disclosed: an electrode is provided to apply a voltage for pinhole detection to the traveling electromagnetic wire, and an electrode is provided upstream of the wire to apply a voltage of several kV. After applying a high voltage of several kV, a detection voltage of several hundred V is applied to the exposed pinhole, thereby improving the reliability of detection (e.g., Patent Document 1).

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent No. 5949612 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] However, in the method of Patent Document 1, the detection frequency of pinholes is increased by applying a high voltage to the electromagnetic wire. However, when the applied voltage is too high, spark discharge is generated, which may also damage the normal coating.

[0009] This application discloses a technology for solving the above-mentioned problems, the purpose of which is to provide a highly reliable detection method and system that can detect insulation defects without applying excessively high voltage to the entire electromagnetic wire before winding.

[0010] Methods for solving problems

[0011] The insulation defect detection method for the electromagnetic wire sheathing layer disclosed in this application detects defects in the electromagnetic wire sheathing layer. The method includes the following steps: a traveling step, in which the electromagnetic wire travels along the wire direction; a first discharge detection step, in which an AC voltage is applied to a first measuring point on the traveling electromagnetic wire to detect a first discharge; a second discharge detection step, in which, after detecting the first discharge, an AC voltage is applied to a second measuring point on the electromagnetic wire to detect a second discharge; and a determination step, in which the first discharge and the second discharge are compared to determine whether there is a defect in the electromagnetic wire sheathing layer.

[0012] The insulation defect detection system for electromagnetic wire sheathing disclosed in this application detects defects in the electromagnetic wire sheathing. The system includes a delivery device and a winding device at the beginning and end of the electromagnetic wire's travel path to allow the electromagnetic wire to travel at a constant speed along its direction. The system has an AC power supply that generates an AC voltage applied to detect discharges from defects in the electromagnetic wire sheathing along the travel path. The system has a first discharge detection electrode at a first measurement point and a second discharge detection electrode at a second measurement point. The system includes a first discharge detection device for detecting the discharge signal detected by the first discharge detection electrode and a second discharge detection device for detecting the discharge signal detected by the second discharge detection electrode. The system also includes an evaluation device with a comparison unit that compares the discharge signal of the first discharge detected at the first measurement point with the discharge signal of the second discharge detected at the second measurement point to determine whether the electromagnetic wire sheathing has a defect.

[0013] The method for manufacturing electric machinery disclosed in this application includes the following steps: manufacturing electric machinery using an iron core wound with an electromagnetic wire inspected by an insulation defect detection system that has been covered by the aforementioned electromagnetic wire.

[0014] The electromechanical device disclosed in this application is manufactured using an iron core wound with an electromagnetic wire that has been inspected by an insulation defect detection system that has been covered by the aforementioned electromagnetic wire.

[0015] Invention Effects

[0016] The method for detecting insulation defects in the electromagnetic wire sheath disclosed in this application provides a highly reliable detection method that can detect insulation defects without applying excessively high voltage to the entire electromagnetic wire before winding.

[0017] The insulation defect detection system for the electromagnetic wire sheath disclosed in this application provides a highly reliable detection system that can detect insulation defects without applying excessively high voltage to the entire electromagnetic wire before winding.

[0018] According to the manufacturing method of the electric machinery disclosed in this application, it is possible to provide a manufacturing method for electric machinery that uses an inspection system that detects insulation defects and is capable of detecting electromagnetic wires after inspection, which does not apply excessively high voltage to the entire electromagnetic wire before winding.

[0019] According to the electric machinery disclosed in this application, it is possible to provide an electric machinery that uses an inspection system that is capable of detecting insulation defects and applies excessively high voltage to the entire electromagnetic wire before winding. Attached Figure Description

[0020] Figure 1 This is a structural diagram of the insulation defect detection system for the electromagnetic wire sheathing layer according to Embodiment 1.

[0021] Figure 2 This is a schematic diagram of the delivery device and winding device of the insulation defect detection system for the electromagnetic wire sheath layer in Embodiment 1.

[0022] Figure 3 This is an explanatory diagram of the structure of the electromagnetic wire in the insulation defect detection system of the electromagnetic wire sheath layer according to Embodiment 1.

[0023] Figure 4 This is an explanatory diagram showing the shape of the discharge detection electrode in the insulation defect detection system for the electromagnetic wire sheathing layer of Embodiment 1.

[0024] Figure 5 This is an explanatory diagram showing the connection state of the discharge detection electrode and the discharge detection device in the insulation defect detection system of the electromagnetic wire sheathing layer according to Embodiment 1.

[0025] Figure 6 This is an equivalent circuit diagram showing the connection state of the discharge detection electrode and the discharge detection device in the insulation defect detection system of the electromagnetic wire sheathing layer according to Embodiment 1.

[0026] Figure 7 This is a basic flowchart of the insulation defect detection method for the electromagnetic wire sheathing layer in Implementation Method 1.

[0027] Figure 8 This is a flowchart of the insulation defect detection method for the electromagnetic wire sheathing layer in Implementation Method 1.

[0028] Figure 9 This is a structural diagram of the insulation defect detection system for the electromagnetic wire sheathing layer in Embodiment 2.

[0029] Figure 10 This is a structural diagram of the insulation defect detection system for the electromagnetic wire sheathing layer in Embodiment 3.

[0030] Figure 11 This is an explanatory diagram of the noise removal mechanism of the insulation defect detection system for the electromagnetic wire sheath layer in Embodiment 4.

[0031] Figure 12 This is an explanatory diagram of the travel stabilization mechanism of the insulation defect detection system for the electromagnetic wire sheath layer in Embodiment 5.

[0032] Figure 13 This is a structural diagram of the insulation defect detection system for the electromagnetic wire sheath layer according to Embodiment 6.

[0033] Figure 14This is a smoothed embodiment of the discharge waveform of the insulation defect detection system for the electromagnetic wire sheath layer in Embodiment 6.

[0034] Figure 15 This is a smoothed embodiment of the discharge waveform of the insulation defect detection system for the electromagnetic wire sheath layer in Embodiment 6.

[0035] Figure 16 This is a smoothed embodiment of the discharge waveform of the insulation defect detection system for the electromagnetic wire sheath layer in Embodiment 6.

[0036] Figure 17 This is a structural diagram of the insulation defect detection system for the electromagnetic wire sheath layer according to Embodiment 7.

[0037] Figure 18 This is an explanatory diagram illustrating an application example of the insulation defect detection system for the electromagnetic wire sheath layer in embodiment 7 for a stator core.

[0038] Figure 19 This is a block diagram illustrating an example of the hardware structure of an evaluation device for a system that detects insulation defects in the sheathing of electromagnetic wires. Detailed Implementation

[0039] Implementation Method 1

[0040] Embodiment 1 relates to an insulation defect detection system for an electromagnetic wire sheath: The system includes a feeding and winding device before and after the electromagnetic wire's travel path, allowing the electromagnetic wire to travel at a constant speed along its direction. The system also includes an AC power supply that generates an AC voltage at a first and a second measurement point along the travel path to detect discharges from defects in the electromagnetic wire sheath; first and second discharge detection electrodes that detect discharges from defects in the electromagnetic wire sheath; first and second discharge detection devices that detect discharge signals detected by the first and second discharge detection electrodes; and an evaluation device that compares the discharge signals detected at the first and second measurement points to determine whether the electromagnetic wire sheath has a defect. Furthermore, Embodiment 1 relates to a method for detecting insulation defects in an electromagnetic wire sheath using an insulation defect detection system for electromagnetic wire sheaths.

[0041] Below is a structural diagram of the insulation defect detection system for the electromagnetic wire sheath. Figure 1 A schematic diagram of the feeding device and the winding device. Figure 2 A diagram illustrating the structure of electromagnetic wires. Figure 3 A diagram illustrating the shape of the discharge detection electrode. Figure 4 A diagram illustrating the connection status of the discharge detection electrode and the discharge detection device. Figure 5 The equivalent circuit diagram of the connection state of the discharge detection electrode and the discharge detection device is as follows: Figure 6 The basic flowchart of the method for detecting insulation defects in the electromagnetic wire sheath is as follows: Figure 7 and flowchart Figure 8 The structure, operation, and detection method of the insulation defect detection system for the electromagnetic wire sheathing layer in Embodiment 1 will be described.

[0042] In addition, in each figure, the same or similar parts are indicated by the same labels, and repeated descriptions are omitted.

[0043] First, according to Figure 1 The structure of the insulation defect detection system 100 for the electromagnetic wire sheathing layer in Embodiment 1 will be described.

[0044] The insulation defect detection system 100 of the electromagnetic wire sheathing layer in Embodiment 1 consists of a traveling block, a discharge detection block, and an evaluation block.

