A stator impregnation tool and method

Abstract

This invention discloses a stator impregnation fixture and impregnation method. The stator impregnation fixture includes an outer positioning ring, an inner positioning ring, multiple limiting blocks, multiple fastening screws, multiple adjusting screws, and multiple eye bolts. The impregnation method includes the following steps: 1) placing the stator to be impregnated into the impregnation fixture, so that the end of the stator coil is inserted into the ring groove of the fixture; 2) securing the stator to be impregnated on the impregnation fixture; 3) transferring the impregnation fixture and the stator to be impregnated to an oven for preheating and dehumidification; after holding at the temperature for t1 time, removing them and cooling them to T℃, then placing the impregnation fixture and the stator to be impregnated into a vacuum impregnation machine for impregnation; 4) dripping paint and cleaning, then sending the impregnation fixture and the stator into an oven for heating and curing; 5) after curing, removing the impregnation fixture and the stator, and demolding the stator after it cools to obtain the impregnated stator. This invention solves the problem of stator coil damage caused by secondary shaping.

Description

Technical Field

[0001] This invention relates to the field of stator impregnation, specifically a stator impregnation fixture and impregnation method. Background Technology

[0002] As customers' demands for motor performance increase, the insulation requirements for motors are also becoming more stringent. Therefore, to ensure sufficient dielectric strength, good heat resistance, moisture resistance, and operational reliability, many companies perform stator impregnation insulation treatment, with some even using vacuum impregnation machines to guarantee the overall mechanical strength of the motor coils. However, for stators with high slot fill factor, small end dimensions, and large volume, the coils are prone to elastic deformation due to temperature increases during vacuum impregnation, causing changes in end dimensions. This change can potentially affect subsequent rotor assembly and the operation of the entire motor, even leading to motor burnout. Currently, most companies use secondary shaping to address this issue, but because the insulating varnish hardens after curing, secondary shaping may compromise the overall integrity of the motor and easily damage the coils.

[0003] Currently, companies in the market generally use a process of pre-baking to remove moisture, cooling, vacuum impregnation, drip drying, and final drying for stator insulation treatment. Some special or larger stators require secondary impregnation. The entire process involves at least two heating stages, during which the coil expands due to heat, changing its inner and outer diameters. This is particularly noticeable for stators with high slot fill factor and small end dimensions. A common solution is secondary shaping after impregnation. However, during impregnation, the insulating varnish fully fills the stator gaps under pressure and the capillary action of the coil, and after drying, it forms a single unit. Shaping at this point is extremely difficult; excessive force can easily damage the insulation of the entire coil, rendering the stator unusable. While theoretically, the impregnation allowance can be adjusted by changing the shaper size, this value is difficult to determine in practice due to the complexity of the impregnation process. Adjusting for this allowance is even more challenging for stators with high slot fill factor and small end dimensions. Summary of the Invention

[0004] The purpose of this invention is to provide a stator impregnation fixture, including an outer positioning ring, an inner positioning ring, multiple limit blocks, multiple fastening screws, multiple adjusting screws, and multiple eye bolts.

[0005] The outer positioning ring is supported on the end face of the stator to be impregnated and is used to limit the outer diameter of the end of the stator coil to be impregnated.

[0006] The lower end of the outer positioning ring has a first threaded mounting hole.

[0007] The inner positioning ring is supported on the stator to be impregnated and is used to limit the inner diameter and height of the end of the stator coil to be impregnated.

[0008] The upper end of the inner positioning ring has a wide groove, and the bottom has an incline to facilitate the flow of paint liquid when dripping paint.

[0009] The lower end of the inner positioning ring is provided with a second threaded mounting hole.

[0010] The inner and outer positioning rings are connected by a first threaded mounting hole, a second threaded mounting hole, and a screw to form an annular groove for limiting the position of the stator to be impregnated.

[0011] The limiting block has a T-shaped structure.

[0012] The limiting block is provided with a horizontal threaded hole, a vertical threaded hole and an end face threaded hole.

