Inspection device for electromagnetic wire covering, inspection method for electromagnetic wire covering, and manufacturing method for electric machine

Abstract

An inspection device (100) for a coating layer of an electromagnetic wire has a traveling path forming device (3, 4) for forming a traveling path (1) in which a coated electromagnetic wire (2) travels at a constant speed in a wire direction before being wound. The inspection device (100) has a discharge detection electrode (5) for applying an alternating voltage to the electromagnetic wire (2) at a predetermined position in the traveling path (1) and collecting a discharge charge generated thereby, a detection device (10) for detecting a discharge signal based on the discharge charge, and a discharge promoting device (7A, 7B) for promoting discharge of the discharge detection electrode (5) from a wire core (21) of the electromagnetic wire (2) at a voltage application point.

Description

Technical Field

[0001] This application relates to an inspection apparatus for electromagnetic wire coating, a method for inspecting electromagnetic wire coating, and a method for manufacturing electromechanical equipment. Background Technology

[0002] Traditionally, coils used in motor stators and other components were made of wires called electromagnetic wires, which consisted of an organic insulator covering the surface of a core made of copper or aluminum. When there are abnormalities such as pinholes or damage in the electromagnetic wire sheath, the insulation performance of the electromagnetic wire decreases, causing short circuits during motor operation.

[0003] Existing insulation characteristic inspection devices include: a guarantee voltage application unit that applies a guarantee voltage to the traveling line; a grounding unit disposed downstream of the guarantee voltage application unit to ground the traveling line and remove the charge carried on the traveling line; and a test voltage application unit disposed downstream of the grounding unit to apply a test voltage lower than the guarantee voltage to the traveling line and detect leakage current value (e.g., Patent Document 1).

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2014-182053 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] The inspection device described in Patent Document 1 applies a guarantee voltage to the traveling electromagnetic wire, thereby improving the reliability of detecting abnormal insulation characteristics. However, since a guarantee voltage, which is a relatively high voltage, is applied to the electromagnetic wire, spark discharge is generated, sometimes damaging the normal electromagnetic wire sheath.

[0009] This application discloses technology for solving the above-mentioned problems, with the aim of providing an inspection device and method for electromagnetic wire insulation properties that can be reliably inspected before winding without damaging the normal electromagnetic wire insulation layer.

[0010] Methods for solving problems

[0011] The electromagnetic wire coating inspection apparatus disclosed in this application comprises: a travel path forming device that causes the coated electromagnetic wire to travel at a constant speed along the wire direction to form a travel path before winding; a discharge detection device having a discharge detection electrode and a detection device, wherein the discharge detection electrode applies an alternating voltage to the electromagnetic wire at a predetermined location within the travel path and collects discharge charges generated from the core of the electromagnetic wire, and the detection device detects a discharge signal based on the discharge charges from the discharge detection electrode; and a discharge promoting device that promotes discharge from the core of the electromagnetic wire at a voltage application point that is the predetermined location within the travel path.

[0012] Furthermore, the method for inspecting the coating layer of the electromagnetic wire disclosed in this application includes the following steps: Step 1, causing the coated electromagnetic wire to travel at a constant speed along the wire direction before winding; Step 2, applying an alternating voltage to the electromagnetic wire at a predetermined location within the travel path of the electromagnetic wire using a discharge detection electrode and collecting discharge charges generated from the core of the electromagnetic wire; Step 3, detecting a discharge signal based on the discharge charges from the discharge detection electrode; and Step 4, promoting discharge from the core of the electromagnetic wire at the voltage application point, which is the predetermined location within the travel path.

[0013] Furthermore, the method for manufacturing electric machinery disclosed in this application involves winding the electromagnetic wire, after inspection using the inspection device for the electromagnetic wire coating layer, onto an iron core to manufacture the electric machinery.

[0014] Invention Effects

[0015] According to the inspection device for the electromagnetic wire sheathing disclosed in this application, the insulation characteristics of the electromagnetic wire can be reliably inspected before winding without damaging the normal electromagnetic wire sheathing.

[0016] Furthermore, the inspection method for the electromagnetic wire sheath disclosed in this application can reliably inspect the insulation characteristics of the electromagnetic wire before winding without damaging the normal electromagnetic wire sheath.

[0017] According to the manufacturing method of the electric machinery disclosed in this application, a highly reliable electric machinery using electromagnetic wire with good insulation properties can be obtained. Attached Figure Description

[0018] Figure 1 This is a diagram showing the structure of the inspection device for the electromagnetic wire coating layer according to Embodiment 1.

[0019] Figure 2 It is a diagram illustrating the structure of electromagnetic wires.

[0020] Figure 3 This is a diagram showing the structure of the discharge detection electrode according to Embodiment 1.

[0021] Figure 4 This is a diagram illustrating the discharge detection in Implementation Method 1.