[0045] exist Figure 1 In the middle, the traveling block has a traveling path 1 for the electromagnetic wire 2, a feeding reel 3 for feeding the electromagnetic wire 2 and a winding reel 4 for winding the electromagnetic wire 2, as well as a feeding machine 5 and a winding machine 6.

[0046] The discharge detection block has an AC power supply 10 that generates an AC voltage for detecting insulation defects in the electromagnetic wire sheath, a first discharge detection electrode 11 and a second discharge detection electrode 12, and a first discharge detection device 13 and a second discharge detection device 14.

[0047] The evaluation block receives signals from the first and second discharge detection devices 13 and 14 to determine whether there are insulation defects in the coating layer of the electromagnetic wire 2, and has an evaluation device 30. The evaluation device 30 internally includes an A / D converter 31, a storage unit 32, a calculation unit 33, a measurement unit 34, and a comparison unit 35.

[0048] First, according to Figure 1 , Figure 2 and Figure 3 The movement block is explained.

[0049] A feed reel 3 and a take-up reel 4 are provided before and after the travel path 1 of the electromagnetic wire 2. Furthermore, a feeder 5 and a take-up machine 6 are respectively provided on the feed reel 3 and the take-up reel 4.

[0050] The speeds of the feeder 5 and the winding machine 6 are adjusted to ensure that the electromagnetic wire 2 travels at a constant speed.

[0051] like Figure 2 As shown, a turntable 7 can also be used to form a feeder 5 and a winding machine 6.

[0052] exist Figure 2In this context, "RS" stands for "In Progress Signal," which is sent from the feeder 5 and the winding machine 6 to the evaluation device 30. The function of this In Progress Signal will be explained later.

[0053] Here, the electromagnetic wire 2 will be explained.

[0054] like Figure 3 As shown, the electromagnetic wire 2 is composed of an electromagnetic wire core 2A and an electromagnetic wire sheathing layer 2B.

[0055] like Figure 1 As shown, the end of the electromagnetic wire 2 peels off the electromagnetic wire sheath 2B, so that the electromagnetic wire core 2A is grounded.

[0056] Next, according to Figure 1 and Figure 4 The discharge detection block is explained.

[0057] A first discharge detection electrode 11 and a second discharge detection electrode 12 are set in the travel path of the electromagnetic wire 2.

[0058] In addition, unless otherwise specified, the first discharge detection electrode 11 and the second discharge detection electrode 12 are referred to as discharge detection electrodes.

[0059] Discharge detection electrodes can also be formed as Figure 4 The cross-sectional shape shown is a circular ring.

[0060] The discharge detection electrode can also be formed from metallic materials such as iron, aluminum, and copper. Alternatively, it can be formed from conductive rubber or resin materials with aluminum or other metallic materials deposited on their surface.

[0061] Alternatively, the inner diameter of the ring of the discharge detection electrode can be formed to match the outer diameter of the electromagnetic wire 2, so as to form contact with the electromagnetic wire 2. Furthermore, to avoid friction caused by contact, a margin of approximately 10μm to 100μm can be provided.

[0062] The first discharge detection electrode 11 and the second discharge detection electrode 12, thus formed, are connected to an AC power supply 10, and an AC voltage is applied. The other terminal of the AC power supply 10 is grounded in the same way as the core 2A of the electromagnetic wire 2.

[0063] The discharge signal detected by the first discharge detection electrode 11 is detected by the first discharge detection device 13.

[0064] The discharge signal detected by the second discharge detection electrode 12 is detected by the second discharge detection device 14.

[0065] The specific detection methods for discharge signals by the first and second discharge detection devices 13 and 14 will be explained later.

[0066] Next, regarding the evaluation block, including its relationship with the discharge detection block, according to... Figure 1 , Figure 5 and Figure 6 Please provide an explanation.

[0067] The evaluation device 30 performs A / D conversion on the discharge signals detected by the first discharge detection device 13 and the second discharge detection device 14 at a constant sampling frequency using the A / D converter 31, and then stores the signals in the storage unit 32.

[0068] Figure 5 This is an explanatory diagram illustrating the connection state of the first discharge detection electrode 11 and the first discharge detection device 13 as an example. Furthermore, Figure 6 This is an equivalent circuit showing the connection state of the first discharge detection electrode 11 and the first discharge detection device 13.

[0069] Figure 5 This shows the state of insulation defects 41, such as pinholes or damage, occurring in the sheathing layer 2B of the electromagnetic wire 2.

[0070] The first discharge detection device 13 consists of a coupling capacitor 42, a detection impedance 43, and a discharge detector 44 connected in parallel with the detection impedance 43.

[0071] An AC voltage is applied to the coupling capacitor 42 and the detection impedance 43, which are connected in parallel with the electromagnetic wire core 2A and the cladding layer 2B, via the AC power supply 10 and the first discharge detection electrode 11.

[0072] When a discharge occurs from the electromagnetic wire core 2A to the first discharge detection electrode 11, the applied AC voltage changes drastically. The discharge detector 44 detects this change in AC voltage as the voltage value generated across the detection impedance 43 due to the discharge current flowing through the detection impedance 43.

[0073] Figure 6 Is with Figure 5 The equivalent circuit corresponding to the connection state.

[0074] The series circuit of the electrostatic capacitance 45 of the normal part of the electromagnetic wire sheath, the electrostatic capacitance 46 of the insulation defect part of the electromagnetic wire sheath, and the electrostatic capacitance 47 of the part connected in series with the insulation defect part of the electromagnetic wire sheath, the series circuit of the electrostatic capacitance 48 of the coupling capacitor and the series circuit of the detection impedance 43 are connected in parallel with the AC power supply.

[0075] When a discharge occurs from the electromagnetic wire core 2A to the first discharge detection electrode 11, the generated discharge charge is released to the grounding point through a closed circuit consisting of the electrostatic capacitance 46 of the insulation defect portion, the electrostatic capacitance 47 of the portion connected in series with the insulation defect portion, the electrostatic capacitance 48 of the coupling capacitor, and the detection impedance 43.

[0076] When no discharge charge q flows through the detection impedance 43, no voltage is generated across the detection impedance 43. However, when the discharge charge q flows through, a voltage ΔV is generated according to equation (1).

[0077] ΔV=Z×(dq / dt) (1)

[0078] In addition, regarding the discharge detector 44, some commercially available discharge measurement devices can be used, so no details are provided.

[0079] If a discharge is detected by the first discharge detection electrode 11, the discharge signal from the first discharge detection electrode 11 is stored in the storage unit 32 of the evaluation device 30 via the first discharge detection device 13 and the A / D converter 31.

[0080] Furthermore, when a discharge is detected by the first discharge detection electrode 11, the calculation unit 33 of the evaluation device 30 calculates the time t = L / V from the position (let's call it r) on the electromagnetic line 2 where the discharge is detected by the first discharge detection electrode 11 to the second discharge detection electrode 12, based on the preset travel speed V and the distance L between the first discharge detection electrode 11 and the second discharge detection electrode 12.

[0081] The calculation unit 33 outputs the calculation result to the measurement unit 34 of the evaluation device 30. The measurement unit 34 receives the calculation result from the calculation unit 33 and starts timer measurement with reference to the time t calculated by the calculation unit 33.

[0082] If the second discharge detection electrode 12 does not detect a discharge when the timer count of the measurement unit 34 is completed, it is considered noise, and the discharge signal from the first discharge detection electrode 11 stored in the storage unit 32 is deleted.

[0083] If the second discharge detection electrode 12 detects a discharge after time t, the discharge signal from the second discharge detection electrode 12 is also stored in the storage unit 32 via the second discharge detection device 14 and the A / D converter 31.

[0084] Next, the calculation unit 33 calculates the characteristic quantity based on the latest discharge signals of the first discharge detection electrode 11 and the second discharge detection electrode 12 stored in the storage unit 32.

[0085] The comparison unit 35 of the evaluation device 30 determines that the covering layer 2B of the electromagnetic wire 2 has an insulation defect when the two discharge signals meet a preset consistent or similar benchmark, based on the calculation results of the calculation unit 33.

[0086] If the discharge signals of the two discharges do not meet the similarity benchmark, they are considered noise, and the discharge signals from the first discharge detection electrode 11 and the second discharge detection electrode 12 stored in the storage unit 32 are deleted.

[0087] In addition, the two discharge signals are judged to be consistent or similar based on whether the difference between them is within a preset range.

[0088] Here, the determination of characteristic quantities based on discharge signals is explained.

[0089] As characteristic quantities of the discharge, for example, the peak discharge charge, the duration of the discharge, and the total discharge charge can be used.