[0013] The fastening screw engages with the transverse threaded hole to fasten the limiting block to the outer positioning ring.

[0014] The adjusting screw is connected to a vertical threaded hole. The adjusting screw is adjustable and used for positioning the stator winding core to be impregnated.

[0015] The eye bolt mates with the threaded hole on the end face and is used for hoisting the stator impregnation fixture.

[0016] Furthermore, a wide groove is formed on the upper outer diameter surface of the outer positioning ring. The wide groove is used for venting.

[0017] Furthermore, the first threaded mounting hole is located on the outer circular surface at the lower end of the outer positioning ring.

[0018] Furthermore, the inner positioning ring has a stepped structure.

[0019] Furthermore, the edges and working surfaces of the stator impregnation fixture have rounded corners to prevent damage to the stator coils to be impregnated during fixture assembly. The working surface is the part of the stator impregnation fixture that contacts the stator to be impregnated.

[0020] Furthermore, the outer positioning ring, inner positioning ring, multiple limit blocks, multiple fastening screws, multiple adjusting screws, and multiple eye bolts have all undergone high-temperature blanching treatment.

[0021] A method for impregnating a stator using the aforementioned stator impregnation fixture includes the following steps:

[0022] 1) Apply release agent or silicone grease to the parts of the stator impregnation fixture that contact the stator to be impregnated, as well as to the vertical threaded holes of the limiting block.

[0023] 2) Place the stator to be impregnated into the impregnation fixture, so that the coil end of the stator is inserted into the annular groove of the fixture. At this time, the upper end face of the impregnation fixture is in contact with the end face of the stator to be impregnated, thereby supporting the stator.

[0024] 3) Adjust the adjusting screw so that the end of the adjusting screw contacts and abuts against the outer circle of the stator to be impregnated, thereby making the stator to be impregnated securely on the impregnation fixture.

[0025] 4) Insert the hook into the eye bolt and move the impregnation fixture and the stator to be impregnated to the oven for preheating and dehumidification. After holding at the temperature for t1 time, take them out and let them cool to T℃. Then, put the impregnation fixture and the stator to be impregnated into the vacuum impregnation machine for impregnation.

[0026] After the impregnation is completed, the impregnation fixture and stator are removed, and then the impregnation fixture and stator are dripped with paint and cleaned. Then the impregnation fixture and stator are sent into the oven for heating and curing.

[0027] 5) After curing, remove the impregnation fixture and stator. After the stator cools down, demold to obtain the impregnated stator.

[0028] Furthermore, the demolding process after the stator has cooled down includes: turning the adjusting screw outwards, and then removing the stator upwards.

[0029] The technical effect of this invention is beyond doubt. This invention provides a method for ensuring the stator end size during impregnation using an impregnation fixture, which is suitable for vacuum impregnation of stators with high fill factor, small end size, and large volume.

[0030] This invention employs a varnish-dipping fixture to ensure a high tank fill rate, small end dimensions, and relatively large stator end dimensions during varnishing. The fixture is assembled onto the stator before pre-drying and remains in place throughout the varnishing process until drying is complete, at which point it is removed. This invention completely avoids stator end deformation and solves the problem of stator coil damage caused by secondary shaping, thus improving product quality. Furthermore, the fixture includes eye bolts for easy movement using a crane, resolving the difficulty of transporting heavy stators. Attached Figure Description

[0031] Figure 1 A schematic diagram of the stator impregnation fixture in operation;

[0032] Figure 2 This is a schematic diagram of the outer positioning ring;

[0033] Figure 3 This is a schematic diagram of the inner positioning ring;

[0034] Figure 4 Schematic diagram of the limit block

[0035] Figure 5 This is a top view of the assembly diagram of the paint impregnation fixture.