[0022] Figure 5 This is an equivalent circuit diagram illustrating the discharge detection of Implementation Method 1.

[0023] Figure 6 This is a waveform diagram showing the temperature-dependent characteristics of the discharge start voltage in Embodiment 1.

[0024] Figure 7 This is a flowchart illustrating the operation of the inspection device for the electromagnetic wire coating layer in Embodiment 1.

[0025] Figure 8 This is a waveform diagram of the detected discharge signal in Implementation Method 1.

[0026] Figure 9 This is a waveform diagram of the discharge signal after smoothing in Implementation Method 1.

[0027] Figure 10 This is a diagram showing the structure of a travel path forming apparatus according to another example of Embodiment 1.

[0028] Figure 11 This is a diagram showing the structure of an inspection device for an electromagnetic wire coating layer, another example of Embodiment 1.

[0029] Figure 12 This is a diagram showing the structure of the inspection device for the electromagnetic wire coating layer according to Embodiment 2.

[0030] Figure 13 This is a diagram showing the structure of an inspection device for an electromagnetic wire coating layer, another example of Embodiment 2.

[0031] Figure 14 This is a diagram showing the structure of the thermometer in Embodiment 2.

[0032] Figure 15 This is a diagram showing the structure of the inspection device for the electromagnetic wire coating layer according to Embodiment 3.

[0033] Figure 16 This is a diagram showing the structure of the heating device according to Embodiment 4.

[0034] Figure 17 This is a diagram illustrating the operation of the heating device in Embodiment 4.

[0035] Figure 18 This is a diagram showing the structure of the heating device according to Embodiment 5.

[0036] Figure 19 This is a diagram illustrating the operation of the heating device in Embodiment 5.

[0037] Figure 20 A is a diagram illustrating the guide block of the electromagnetic wire in Embodiment 6.

[0038] Figure 20 B is a diagram illustrating the guide block of the electromagnetic wire in embodiment 6.

[0039] Figure 20 C is a diagram illustrating the guide block of the electromagnetic wire in embodiment 6.

[0040] Figure 21 A is a diagram illustrating the guide block of the electromagnetic wire in embodiment 7.

[0041] Figure 21 B is a diagram illustrating the guide block of the electromagnetic wire in Embodiment 7.

[0042] Figure 21 C is a diagram illustrating the guide block of the electromagnetic wire in embodiment 7.

[0043] Figure 22 A is a diagram illustrating another example of an electromagnetic wire guide block in Embodiment 7.

[0044] Figure 22 B is a diagram illustrating another example of the electromagnetic wire guide block in Embodiment 7.

[0045] Figure 23 This is a diagram showing the structure of the inspection device for the electromagnetic wire coating layer according to Embodiment 8.

[0046] Figure 24 This is a partially enlarged view showing the winding device and stator core connected to the inspection device for the electromagnetic wire coating layer according to Embodiment 8.

[0047] Figure 25 This is a diagram showing the structure of the stator after winding in Embodiment 8.

[0048] Figure 26 This is a diagram showing the structure of an electric motor using a wound stator in Embodiment 8.

[0049] Figure 27 This is a diagram showing the structure of the inspection device for the electromagnetic wire coating layer according to Embodiment 9.

[0050] Figure 28 This is a diagram showing the structure of the pressure-reducing device according to Embodiment 9.

[0051] Figure 29 This is a diagram showing the structure of a pressure-reducing device according to another example of Embodiment 9.

[0052] Figure 30 This is a graph showing the relationship between the pressure around the electromagnetic wire and the discharge initiation voltage in Embodiment 9.

[0053] Figure 31 This is a diagram showing the hardware structure of the control device in embodiments 1 to 9. Detailed Implementation

[0054] Implementation Method 1

[0055] Figure 1 This is a diagram showing the structure of the inspection device for the electromagnetic wire coating layer according to Embodiment 1.

[0056] like Figure 1 As shown, the inspection device 100 for the electromagnetic wire coating layer includes a delivery device 3 for delivering the coated electromagnetic wire 2 and a winding device 4 for winding the electromagnetic wire 2, forming a travel path 1 for the electromagnetic wire 2. In this case, the delivery device 3 and the winding device 4 constitute a travel path forming device.

[0057] Furthermore, the inspection device 100 includes a discharge detection device and a heating device 7A for heating the core of the electromagnetic wire 2. The discharge detection device consists of a discharge detection electrode 5 for detecting discharge generated from the core of the electromagnetic wire 2 and a detection device 10 for detecting discharge signals. The heating device 7A is provided as a discharge promotion device to promote discharge generated from the core of the electromagnetic wire 2.