[0090] As a benchmark for being considered consistent or similar, it can be set to the difference between the two discharges detected by the first discharge detection electrode 11 and the second discharge detection electrode 12 being within a predetermined ratio range. That is, it can also be determined by a combination of any one or more of the characteristic quantities of the discharge signal, namely, the peak discharge charge, the discharge duration, and the total discharge charge.

[0091] For example, with the baseline set at 80%, if the peak discharge charge, peak discharge charge, and discharge duration are all consistent at 80% or higher for two discharges, it can be determined that the sheathing layer 2B of the electromagnetic wire 2 has an insulation defect.

[0092] As explained above, the discharge signal detected by the first discharge detection electrode 11 and the discharge signal detected by the second discharge detection electrode 12, which is considered to be identical or similar, are sequentially stored in the storage unit 32. In this way, the discharge signals from the first discharge detection electrode 11 and the second discharge detection electrode 12 are stored as a pair in advance, thereby enabling the number of insulation defects (pinholes or damage) generated during the operation of detecting the electromagnetic wire 2 to be determined based on the number of stored data.

[0093] Furthermore, the movement of the electromagnetic wire 2 may stop after the measurement unit 34 starts measurement and before the measurement is completed. In contrast, a moving signal (RS) is continuously sent to the measurement unit 34 from one or both of the feeder 5 and the winding machine 6. The measurement unit 34 continues to perform measurement while receiving the moving signal and stops measurement when the moving signal disappears, thereby enabling a response.

[0094] This illustrates the case where a travel signal (RS) is always sent from the feeder 5 and the take-up machine 6; however, a travel stop signal can also be sent from the feeder 5 and the take-up machine 6.

[0095] The above description focuses on the structure, function, and operation of the insulation defect detection system for the electromagnetic wire sheathing layer according to Embodiment 1. Here, based on... Figure 7 Basic flowchart and Figure 8 The flowchart illustrates the method for detecting insulation defects in the electromagnetic wire sheath.

[0096] The basic processing of the electromagnetic wire sheath insulation defect detection method consists of a process step (S01), a first discharge detection step (S02), a second discharge detection step (S03), a second discharge detection step (S04-S06), and a judgment step.

[0097] In the travel step (S01), the electromagnetic wire 2 is traveled along the line direction.

[0098] In the first discharge detection step (S02), an AC voltage is applied at the first measurement point on the traveling electromagnetic line 2 to detect the first discharge.

[0099] In the second discharge detection step (S03), an AC voltage is applied at the second measurement point on the electromagnetic wire 2 to detect the second discharge.

[0100] In the determination steps (S04-S06), the first discharge and the second discharge are compared. If the two discharge signals are consistent or similar, it is determined that the covering layer 2B of the electromagnetic wire 2 has an insulation defect. If they are neither consistent nor similar, it is determined that there is no insulation defect.

[0101] Next, the overall process of the method for detecting insulation defects in the electromagnetic wire sheath described in Embodiment 1 will be explained.

[0102] The overall processing configuration is such that, in addition to the proceeding steps (S01) to the determination steps (S04-S06) described in the basic processing, a first discharge storage step S11 to a second discharge storage step S14 are added. Thereafter, the content of the newly added processing beyond the basic processing will be described.

[0103] In the first discharge storage step (S11), if a discharge is detected by the first discharge detection electrode 11, the discharge signal is stored in the storage unit 32 via the first discharge detection device 13.

[0104] In the time calculation step (S12), if a discharge is detected by the first discharge detection electrode 11, the calculation unit 33 calculates the time t from when the position on the electromagnetic line 2 where the discharge was detected by the first discharge detection electrode 11 reaches the second discharge detection electrode 12.

[0105] In the time measurement step (S13), the measurement unit 34 receives the calculation result t from the calculation unit 33, and at the same time, starts the timer measurement.

[0106] In the second discharge storage step (S14), the discharge signal detected by the second discharge detection electrode 12 is stored in the storage unit 32 via the second discharge detection device 14.

[0107] In addition, Figure 8 The flowchart does not describe this, but the processing steps of the method for detecting insulation defects in the electromagnetic wire sheath include a discharge characteristic quantity calculation step and an electromagnetic wire travel detection step.

[0108] In the discharge characteristic calculation step, the peak discharge charge, duration, and total discharge charge detected by the first discharge detection electrode 11 and the second discharge detection electrode 12 are calculated.

[0109] In the electromagnetic wire travel detection step, the measurement unit 34 continuously performs measurement while receiving the travel signal from the feeder 5 and the winding machine 6, and stops measurement when the travel signal disappears.

[0110] As described above, Embodiment 1 relates to an insulation defect detection system for an electromagnetic wire sheath: the system has a delivery and winding device at the beginning and end of the electromagnetic wire's travel path for advancing the electromagnetic wire at a constant speed along the wire direction; the system has an AC power supply that generates an AC voltage at a first and a second measurement point in the travel path to detect discharges from defects in the electromagnetic wire sheath; first and second discharge detection electrodes for detecting discharges from defects in the electromagnetic wire sheath; first and second discharge detection devices for detecting discharge signals detected by the first and second discharge detection electrodes; and the system compares the discharge signals detected at the first and second measurement points to determine whether there is a defect in the electromagnetic wire sheath. Furthermore, Embodiment 1 relates to a method for detecting insulation defects in an electromagnetic wire sheath using an insulation defect detection system for an electromagnetic wire sheath.

[0111] Therefore, the insulation defect detection system and method for the electromagnetic wire sheathing layer in Embodiment 1 do not apply excessively high voltage to the entire electromagnetic wire before winding, thus enabling the detection of insulation defects and improving reliability.

[0112] Implementation Method 2

[0113] The insulation defect detection system for the electromagnetic wire sheathing layer in Implementation Method 2 sets up a charge removal electrode along the travel path of the electromagnetic wire to remove the charge remaining on the sheathing layer of the electromagnetic wire.

[0114] According to the structural diagram of the insulation defect detection system for electromagnetic wire sheathing, Figure 9The insulation defect detection system for the electromagnetic wire sheathing layer of Embodiment 2 will be described with a focus on the differences between Embodiment 2 and Embodiment 1.

[0115] In the structural diagram of Embodiment 2, the parts that are the same as or equivalent to those in Embodiment 1 are labeled with the same reference numerals.

[0116] In addition, to distinguish it from Embodiment 1, it is provided as an insulation defect detection system 200 for the electromagnetic wire sheath layer.

[0117] When an alternating voltage is applied to the electromagnetic wire 2, it can be assumed that the charge remains on the outer surface of the coating layer 2B of the electromagnetic wire 2. In Embodiment 1... Figure 1 In the travel path 1, when the first discharge detection electrode 11 applies an AC voltage to a position (r) on the electromagnetic wire 2 and causes the charge to remain at position r, the detection accuracy of the second discharge detection electrode 12 at position r is affected.

[0118] Furthermore, when winding the charged electromagnetic wire 2 using the winding spool 4, discharge may occur due to uneven residual charge, or new insulation defects (pinholes or damage) may be generated.

[0119] exist Figure 9 In the travel path 1, based on the device or apparatus that constitutes the discharge detection block described in Embodiment 1, a first discharge removal electrode 21 is provided between the first discharge detection electrode 11 and the second discharge detection electrode 12. The first discharge removal electrode 21 removes the charge that remains on the outer surface of the coating layer 2B of the electromagnetic wire 2 due to the application of an AC voltage from the first discharge detection electrode 11.

[0120] Furthermore, a second charge-removing electrode 22 is provided downstream of the second discharge detection electrode 12. The second charge-removing electrode 22 removes the charge retained due to the application of an AC voltage from the second discharge detection electrode 12.

[0121] The two first and second discharge electrodes 21 and 22 are grounded to remove the charge that remains on the outer surface of the electromagnetic wire coating layer 2B between the first discharge detection electrode 11 and the second discharge detection electrode 12 and downstream of the second discharge detection electrode 12.

[0122] As described above, the insulation defect detection system for the electromagnetic wire sheathing layer in Embodiment 2 provides a charge removal electrode along the travel path of the electromagnetic wire to remove the charge remaining on the sheathing layer of the electromagnetic wire.

[0123] Therefore, the insulation defect detection system for the electromagnetic wire sheathing layer in Embodiment 2 does not apply excessively high voltage to the entire electromagnetic wire before winding, enabling the detection of insulation defects and improving reliability. Furthermore, it improves the detection accuracy of the discharge detection electrode and prevents the generation of new insulation defects.

[0124] Implementation Method 3

[0125] The insulation defect detection system for the electromagnetic wire sheath in Embodiment 3 further includes three or more discharge detection electrodes in addition to the first and second discharge detection electrodes. Furthermore, the insulation defect detection method for the electromagnetic wire sheath adds a third to an Nth (N being an integer greater than or equal to 3) discharge detection step to the first and second discharge detection steps.