[0036] In the diagram: outer positioning ring 101, inner positioning ring 102, limit block 103, screw 104, adjusting screw 105, eye bolt 106. Detailed Implementation

[0037] The present invention will be further described below with reference to embodiments, but it should not be construed that the scope of the present invention is limited to the following embodiments. Various substitutions and modifications made based on ordinary technical knowledge and common practices in the art without departing from the above-described technical concept of the present invention should be included within the scope of protection of the present invention.

[0038] Example 1:

[0039] See Figures 1 to 5 A stator impregnation fixture includes an outer positioning ring 101, an inner positioning ring 102, multiple limit blocks 103, multiple fastening screws 104, multiple adjusting screws 105, and multiple eye bolts 106.

[0040] The outer positioning ring 101 is supported on the end face of the stator to be impregnated and is used to limit the outer diameter of the end of the stator coil to be impregnated.

[0041] The lower end of the outer positioning ring 101 is provided with a first threaded mounting hole.

[0042] The inner positioning ring 102 is supported on the stator to be impregnated and is used to limit the inner diameter and height of the end of the stator coil to be impregnated.

[0043] The upper end of the inner positioning ring 102 is provided with a wide groove and the bottom is inclined to facilitate the flow of paint liquid when dripping paint.

[0044] The lower end of the inner positioning ring 102 is provided with a second threaded mounting hole.

[0045] The inner positioning ring 102 and the outer positioning ring 101 are connected by a first threaded mounting hole, a second threaded mounting hole and a screw to form an annular groove for limiting the position of the stator to be impregnated.

[0046] The limiting block 103 has a T-shaped structure.

[0047] The limiting block 103 has a horizontal threaded hole, a vertical threaded hole and an end face threaded hole.

[0048] The fastening screw 104 engages with the transverse threaded hole to fasten the limiting block 103 to the outer positioning ring 101.

[0049] The adjusting screw 105 is connected to a vertical threaded hole. The adjusting screw 105 is adjustable and used for positioning the stator winding core to be impregnated.

[0050] The eye bolt 106 mates with the threaded hole on the end face and is used for hoisting the stator impregnation fixture.

[0051] The outer positioning ring 101 has a wide groove on its upper outer diameter surface. The wide groove is used for venting.

[0052] The first threaded mounting hole is located on the lower outer surface of the outer positioning ring 101.

[0053] The inner positioning ring 102 has a stepped structure.

[0054] The stator impregnation fixture has rounded edges and working surfaces to prevent damage to the stator coils to be impregnated during assembly. The working surface is the part where the stator impregnation fixture contacts the stator to be impregnated.

[0055] The outer positioning ring 101, inner positioning ring 102, multiple limiting blocks 103, multiple fastening screws 104, multiple adjusting screws 105 and multiple eye bolts 106 have all undergone high-temperature blanching treatment.

[0056] A method for impregnating a stator using the aforementioned stator impregnation fixture includes the following steps:

[0057] 1) Apply release agent or silicone grease to the parts of the stator impregnation fixture that contact the stator to be impregnated, as well as to the vertical threaded hole of the limiting block 103.

[0058] 2) Place the stator to be impregnated into the impregnation fixture, so that the coil end of the stator is inserted into the annular groove of the fixture. At this time, the upper end face of the impregnation fixture is in contact with the end face of the stator to be impregnated, thereby supporting the stator.

[0059] 3) Adjust the adjusting screw 105 so that the end of the adjusting screw 105 contacts and abuts against the outer circle of the stator to be impregnated, thereby making the stator to be impregnated securely on the impregnation fixture.

[0060] 4) Insert the hook into the eye bolt 106, and move the impregnation fixture and the stator to be impregnated to the oven for preheating and dehumidification. After holding at the temperature for t1 time, take them out and let them cool to T℃. Then, put the impregnation fixture and the stator to be impregnated into the vacuum impregnation machine for impregnation.

[0061] After the impregnation is completed, the impregnation fixture and stator are removed, and then the impregnation fixture and stator are dripped with paint and cleaned. Then the impregnation fixture and stator are sent into the oven for heating and curing.