[0126] According to the structural diagram of the insulation defect detection system for electromagnetic wire sheathing, Figure 10 The structure and operation of the insulation defect detection system for the electromagnetic wire sheath in Embodiment 3 will be explained, focusing on the differences between Embodiment 3 and Embodiment 1.

[0127] In the structural diagram of Embodiment 3, the parts that are the same as or equivalent to those in Embodiments 1 and 2 are labeled with the same reference numerals.

[0128] In addition, to distinguish it from Embodiment 1, it is provided as an insulation defect detection system 300 for the electromagnetic wire sheath layer.

[0129] When the insulation defect (pinhole or damage) in the sheathing layer 2B of the electromagnetic wire 2 is small, the discharge is unstable. For example, even if a discharge is detected in the first discharge detection electrode 11, it may not be detected in the second discharge detection electrode 12. Conversely, it may be undetectable in the first discharge detection electrode 11 but detected in the second discharge detection electrode 12.

[0130] In addition, the following situation should also be considered: Although it is detected in both the first discharge detection electrode 11 and the second discharge detection electrode 12, the discharge is unstable. Therefore, the consistency rate of characteristic quantities such as peak discharge charge, discharge duration, and total discharge charge described in Embodiment 1 is low, and it cannot be determined that the discharge is from an insulation defect.

[0131] The three examples described above were identified as noise in Implementation Method 1, resulting in the missed detection of insulation defects. As a countermeasure, installing three or more discharge detection electrodes is effective.

[0132] Figure 10 An example is shown where three discharge detection electrodes are provided, with a third discharge detection electrode 15 provided downstream of the second discharge detection electrode 12, based on the first discharge detection electrode 11 and the second discharge detection electrode 12.

[0133] Furthermore, the third discharge detection electrode 15 is positioned at the same distance from the second discharge detection electrode 12 as the distance between the first discharge detection electrode 11 and the second discharge detection electrode 12. Additionally, the third discharge detection electrode 15 is connected to a third discharge detection device 16, which detects the discharge signal detected by the third discharge detection electrode 15.

[0134] Furthermore, a third discharge removal electrode 23, as described in Embodiment 2, is provided downstream of the third discharge detection electrode 15. The following seven combinations can be considered as combinations for detecting insulation defects in the sheathing layer 2B of the electromagnetic wire 2.

[0135] (1) All discharge detection electrodes 11, 12 and 15 detected discharge, and the characteristic quantities of all discharge signals were considered to be consistent or similar.

[0136] (2) All three discharge detection electrodes 11, 12, and 15 detect discharge, and the discharge signals detected by the first discharge detection electrode 11 and the second discharge detection electrode 12 are considered to be consistent or similar.

[0137] (3) All three discharge detection electrodes 11, 12, and 15 detect discharge, and the discharge signals detected by the first discharge detection electrode 11 and the third discharge detection electrode 15 are considered to be consistent or similar.

[0138] (4) All three discharge detection electrodes 11, 12, and 15 detect discharge, and the discharge signals detected by the first discharge detection electrode 11 and the second discharge detection electrode 12 and the third discharge detection electrode 15 are considered to be consistent or similar.

[0139] (5) The first discharge detection electrode 11 and the second discharge detection electrode 12 detect discharge, and the discharge signals detected by the first discharge detection electrode 11 and the second discharge detection electrode 12 are considered to be consistent or similar.

[0140] (6) The first discharge detection electrode 11 and the third discharge detection electrode 15 detect discharge, and the discharge signals detected by the first discharge detection electrode 11 and the third discharge detection electrode 15 are considered to be consistent or similar.

[0141] (7) The second discharge detection electrode 12 and the third discharge detection electrode 15 detect discharge, and the discharge signals detected by the second discharge detection electrode 12 and the third discharge detection electrode 15 are considered to be consistent or similar.

[0142] As described above, by adding only one discharge detection electrode, the detection capability is increased by 2.3 times compared to the situation in Embodiment 1 where insulation defects (pinholes or damages) can only be detected in all situations from (1) to (7).

[0143] Furthermore, in Embodiment 3, an example of adding one discharge detection electrode to set up three electrodes was described. However, it is possible to further increase the number of discharge detection electrodes to four or more. That is, by having N or more discharge detection electrodes (N being an integer of 3 or more), the insulation defect detection capability can be further improved.

[0144] In addition, in the method for detecting insulation defects in the electromagnetic wire sheath, based on the first discharge detection step and the second discharge detection step, there are sequentially third to Nth (N is an integer greater than or equal to 3) discharge detection steps that apply an AC voltage to the measurement point on the electromagnetic wire 2 to detect the discharge. In the determination step, the discharge signals detected in the third to Nth discharge detection steps are also compared to determine whether there is an insulation defect in the electromagnetic wire sheath 2B.

[0145] As explained above, the insulation defect detection system for the electromagnetic wire sheath in Embodiment 3 further includes three or more discharge detection electrodes in addition to the first and second discharge detection electrodes. Furthermore, the insulation defect detection method for the electromagnetic wire sheath adds a third to an Nth (N being an integer greater than or equal to 3) discharge detection step to the first and second discharge detection steps.

[0146] Therefore, the insulation defect detection system and method for the electromagnetic wire sheathing layer in Embodiment 3 do not apply excessively high voltage to the entire electromagnetic wire before winding, enabling the detection of insulation defects and improving reliability. Furthermore, it can further enhance the insulation defect detection capability of the electromagnetic wire sheathing layer.

[0147] Implementation Method 4

[0148] The insulation defect detection system for the electromagnetic wire sheath in Embodiment 4 includes a reference signal generator to remove noise. Furthermore, the insulation defect detection method for the electromagnetic wire sheath adds a reference signal generation step to remove noise.

[0149] The diagram illustrates the noise signal removal mechanism of the insulation defect detection system for electromagnetic wire sheathing. Figure 11 The insulation defect detection system for the electromagnetic wire sheathing layer of Embodiment 4 will be described with a focus on the differences between Embodiment 4 and Embodiment 1.

[0150] In the structural diagram of Embodiment 4, the parts that are the same as or equivalent to those in Embodiment 1 are labeled with the same reference numerals.

[0151] Furthermore, in the description of the insulation defect detection system for the electromagnetic wire sheath in Embodiment 4, the structural diagram of the insulation defect detection system for the electromagnetic wire sheath in Embodiment 3 shall be appropriately referenced. Figure 10 .

[0152] In addition, to distinguish it from Embodiment 1, it is provided as an insulation defect detection system 400 for the electromagnetic wire sheath layer.

[0153] The following two factors can be considered as factors that may hinder the detection of insulation defects (pinholes or damage) in the electromagnetic wire sheath 2B.

[0154] (1) The potential of the grounding point, which grounds the core 2A of the electromagnetic wire 2, the AC power supply 10, the first de-energizing electrode 21, the second de-energizing electrode 22, and the third de-energizing electrode 23, is unstable. Therefore, the first discharge detection electrode 11, the second discharge detection electrode 12, and the third discharge detection electrode 15 detect noise unrelated to discharge, which becomes a factor of external interference in the calculation of the characteristic quantities of the discharge signal and the determination of whether the discharge signals are consistent or similar.

[0155] (2) A discharge also occurs from the surface of the normal covering layer 2B of the electromagnetic wire 2 at a lower level than the discharge from the insulation defect. Therefore, it becomes an external interference factor in the calculation of the characteristic quantities of the discharge signals detected by the first discharge detection electrode 11, the second discharge detection electrode 12, and the third discharge detection electrode 15, as well as in the determination of whether the discharge signals are consistent or similar.

[0156] As a countermeasure against these external interference noises and discharges from the surface of the electromagnetic wire sheath 2B, it is necessary to make every effort to remove unnecessary noises unrelated to discharges from insulation defects.

[0157] according to Figure 11 An example of how to implement this countermeasure will be provided.

[0158] A reference signal with a certain charge amount, for example 100 picocoulombs, is generated when no voltage is applied from the AC power supply 10. The reference signal generator 20 is connected in parallel with respect to the electromagnetic wire sheath 2B to generate the reference signal.

[0159] The reference signal is detected by the first, second, and third discharge detection electrodes 11, 12, and 15, and then sent to the storage unit 32 for storage via the first, second, and third discharge detection devices 13, 14, and 16 and the A / D converter 31.

[0160] Subsequently, signals with a strength lower than the stored reference signal strength are not stored. For example, signals with a strength lower than the reference signal strength can be removed from the discharge signal.

[0161] By removing signals below the reference signal strength in this way, even weak noise unrelated to the discharge from the insulation defect in the electromagnetic wire sheath 2B detected in the first, second, and third discharge detection electrodes 11, 12, and 15 can be eliminated. As a result, the detection capability for insulation defects in the electromagnetic wire sheath can be further improved.