[0062] 5) After curing, remove the impregnation fixture and stator. After the stator cools down, demold to obtain the impregnated stator.

[0063] The steps for demolding after the stator has cooled include: turning the adjusting screw 105 outward, and then taking the stator upward.

[0064] Example 2:

[0065] A stator impregnation fixture includes an outer positioning ring 101, an inner positioning ring 102, multiple limit blocks 103, multiple fastening screws 104, multiple adjusting screws 105, and multiple eye bolts 106.

[0066] The outer positioning ring 101 is supported on the end face of the stator to be impregnated and is used to limit the outer diameter of the end of the stator coil to be impregnated.

[0067] The lower end of the outer positioning ring 101 is provided with a first threaded mounting hole.

[0068] The outer positioning ring 101 and the inner positioning ring 102 cooperate to form an annular groove for limiting the position of the stator to be impregnated.

[0069] The inner positioning ring 102 is supported on the stator to be impregnated and is used to limit the inner diameter and height of the end of the stator coil to be impregnated.

[0070] The upper end of the inner positioning ring 102 is provided with a wide groove and the bottom is inclined to facilitate the flow of paint liquid when dripping paint.

[0071] The lower end of the inner positioning ring 102 is provided with a second threaded mounting hole.

[0072] The limiting block 103 has a T-shaped structure.

[0073] The limiting block 103 has a horizontal threaded hole, a vertical threaded hole and an end face threaded hole.

[0074] The fastening screw 104 engages with the transverse threaded hole to fasten the limiting block 103 to the outer positioning ring 101.

[0075] The adjusting screw 105 is connected to a vertical threaded hole. The adjusting screw 105 is adjustable and used for positioning the stator winding core to be impregnated.

[0076] The eye bolt 106 mates with the threaded hole on the end face and is used for hoisting the stator impregnation fixture.

[0077] Example 3:

[0078] A stator impregnation fixture, the main contents of which are described in Embodiment 2, wherein a wide groove is formed on the upper outer diameter surface of the outer positioning ring 101. The wide groove is used for venting.

[0079] Example 4:

[0080] A stator impregnation fixture, the main contents of which are described in Embodiment 2, wherein the first threaded mounting hole is formed on the lower outer circular surface of the outer positioning ring 101.

[0081] Example 5:

[0082] A stator impregnation fixture, the main contents of which are described in Embodiment 2, wherein the inner positioning ring 102 has a stepped structure.

[0083] Example 6:

[0084] A stator impregnation fixture, the main contents of which are described in Embodiment 2, wherein the edges and working surfaces of the stator impregnation fixture have rounded corners to avoid damage to the stator coils to be impregnated during assembly. The working surface is the part of the stator impregnation fixture that contacts the stator to be impregnated.

[0085] Example 7:

[0086] A stator impregnation fixture, the main contents of which are described in Embodiment 2, wherein the outer positioning ring 101, the inner positioning ring 102, the multiple limiting blocks 103, the multiple fastening screws 104, the multiple adjusting screws 105 and the multiple eye screws 106 are all subjected to high-temperature bluing treatment.

[0087] Example 8:

[0088] A method for impregnation using the stator impregnation fixture described in Examples 2-7 includes the following steps:

[0089] 1) Apply release agent or silicone grease to the parts of the stator impregnation fixture that contact the stator to be impregnated, as well as to the vertical threaded hole of the limiting block 103.

[0090] 2) Place the stator to be impregnated into the impregnation fixture, so that the coil end of the stator is inserted into the annular groove of the fixture. At this time, the upper end face of the impregnation fixture is in contact with the end face of the stator to be impregnated, thereby supporting the stator.

[0091] 3) Adjust the adjusting screw 105 so that the end of the adjusting screw 105 contacts and abuts against the outer circle of the stator to be impregnated, thereby making the stator to be impregnated securely on the impregnation fixture.