[0162] In addition, in the method for detecting insulation defects in the electromagnetic wire sheath, there is a reference signal transmission step for transmitting a reference signal, in which the reference signal is pre-detected in the first, second, and third discharge detection electrodes 11, 12, and 15, and in the discharge storage step, discharge signals below the reference signal are removed.

[0163] As explained above, the insulation defect detection system for the electromagnetic wire sheath in Embodiment 4 includes a reference signal generator to remove noise. Furthermore, the insulation defect detection method for the electromagnetic wire sheath adds a reference signal generation step to remove noise.

[0164] Therefore, the insulation defect detection system and method for the electromagnetic wire sheathing layer in Embodiment 4 do not apply excessively high voltage to the entire electromagnetic wire before winding, enabling the detection of insulation defects and improving reliability. Furthermore, it can further enhance the insulation defect detection capability of the electromagnetic wire sheathing layer.

[0165] Implementation Method 5

[0166] The insulation defect detection system for the electromagnetic wire sheathing layer in Implementation 5 includes a stabilization mechanism along the travel path of the electromagnetic wire.

[0167] The diagram illustrates the stabilization mechanism for the electromagnetic line's path. Figure 12 The insulation defect detection system for the electromagnetic wire sheath of Embodiment 5 will be described with a focus on the differences between Embodiment 5 and Embodiment 1.

[0168] In the structural diagram of Embodiment 5, the parts that are the same as or equivalent to those in Embodiment 1 are labeled with the same reference numerals.

[0169] In addition, to distinguish it from Embodiment 1, it is provided as an insulation defect detection system 500 for the electromagnetic wire sheath layer.

[0170] Furthermore, for the sake of simplicity, the first, second, and third discharge detection electrodes 11, 12, and 15 may be referred to simply as each discharge detection electrode unless a distinction is required.

[0171] As a factor hindering the detection of insulation defects (pinholes or damage) in the electromagnetic wire sheath 2B, there is instability in the travel path 1 of the electromagnetic wire 2. Due to the slight serpentine movement or slight vibration of the travel path 1, the contact state or distance between the electromagnetic wire 2 and the first, second, and third discharge detection electrodes 11, 12, and 15 changes.

[0172] When the electromagnetic wire 2 can make good contact with each discharge detection electrode, it can stably detect high-intensity discharges. However, when the contact is insufficient or unstable, it becomes a low-intensity, unstable discharge, and the first, second, and third discharge detection electrodes 11, 12, and 15 cannot stably detect the discharge.

[0173] Furthermore, when the distance between the electromagnetic wire 2 and each discharge detection electrode is properly maintained, high-intensity discharges can be detected stably. However, when the distance is too far or unstable, the discharge becomes low-intensity and unstable, and the first, second, and third discharge detection electrodes 11, 12, and 15 cannot detect the discharge stably.

[0174] To address these issues, setting a stabilization mechanism along the travel path 1 of the electromagnetic wire 2 is effective.

[0175] set up Figure 12 The guide block 51 shown can guide the electromagnetic line 2 toward each discharge detection electrode.

[0176] That is, a through hole with an upstream guide hole 52 and a downstream guide hole 53 is provided in the roughly cubic guide block 51, and a groove 59 is provided to house the first, second, and third discharge detection electrodes 11, 12, and 15 within the guide block 51. The first, second, and third discharge detection electrodes 11, 12, and 15 are housed in the groove 59. The through hole is provided such that it penetrates the two opposing surfaces of each discharge detection electrode separated by a circular surface, and the center point coincides with the center point of each discharge detection electrode. The inner diameter of the through hole is about 10 μm to 100 μm larger than the outer diameter of the electromagnetic wire 2.

[0177] The electromagnetic wire 2 is guided through the guide hole 52 on the upstream side of the guide block 51 to approach the first, second, and third discharge detection electrodes 11, 12, and 15, ensuring a stable contact state or an appropriate distance for it to pass through and exit through the guide hole 53 on the downstream side. In this way, if a stabilization mechanism is configured in the travel path of the electromagnetic wire 2, the first, second, and third discharge detection electrodes 11, 12, and 15 can always stably detect high-intensity discharges.

[0178] In addition, Figure 12 The diagram shows an example of a guide block 51 that houses one discharge detection electrode; however, multiple discharge detection electrodes can also be housed by extending the guide block in the direction of travel of the electromagnetic wire 2. Furthermore, the guide block 51 can also be held on a stand within a travel path not shown.

[0179] Considering the damage to the electromagnetic wire 2 caused by friction, the guide block 51 is preferably made of resin material, preferably fluororesin such as PTFE (polytetrafluoroethylene) with a low coefficient of friction.

[0180] On the other hand, when the guide block 51 is formed of metal materials such as iron, aluminum, and copper, the discharge detection electrode is not housed in the guide block 51. Instead, the inner diameter of the hole that passes through the guide block and forms the travel path 1 of the electromagnetic wire 2 is adjusted to be about 10 μm to 100 μm larger than the outer diameter of the electromagnetic wire 2, and it can also be used as a discharge detection electrode.

[0181] In this embodiment 5, in Figure 12 The diagram shows an example of the guiding structure for the guiding electromagnetic wire 2. However, the guiding structure is not limited to this example; any structure can be used as long as it has the same function.

[0182] As described above, the insulation defect detection system for the electromagnetic wire sheathing layer in Embodiment 5 includes a stabilization mechanism along the travel path of the electromagnetic wire.

[0183] Therefore, the insulation defect detection system for the electromagnetic wire sheathing layer in Embodiment 5 does not apply excessively high voltage to the entire electromagnetic wire before winding, thus enabling the detection of insulation defects and improving reliability. Furthermore, it can further enhance the insulation defect detection capability of the electromagnetic wire sheathing layer.

[0184] Implementation Method 6

[0185] The insulation defect detection system for the electromagnetic wire sheath in Embodiment 6 smooths the discharge signal to reduce noise. Furthermore, the insulation defect detection method for the electromagnetic wire sheath adds smoothing processing to the determination step to further reduce noise.

[0186] According to the structural diagram of the insulation defect detection system for electromagnetic wire sheathing, Figure 13 And the smoothing of the discharge waveform, i.e. Figures 14-16 The insulation defect detection system for the electromagnetic wire sheathing layer of Embodiment 6 will be described with a focus on the differences between Embodiment 6 and Embodiment 1.

[0187] In the structural diagram of Embodiment 6, the parts that are the same as or equivalent to those in Embodiment 1 are labeled with the same reference numerals.

[0188] In addition, to distinguish it from Embodiment 1, it is provided as an insulation defect detection system 600 for the electromagnetic wire sheath layer.

[0189] In the insulation defect detection system 600 for electromagnetic wire sheathing, an image output unit 36 ​​and an image display device 37 are added to the evaluation block within the evaluation device 30.

[0190] As another method to reduce unnecessary noise that hinders the detection of insulation defects (pinholes or damage) in the electromagnetic wire sheath 2B, smoothing the discharge signal stored in the storage unit 32 is effective.

[0191] Figure 14 The simulation shows the discharge signal detected by the insulation defect detection system of the electromagnetic wire sheath of this application and stored in the storage unit 32.

[0192] exist Figure 14 In the diagram, the horizontal axis represents the sampling number, and the vertical axis represents the discharge charge. Figure 15 , Figure 16 The same applies to China.

[0193] For ease of calculation, it is assumed that the sampling frequency for the storage unit 32 is 256Hz.

[0194] exist Figure 14 Near point 500 on the horizontal axis of the graph, a strong discharge peak, believed to originate from an insulation defect in the electromagnetic wire sheath 2B, can be identified. The noise levels near points 400 and 550 are relatively high, making it difficult to grasp the full shape of the peak. Therefore, it is challenging to accurately calculate characteristic quantities such as the duration of the discharge and the total discharge charge associated with this peak.

[0195] Therefore, considering Figure 15 The smoothing process shown is applied to the discharge signal.

[0196] In Implementation 6, as an example of a smoothing method, a simple moving average is performed.

[0197] The calculation unit 33 calculates the characteristic quantity after performing a moving average process based on the latest discharge signals of the first discharge detection electrode 11 and the second discharge detection electrode 12 stored in the storage unit 32, according to a preset number of moving average points.

[0198] exist Figure 15 The results are shown when the moving average is set to 5 points. Furthermore, in... Figure 16 The result is shown when the moving average is set to 9 points. Figure 15 The discharge signal waveform, Figure 16 Unnecessary noise has been removed from the discharge signal waveforms to remove its influence on the main discharge signal, and the full shape of the peaks has become clear. Therefore, if using Figure 15 or Figure 16 By observing the discharge signal waveform, the duration of the discharge and the total amount of discharge charge can be reliably determined.

[0199] The comparison unit 35 determines whether there is a discharge from an insulation defect in the electromagnetic wire sheath 2B based on the calculation results of the calculation unit 33. When the number of moving average points is excessively increased, the absolute value of the discharge peak decreases. However, in Embodiment 6, as described in Embodiment 1, the discharge signal detected by the first discharge detection electrode 11 and the discharge signal detected by the second discharge detection electrode 12 are compared to determine whether the two signals are identical or similar. Therefore, the decrease in the absolute value does not affect the detection of insulation defects in the electromagnetic wire sheath 2B.

[0200] It is effective to determine the appropriate number of moving average points by conducting prior tests on the insulation defect detection system for the electromagnetic wire sheath 2B. That is, the number of moving average points is set based on the environment of the work site where the insulation defect detection operation of the electromagnetic wire sheath 2B is performed and the discharge amount from the normal electromagnetic wire 2 sheath 2B, without causing a reduction in detection capability.

[0201] In addition, such as Figure 13 As shown in the structural diagram, the evaluated device 30 can output the judged discharge signal waveform and the cumulative number of discharge signals from the insulation defects of the electromagnetic wire sheath 2B to the image display device 37 for display via the image output unit 36.

[0202] If this structure is adopted, the operator can check the detection status of insulation defects in the electromagnetic wire sheath 2B at any time.

[0203] Thus, by performing smoothing processing in the insulation defect detection system of the electromagnetic wire sheath in Embodiment 6, unnecessary noise can be reduced, thereby further improving the insulation defect detection capability of the electromagnetic wire sheath.

[0204] In addition, in the method for detecting insulation defects in the electromagnetic wire sheath, the waveform of the detected discharge signal is smoothed during the judgment step.

[0205] As explained above, the insulation defect detection system for the electromagnetic wire sheath in Embodiment 6 smooths the discharge signal to reduce noise. Furthermore, the insulation defect detection method for the electromagnetic wire sheath adds smoothing processing to the determination step to further reduce noise.

[0206] Therefore, the insulation defect detection system and method for the electromagnetic wire sheathing layer in Embodiment 6 do not apply excessively high voltage to the entire electromagnetic wire before winding, enabling the detection of insulation defects and improving reliability. Furthermore, it can further enhance the insulation defect detection capability of the electromagnetic wire sheathing layer.

[0207] Implementation Method 7

[0208] The insulation defect detection system and method of the electromagnetic wire sheathing layer of Embodiment 7 are applied to the winding process of the armature, i.e., the stator, of a rotary motor or a linear motor, which is an example of electric machinery.

[0209] According to the structural diagram of the insulation defect detection system for electromagnetic wire sheathing, Figure 17 And an explanatory diagram for application examples of stator cores, i.e. Figure 18 The insulation defect detection system for the electromagnetic wire sheathing layer of Embodiment 7 will be described with a focus on the differences between Embodiment 7 and Embodiment 1.

[0210] In the structural diagram of Embodiment 7, the parts that are the same as or equivalent to those in Embodiment 1 are labeled with the same reference numerals.

[0211] In addition, to distinguish it from Embodiment 1, it is provided as an insulation defect detection system 700 for the electromagnetic wire sheath layer.

[0212] exist Figure 17 In the electromagnetic wire sheath insulation defect detection system 700, only the delivery reel 3 for delivering electromagnetic wire 2 is provided in the traveling block.

[0213] The discharge detection block includes an AC power supply 10, a first discharge detection electrode 11, a second discharge detection electrode 12, a fourth discharge detection electrode 17, a first discharge detection device 13, a second discharge detection device 14, and a fourth discharge detection device 18. The discharge detection block also includes a first discharge removal electrode 21, a second discharge removal electrode 22, and a fourth discharge removal electrode 24. Additionally, in... Figure 17 Descriptions of the third discharge detection electrode 15, the third discharge detection device 16, and the third discharge removal electrode 23 are omitted.

[0214] like Figure 17 , Figure 18 As indicated by the symbol "Y", the electromagnetic wire 2, which has undergone insulation defect detection of the electromagnetic wire sheath layer using the electromagnetic wire insulation defect detection system and detection method described in Embodiments 1 to 6, is not sent to the winding spool 4, but to a winding machine (not shown).

[0215] The winding machine winds the inspected electromagnetic wires 2 sequentially onto the stator core 62 through the nozzle 61 of the winding machine.

[0216] At this point, consider the following situation: The insulation defect detection system 700 of the electromagnetic wire sheath determines that there is a discharge from the electromagnetic wire sheath 2B due to an insulation defect (pinhole or damage) based on the discharge signals from the first, second, third, and fourth discharge detection electrodes 11, 12, 15, and 17.

[0217] The travel path length XL of the electromagnetic wire 2 between the first electrode that detects a discharge signal that is determined to be consistent or similar and the wound stator 62 is determined. The calculation unit 33 calculates the time T=XL / V until the insulation defect of the electromagnetic wire sheath 2B reaches the wound stator core 62 based on the travel speed V and the travel path length XL, and sends it to the measurement unit 34.

[0218] The measurement unit 34 receives the calculation results from the calculation unit 33, and simultaneously begins timer measurement from the point when it is determined that the discharge originates from an insulation defect in the electromagnetic wire sheath 2B. As a result, it is determined that the stator core 62 is in the process of winding at the point when the measurement unit 34 completes the measurement.

[0219] As explained above, stator cores 62 that are wound and confirmed to contain insulation defects in the electromagnetic wire 2, or stators using stator cores 62, will not flow into subsequent processes. They can be distinguished from qualified products as non-conforming products by means of conveying them to conveyors, trolleys, etc., for discharging non-conforming products.

[0220] In addition, these defective stator cores can be re-inspected separately using known methods such as surge voltage application (pulse voltage application) tests.

[0221] Furthermore, as described in Embodiment 1, the movement of the electromagnetic wire 2 may stop due to the winding machine stopping before the measurement unit 34 completes the measurement for the predetermined time. In this case, as in Embodiment 1, the signal during the winding operation is received from the winding machine, and the measurement is only performed during the reception of the signal during the winding operation.

[0222] In addition, a winding operation stop signal can also be received from the winding machine.

[0223] Figure 18 An electromechanical device 70 is shown, which has a stator core 62 wound with an electromagnetic wire 2, which an insulation defect detection system has confirmed is free of insulation defects by applying an electromagnetic wire sheath. Figure 18 In the example of electric machinery 70, a rotary motor is described.

[0224] An electric motor 70 is manufactured using an electric motor manufacturing method that includes the step of manufacturing an electric motor having the stator core 62, which is capable of being confirmed to be free of insulation defects by an insulation defect detection system that uses an applied electromagnetic wire sheathing layer.

[0225] As explained above, the insulation defect detection system and method of the electromagnetic wire sheathing layer of Embodiment 7 are applied to the winding process of the armature, i.e., the stator, of a rotary motor or a linear motor, which is an example of an electric machine.

[0226] Therefore, the insulation defect detection system and method for the electromagnetic wire sheathing layer of Embodiment 7 can supply the armature, i.e., the stator, of a rotary motor or linear motor that uses electromagnetic wire that does not apply excessively high voltage to the entire electromagnetic wire before winding, thereby detecting insulation defects and improving reliability.

[0227] As described above, according to the insulation defect detection system and method for the electromagnetic wire sheathing layer according to Embodiments 1 to 7, a characteristic quantity is calculated based on the discharge signals detected more than twice in the travel path of the insulation defect detection of the electromagnetic wire sheathing layer. If the results can be determined to be consistent or similar, an insulation defect in the electromagnetic wire sheathing layer is determined to have been detected. Therefore, excessive voltage is not applied to the electromagnetic wire in order to detect insulation defects in the electromagnetic wire sheathing layer through a single discharge detection, thus avoiding damage.

[0228] Therefore, in the electromagnetic wire sheath insulation defect detection system and detection method of Embodiments 1 to 7, it is possible to check the total amount of electromagnetic wire supplied for winding before the winding process with high precision.

[0229] Here, in Figure 19 The image shows an example of the hardware of an evaluation device 30 for a system that detects insulation defects in the electromagnetic wire sheath. For example... Figure 19 As shown, it consists of a processor 1000 and a storage device 1001. The storage device is not shown, but it includes volatile storage devices such as random access memory and non-volatile auxiliary storage devices such as flash memory.

[0230] Alternatively, an auxiliary storage device, such as a hard disk, can be used instead of flash memory. The processor 1000 executes a program input from the storage device 1001. In this case, the program is input to the processor 1000 from the auxiliary storage device via a volatile storage device. Furthermore, the processor 1000 can output data such as calculation results to the volatile storage device of the storage device 1001, or it can save data in the auxiliary storage device via the volatile storage device.