[0092] 4) Insert the hook into the eye bolt 106, and move the impregnation fixture and the stator to be impregnated to the oven for preheating and dehumidification. After holding at the temperature for t1 time, take them out and let them cool to T℃. Then, put the impregnation fixture and the stator to be impregnated into the vacuum impregnation machine for impregnation.

[0093] After the impregnation is completed, the impregnation fixture and stator are removed, and then the impregnation fixture and stator are dripped with paint and cleaned. Then the impregnation fixture and stator are sent into the oven for heating and curing.

[0094] 5) After curing, remove the impregnation fixture and stator. After the stator cools down, demold to obtain the impregnated stator.

[0095] Example 9:

[0096] A method for impregnating a stator using an impregnation fixture is described in Example 8. The step of demolding the stator after it has cooled includes: turning the adjusting screw 105 outward and then taking the stator out upward.

[0097] Example 10:

[0098] A stator impregnation fixture and impregnation method are disclosed, suitable for vacuum impregnation of stators with high tank fill factor, small end dimensions, and large volume. The fixture comprises an outer positioning ring 101, an inner positioning ring 102, four limiting blocks 103, twelve screws 104, four adjusting screws 105, and four eye bolts 106; and includes an impregnation method and steps using this fixture.

[0099] The stator impregnation fixture is as follows:

[0100] The outer positioning ring 101 limits the outer diameter of the stator coil end and supports it on the stator end face, bearing the weight of the stator. It also has a wide groove on its upper outer diameter surface for venting, and a threaded hole on its lower outer surface for mounting. The inner positioning ring 102 has a stepped structure, limiting the inner diameter and height of the stator coil end. It has a wide groove on its upper part and a small slope on its bottom surface to facilitate the flow of varnish during dripping. A threaded hole on its lower surface is also for mounting. The limiting block 103 has a T-shaped structure with threaded holes distributed horizontally, vertically, and on its end face. The horizontal threaded hole is fitted with a screw 104 for fastening to the outer positioning ring, the vertical threaded hole is fitted with an adjusting screw 105 for positioning the stator winding core, and the end face threaded hole is fitted with a lifting eye screw 106 for lifting. Furthermore, the edges and working surfaces of the stator varnishing fixture have rounded corners to prevent damage to the coil during assembly. After each part is machined, it undergoes high-temperature bluing to improve surface adhesion, and then it is assembled with screws. The stator end coils are confined within a certain range by the annular grooves formed by the inner and outer positioning rings to ensure the stator end dimensions throughout the impregnation process.

[0101] The method of use for impregnation is as follows:

[0102] 1) Apply release agent or silicone grease to the parts of the dip-coating fixture that contact the stator, as well as the threaded holes on the limit block used to adjust the rotation of the screws.

[0103] 2) Place the shaped stator, which meets the required dimensions, horizontally into the varnish-impregnating fixture, so that the stator end coil falls into the fixture's annular groove. At this time, the upper end face of the varnish-impregnating fixture contacts the stator end face, providing support.

[0104] 3) Adjust the adjusting screws on the four limit blocks so that their ends contact and abut against the outer circle of the stator. When all the adjusting screws in the four directions are tightened, the stator is stably fixed on the impregnation fixture.

[0105] 4) Use a hook to insert into the eye bolt and move the impregnation fixture together with the stator to the oven for preheating and dehumidification. After keeping it at 120℃ for 4 hours, take it out. When it cools down to 60℃, put it into the vacuum impregnation machine for impregnation. After impregnation, take it out for dripping and cleaning, and put it back into the oven for heating and curing.

[0106] 5) After curing, remove the stator and allow it to cool before demolding. First, unscrew the adjusting screw on the limit block outwards until its head is away from the outer surface of the stator. Then, remove the stator upwards. Because the impregnation fixture has been bluing and coated with release agent, the stator can be easily removed. Any residual paint drips or lumps on the impregnation fixture can be easily removed with a power cutter's knife, without affecting future use.