[0231] This application describes various exemplary implementation methods and embodiments. However, the various features, methods and functions described in one or more embodiments are not limited to the application of a specific embodiment and can be applied to the embodiment alone or in various combinations.

[0232] Therefore, numerous variations not illustrated are conceivable within the scope of the technology disclosed in this application. For example, variations may include modifying at least one structural element, adding at least one structural element, omitting at least one structural element, or extracting at least one structural element and combining it with structural elements of other embodiments.

[0233] Label Explanation

[0234] 1: Travel path; 2: Electromagnetic wire; 2A: Electromagnetic wire core; 2B: Electromagnetic wire sheathing layer; 3: Feed reel; 4: Take-up reel; 5: Feeder; 6: Take-up machine; 7: Turntable; 10: AC power supply; 11: First discharge detection electrode; 12: Second discharge detection electrode; 13: First discharge detection device; 14: Second discharge detection device; 15: Third discharge detection electrode; 16: Third discharge detection device; 17: Fourth discharge detection electrode; 18: Fourth discharge detection device; 20: Reference signal generator; 21: First discharge removal electrode; 22: Second discharge removal electrode; 23: Third discharge removal electrode; 24: Fourth discharge removal electrode; 30: Evaluation device; 31: A / D converter; 32: Storage unit; 33: Calculation unit; 34: Computation unit; 35: Measurement unit; 36: Comparison unit; 37: Image output unit; 41: Image display device; 42: Insulation defect; 43: Coupling capacitor; 44: Detection impedance; 45: Electrostatic capacitance of the normal part of the electromagnetic wire sheath; 46: Electrostatic capacitance of the insulation defect part; 47: Electrostatic capacitance of the part connected in series with the insulation defect part; 48: Electrostatic capacitance of the coupling capacitor; 51: Guide block; 52: Guide hole on the upstream side; 53: Guide hole on the downstream side; 59: Slot; 61: Nozzle of the winding machine; 62: Stator core; 70: Electromechanical equipment; 100, 200, 300, 400, 500, 600, 700: Insulation defect detection system for electromagnetic wire sheath; 1000: Processor; 1001: Storage device.

Claims

1. A method for detecting insulation defects in the sheathing layer of an electromagnetic wire, wherein, The method for detecting insulation defects in the electromagnetic wire sheath includes the following steps: The steps of movement are to cause the electromagnetic wire to travel along the direction of the line; The first discharge detection step involves applying an AC voltage to the first measurement point on the moving electromagnetic wire and detecting the discharge current caused by the first discharge as the change in the AC voltage. as well as The second discharge detection step involves applying the AC voltage to the second measurement point on the electromagnetic wire after the first discharge is detected, and detecting the discharge current caused by the second discharge as the change in the AC voltage. During the travel step, the electromagnetic wire is made to travel at a constant speed along the line direction. The method for detecting insulation defects in the electromagnetic wire sheath also includes the following steps: The discharge storage step stores the first discharge detected in the first discharge detection step and the second discharge detected in the second discharge detection step. The time calculation step involves calculating the time it takes for the electromagnetic line to move from the first measurement point to the second measurement point, based on the traveling speed of the electromagnetic line and the distance from the first measurement point to the second measurement point. The time measurement step involves measuring the time it takes for the electromagnetic line to move from the first measurement point to the second measurement point. as well as The determination step involves comparing the first discharge and the second discharge to determine whether the electromagnetic wire coating layer has any defects.

2. The method for detecting insulation defects in the electromagnetic wire sheathing layer according to claim 1, wherein, In the determination step, the discharge signal of the first discharge is compared with the discharge signal of the second discharge detected at the second measurement point after the time from the detection of the first discharge at the first measurement point to the arrival at the second measurement point. If the difference between the two discharge signals is within a preset range, it is determined that there is a defect in the electromagnetic wire coating layer.

3. The method for detecting insulation defects in the electromagnetic wire sheathing layer according to claim 2, wherein, The determination step further includes a discharge characteristic calculation step for calculating the peak discharge charge, discharge duration, or total discharge charge of the discharge signals of the first discharge and the second discharge. In the determination step, the determination is made by a combination of any one or two or more characteristic quantities among the peak discharge charge, the discharge duration, and the total discharge charge. If the difference of the characteristic quantities or the consistency ratio of the characteristic quantities is within a preset range, it is determined that the electromagnetic wire coating layer has a defect.

4. The method for detecting insulation defects in the electromagnetic wire sheathing layer according to claim 1, wherein, The time measurement step further includes an electromagnetic line travel detection step, which detects that the electromagnetic line is traveling. In the time measurement step, the time of movement of the electromagnetic line is continuously measured only during the period when the electromagnetic line is traveling, and the time of movement is stopped when the electromagnetic line stops.

5. The method for detecting insulation defects in the electromagnetic wire sheathing layer according to claim 2, wherein, The time measurement step further includes an electromagnetic line travel detection step, which detects that the electromagnetic line is traveling. In the time measurement step, the time of movement of the electromagnetic line is continuously measured only during the period when the electromagnetic line is traveling, and the time of movement is stopped when the electromagnetic line stops.

6. The method for detecting insulation defects in the electromagnetic wire sheathing layer according to claim 3, wherein, The time measurement step further includes an electromagnetic line travel detection step, which detects that the electromagnetic line is traveling. In the time measurement step, the time of movement of the electromagnetic line is continuously measured only during the period when the electromagnetic line is traveling, and the time of movement is stopped when the electromagnetic line stops.

7. The method for detecting insulation defects in the electromagnetic wire sheathing layer according to any one of claims 1 to 6, wherein, The method for detecting insulation defects in the electromagnetic wire sheath also includes a reference signal transmission step for transmitting a reference signal of a reference discharge charge quantity. The reference signal is pre-detected at the first discharge detection electrode at the first measurement point and the second discharge detection electrode at the second measurement point. In the discharge storage step, a signal containing the amount of discharge charge below the detected reference signal is removed.

8. The method for detecting insulation defects in the electromagnetic wire sheathing layer according to any one of claims 2 to 6, wherein, In the determination step, waveform smoothing processing is also performed to smooth the waveform of the detected discharge signal.

9. The method for detecting insulation defects in the electromagnetic wire sheathing layer according to claim 7, wherein, In the determination step, waveform smoothing processing is also performed to smooth the waveform of the detected discharge signal.

10. The method for detecting insulation defects in the electromagnetic wire sheathing layer according to claim 8, wherein, In the waveform smoothing process, a moving average of the discharge signal is calculated.

11. The method for detecting insulation defects in the electromagnetic wire sheathing layer according to claim 9, wherein, In the waveform smoothing process, a moving average of the discharge signal is calculated.

12. The method for detecting insulation defects in the electromagnetic wire sheathing layer according to claim 1, wherein, Let N be an integer greater than or equal to 3. The insulation defect detection method for the electromagnetic wire sheath layer sequentially includes the following discharge detection steps from the 3rd to the Nth: After detecting the 2nd discharge, the AC voltage is applied to the 3rd to the Nth measurement points on the electromagnetic wire to detect the discharge. In the determination step, the discharge signals detected in the third to Nth discharge detection steps are also compared to determine whether the electromagnetic wire has defects.

13. A system for detecting insulation defects in an electromagnetic wire sheath, wherein, The insulation defect detection system for the electromagnetic wire sheath has a feeding device and a winding device before and after the electromagnetic wire's travel path to ensure that the electromagnetic wire travels at a constant speed along the wire direction. The insulation defect detection system for the electromagnetic wire sheath has an AC power supply that generates an AC voltage applied to detect discharges from defects in the electromagnetic wire sheath along the travel path. The insulation defect detection system for the electromagnetic wire sheath has a first discharge detection electrode at a first measurement point for detecting discharge from defects in the electromagnetic wire sheath, and a second discharge detection electrode at a second measurement point for detecting discharge from defects in the electromagnetic wire sheath. The insulation defect detection system for the electromagnetic wire sheath includes a first discharge detection device that detects the discharge current detected by the first discharge detection electrode as a change in the AC voltage, and a second discharge detection device that detects the discharge current detected by the second discharge detection electrode as a change in the AC voltage. The insulation defect detection system for the electromagnetic wire sheath includes an evaluation device with a comparison unit. This comparison unit compares the discharge signal of a first discharge detected at a first measurement point with the discharge signal of a second discharge detected at a second measurement point to determine whether the electromagnetic wire sheath has the defect. In the comparison section, The determination is made by combining any one or more of the following characteristic quantities: peak discharge charge, discharge duration, or total discharge charge of the discharge signal of the first discharge and the discharge signal of the second discharge. If the difference of the characteristic quantity or the difference of the ratio of the characteristic quantity is within a preset range, it is determined that there is a defect in the electromagnetic wire coating layer.

14. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 13, wherein, Downstream of the first measuring point and upstream and downstream of the second measuring point, there are also charge-removing electrodes, which remove the charge remaining on the outer surface of the electromagnetic wire by applying an AC voltage at the first measuring point and an AC voltage at the second measuring point.

15. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 13, wherein, The insulation defect detection system for the electromagnetic wire sheath also includes a reference signal generator that transmits a reference signal for a reference discharge charge quantity. The reference signal is detected in the first discharge detection electrode and the second discharge detection electrode. In the first discharge detection device and the second discharge detection device, a signal with a discharge charge amount below the reference signal is removed with reference to the detected reference signal.

16. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 13, wherein, The first discharge detection electrode and the second discharge detection electrode are further provided with guide blocks to guide the electromagnetic wires.

17. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 16, wherein, The guide block is a cube-shaped resin material block. The guide block is provided with a groove that houses the first discharge detection electrode and the second discharge detection electrode. The guide block is provided with a through hole that passes through the two opposing surfaces of the first and second discharge detection electrodes separated by a circular surface. The center point of the groove coincides with the center point of the first and second discharge detection electrodes. The inner diameter of the through hole is 10 μm to 100 μm larger than the outer diameter of the electromagnetic wire.

18. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 17, wherein, The resin material of the guide block is set as fluororesin.

19. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 13, wherein, The comparison unit also has the function of smoothing the waveforms of the discharge signal detected by the first discharge detection device and the discharge signal detected by the second discharge detection device.

20. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 19, wherein, Calculate the moving average of the discharge signal to smooth the waveform of the discharge signal.

21. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 13, wherein, The insulation defect detection system for the electromagnetic wire sheath also includes an image output unit and an image display device, which are used to display the latest discharge signal that is determined to be defective in the electromagnetic wire sheath together with the cumulative number of times the defect has been determined.

22. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 13, wherein, Assuming N is an integer greater than or equal to 3, the insulation defect detection system for the electromagnetic wire sheath further includes a third discharge detection electrode to an Nth discharge detection electrode located at a third to Nth measurement point downstream of the second discharge detection electrode, and a third to an Nth discharge detection device for detecting the discharge signals detected by the third to Nth discharge detection electrodes. The comparison unit also compares the discharge signals detected at the 3rd to Nth measurement points to determine whether the electromagnetic wire coating layer has the defect.

23. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 13, wherein, The electromagnetic wire, after passing through the travel path that detects defects in the electromagnetic wire coating, is made to travel towards a winding device that winds the electromagnetic wire onto an iron core, and the winding mechanism of the winding device winds the electromagnetic wire onto the iron core.

24. A system for detecting insulation defects in the sheathing layer of an electromagnetic wire, wherein, The insulation defect detection system for the electromagnetic wire sheath has a feeding device and a winding device before and after the electromagnetic wire's travel path to ensure that the electromagnetic wire travels at a constant speed along the wire direction. The insulation defect detection system for the electromagnetic wire sheath has an AC power supply that generates an AC voltage applied to detect discharges from defects in the electromagnetic wire sheath along the travel path. The insulation defect detection system for the electromagnetic wire sheath has a first discharge detection electrode at a first measurement point for detecting discharge from defects in the electromagnetic wire sheath, and a second discharge detection electrode at a second measurement point for detecting discharge from defects in the electromagnetic wire sheath. The insulation defect detection system for the electromagnetic wire sheath has a first discharge detection device for detecting the discharge signal detected by the first discharge detection electrode and a second discharge detection device for detecting the discharge signal detected by the second discharge detection electrode. The insulation defect detection system for the electromagnetic wire sheath includes an evaluation device with a comparison unit. This comparison unit compares the discharge signal of a first discharge detected at a first measurement point with the discharge signal of a second discharge detected at a second measurement point to determine whether the electromagnetic wire sheath has the defect. The insulation defect detection system for the electromagnetic wire sheath also has the following features: A discharge storage unit that stores the discharge signal detected by the first discharge detection device and the discharge signal detected by the second discharge detection device; The time calculation unit calculates the time it takes for the electromagnetic line to move from the first measurement point to the second measurement point based on the traveling speed of the electromagnetic line and the distance from the first measurement point to the second measurement point. as well as The time measuring unit measures the time it takes for the electromagnetic line to move from the first measuring point to the second measuring point.

25. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 24, wherein, In the comparison section, Calculate the peak discharge charge, discharge duration, or total discharge charge of the discharge signal of the first discharge and the discharge signal of the second discharge. The determination is made by combining any one or more of the following characteristic quantities: peak discharge charge, discharge duration, and total discharge charge. If the difference in the characteristic quantity or the difference in the ratio of the characteristic quantity is within a preset range, it is determined that the electromagnetic wire coating layer has a defect.

26. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 24, wherein, The time measurement unit receives a travel signal indicating that the electromagnetic line is in motion, and continues to measure only when the electromagnetic line is in motion, and stops measuring when the electromagnetic line stops.

27. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 25, wherein, The time measurement unit receives a travel signal indicating that the electromagnetic line is in motion, and continues to measure only when the electromagnetic line is in motion, and stops measuring when the electromagnetic line stops.

28. The insulation defect detection system for electromagnetic wire sheathing according to any one of claims 24 to 27, wherein, Downstream of the first measuring point and upstream and downstream of the second measuring point, there are also charge-removing electrodes, which remove the charge remaining on the outer surface of the electromagnetic wire by applying an AC voltage at the first measuring point and an AC voltage at the second measuring point.

29. The insulation defect detection system for electromagnetic wire sheathing according to any one of claims 24 to 27, wherein, The insulation defect detection system for the electromagnetic wire sheath also includes a reference signal generator that transmits a reference signal for a reference discharge charge quantity. The reference signal is detected in the first discharge detection electrode and the second discharge detection electrode. In the first discharge detection device and the second discharge detection device, a signal with a discharge charge amount below the reference signal is removed with reference to the detected reference signal.

30. The insulation defect detection system for electromagnetic wire sheathing according to any one of claims 24 to 27, wherein, The first discharge detection electrode and the second discharge detection electrode are further provided with guide blocks to guide the electromagnetic wires.

31. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 30, wherein, The guide block is a cube-shaped resin material block. The guide block is provided with a groove that houses the first discharge detection electrode and the second discharge detection electrode. The guide block is provided with a through hole that passes through the two opposing surfaces of the first and second discharge detection electrodes separated by a circular surface. The center point of the groove coincides with the center point of the first and second discharge detection electrodes. The inner diameter of the through hole is 10 μm to 100 μm larger than the outer diameter of the electromagnetic wire.

32. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 31, wherein, The resin material of the guide block is set as fluororesin.

33. The insulation defect detection system for electromagnetic wire sheathing according to any one of claims 24 to 27, wherein, The comparison unit also has the function of smoothing the waveforms of the discharge signal detected by the first discharge detection device and the discharge signal detected by the second discharge detection device.

34. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 33, wherein, Calculate the moving average of the discharge signal to smooth the waveform of the discharge signal.

35. The insulation defect detection system for electromagnetic wire sheathing according to any one of claims 24 to 27, wherein, The insulation defect detection system for the electromagnetic wire sheath also includes an image output unit and an image display device, which are used to display the latest discharge signal that is determined to be defective in the electromagnetic wire sheath together with the cumulative number of times the defect has been determined.

36. The insulation defect detection system for the electromagnetic wire sheathing layer according to claim 24, wherein, Assuming N is an integer greater than or equal to 3, the insulation defect detection system for the electromagnetic wire sheath further includes a third discharge detection electrode to an Nth discharge detection electrode located at a third to Nth measurement point downstream of the second discharge detection electrode, and a third to an Nth discharge detection device for detecting the discharge signals detected by the third to Nth discharge detection electrodes. The comparison unit also compares the discharge signals detected at the 3rd to Nth measurement points to determine whether the electromagnetic wire coating layer has the defect.

37. The insulation defect detection system for electromagnetic wire sheathing according to any one of claims 24 to 27, wherein, The electromagnetic wire, after passing through the travel path that detects defects in the electromagnetic wire coating, is made to travel towards a winding device that winds the electromagnetic wire onto an iron core, and the winding mechanism of the winding device winds the electromagnetic wire onto the iron core.

38. A method for manufacturing an electric machine, the method comprising the steps of: manufacturing the electric machine using an iron core wound with the electromagnetic wire as described in claim 23.

39. An electromechanical device having an iron core wound with the electromagnetic wire as described in claim 23.

40. A method for manufacturing an electric machine, the method comprising the steps of: manufacturing the electric machine using an iron core wound with the electromagnetic wire as described in claim 37.

41. An electromechanical device having an iron core wound with the electromagnetic wire as described in claim 37.

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