Claims

1. A stator impregnation fixture, characterized in that: It includes an outer positioning ring (101), an inner positioning ring (102), multiple limit blocks (103), multiple fastening screws (104), multiple adjusting screws (105), and multiple eye bolts (106); The outer positioning ring (101) is supported on the end face of the stator to be impregnated and is used to limit the outer diameter of the end of the stator coil to be impregnated; The lower end of the outer positioning ring (101) is provided with a first threaded mounting hole; The inner positioning ring (102) is supported on the stator to be impregnated and is used to limit the inner diameter and height of the end of the stator coil to be impregnated; The upper end of the inner positioning ring (102) is provided with a wide groove and the bottom is inclined to facilitate the flow of paint liquid when dripping paint. The lower end of the inner positioning ring (102) is provided with a second threaded mounting hole; The inner positioning ring (102) and the outer positioning ring (101) are connected by a first threaded mounting hole, a second threaded mounting hole and a screw to form an annular groove for limiting the position of the stator to be impregnated; The limiting block (103) has a T-shaped structure; The limiting block (103) is provided with a horizontal threaded hole, a vertical threaded hole and an end face threaded hole; The fastening screw (104) engages with the transverse threaded hole to fasten the limiting block (103) to the outer positioning ring (101); The adjusting screw (105) is connected to the vertical threaded hole; the adjusting screw (105) is adjustable and used for positioning the stator winding core to be impregnated. The eye bolt (106) mates with the threaded hole on the end face and is used for hoisting the stator impregnation fixture.

2. The stator impregnation fixture according to claim 1, characterized in that: The outer positioning ring (101) has a wide groove on its upper outer diameter surface; the wide groove is used for venting.

3. The stator impregnation fixture according to claim 1, characterized in that: The first threaded mounting hole is located on the outer circular surface of the lower end of the outer positioning ring (101).

4. The stator impregnation fixture according to claim 1, characterized in that: The inner positioning ring (102) has a stepped structure.

5. The stator impregnation fixture according to claim 1, characterized in that: The stator impregnation fixture has rounded edges and working surfaces to prevent damage to the stator coils to be impregnated during assembly; the working surface is the part where the stator impregnation fixture contacts the stator to be impregnated.

6. The stator impregnation fixture according to claim 1, characterized in that: The outer positioning ring (101), inner positioning ring (102), multiple limit blocks (103), multiple fastening screws (104), multiple adjusting screws (105) and multiple eye bolts (106) have all undergone high-temperature blanching treatment.

7. A method for impregnation using the stator impregnation fixture according to any one of claims 1 to 6, characterized in that, Includes the following steps: 1) Apply release agent or silicone grease to the parts of the stator impregnation fixture that contact the stator to be impregnated, as well as to the vertical threaded holes of the limiting block (103). 2) Place the stator to be impregnated into the impregnation fixture, so that the coil end of the stator to be impregnated is inserted into the annular groove of the fixture; at this time, the upper end face of the impregnation fixture is in contact with the end face of the stator to be impregnated, thereby supporting the stator to be impregnated. 3) Adjust the adjusting screw (105) so that the end of the adjusting screw (105) contacts and abuts against the outer circle of the stator to be impregnated, thereby making the stator to be impregnated securely on the impregnation fixture. 4) Insert the hook into the eye bolt (106) and move the impregnation fixture and the stator to be impregnated to the oven for preheating and dehumidification; After holding at the temperature for t1 time, remove the product and wait for it to cool to T℃. Then, place the impregnation fixture and the stator to be impregnated into the vacuum impregnation machine for impregnation. After the impregnation is completed, the impregnation fixture and stator are removed, and the paint is dripped and cleaned. Then the impregnation fixture and stator are sent into the oven for heating and curing. 5) After curing, remove the impregnation fixture and stator. After the stator cools down, demold to obtain the impregnated stator.

8. The method for impregnation using a stator impregnation fixture according to claim 7, characterized in that, The steps for demolding after the stator has cooled include: turning the adjusting screw (105) outward, and then taking the stator upward.

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