[0058] The feeding device 3, comprising a feeder 3A and a reel 3B for feeding the electromagnetic wire 2, is disposed on the upstream side of the travel path 1. The winding device 4, comprising a winding machine 4A and a reel 4B for winding the electromagnetic wire 2, is disposed on the downstream side of the travel path 1. Furthermore, the feeder 3A and the winding machine 4A adjust their speeds to ensure that the electromagnetic wire 2 before winding travels at a uniform speed along the wire direction, forming the travel path 1.

[0059] The discharge detection electrode 5 applies an AC voltage from the AC power supply 6 to the electromagnetic wire 2 at a designated location within the travel path 1 and collects the discharge charge generated from the core of the electromagnetic wire 2, thereby detecting a discharge. The detection device 10 detects a discharge signal based on the discharge charge from the discharge detection electrode 5. The heating device 7A is disposed at at least one of the upstream and downstream sides (in this case, only the upstream side) of the voltage application point of the discharge detection electrode 5 to heat the core of the electromagnetic wire 2 at the voltage application point. The heating device 7A is provided for heating the core of the electromagnetic wire 2 at the voltage application point, and therefore is disposed close to the discharge detection electrode 5.

[0060] Furthermore, the inspection device 100 includes a control device 30 that monitors the discharge signal from the detection device 10 and determines an abnormality in the electromagnetic wire coating layer based on the discharge signal. The control device 30 includes an A / D (analog-to-digital) converter 31, a storage unit 32, a calculation unit 33, a measurement unit 34, and a determination unit 35. The discharge signal from the detection device 10 is converted to digital value by the A / D converter 31 at a constant sampling frequency and then stored in the storage unit 32. The calculation unit 33 retrieves the discharge signal from the storage unit 32, performs the prescribed processing described later, and calculates a characteristic quantity. The determination unit 35 determines an abnormality in the electromagnetic wire coating layer based on the calculated characteristic quantity. Additionally, the measurement unit 34 measures the travel time of the electromagnetic wire 2 as needed.

[0061] Figure 2 This is a diagram illustrating the structure of electromagnetic wire 2.

[0062] like Figure 2 As shown, the electromagnetic wire 2 consists of a core 21 and a sheath 22. The core 21 is made of copper or aluminum, and the sheath 22 is an electromagnetic wire sheath made of an organic insulator that covers the surface of the core 21. At the end of the electromagnetic wire 2, the core 21 after the sheath 22 is stripped is grounded (see reference). Figure 1 ).

[0063] Figure 3 This is a diagram showing the structure of the discharge detection electrode 5. Figure 4 This diagram illustrates the discharge detection performed by the discharge detection electrode 5 and the detection device 10.

[0064] The discharge detection electrode 5 is arranged in a ring around the electromagnetic wire 2, which is located within the travel path 1 of the electromagnetic wire 2, surrounding the point of voltage application. For example, it can be formed into a ring with a circular cross-sectional shape. The discharge detection electrode 5 can be formed from metal materials such as iron, aluminum, or copper, or from conductive rubber or resin materials with aluminum or other metal materials deposited on their surface. Alternatively, the inner diameter of the ring-shaped discharge detection electrode 5 can be made to match the outer diameter of the electromagnetic wire 2, so that the discharge detection electrode 5 is in contact with the electromagnetic wire 2. Or, to avoid friction of the coating layer 22 due to contact, the discharge detection electrode 5 can be arranged with a gap of about 10 μm to 100 μm between it and the electromagnetic wire 2.

[0065] like Figure 4 As shown, one end of the discharge detection electrode 5 is connected to the AC power supply 6, and the other end of the AC power supply 6 is grounded in the same way as the wire core 21. The discharge detection electrode 5 applies an AC voltage from the AC power supply 6 to the electromagnetic wire 2 at a designated location within the travel path 1.

[0066] When there is a defect 23 in the sheath 22 of the electromagnetic wire 2 due to a pinhole or damage, a discharge occurs from the wire core 21 at the voltage application point through the defect 23 in the sheath 22 toward the discharge detection electrode 5. The discharge charge is collected by the discharge detection electrode 5 and sent to the detection device 10.

[0067] The detection device 10, for example, consists of a coupling capacitor 11, a detection impedance 12, and a discharge detector 13. In this case, the series circuit of the coupling capacitor 11 and the detection impedance 12 is connected in parallel with the cladding layer 22, and an AC voltage is applied to this series circuit and the cladding layer 22 from the AC power supply 6. The discharge detector 13 detects the voltage generated across the detection impedance 12.

[0068] When a discharge occurs from the wire core 21 toward the discharge detection electrode 5, the applied AC voltage changes drastically. The discharge detector 13 detects this change in AC voltage as the voltage value generated across the detection impedance 12.

[0069] Figure 5 This is an explanation Figure 4 The equivalent circuit diagram for discharge detection is shown.

[0070] like Figure 5 As shown, the electrostatic capacitance C1 of the defective portion 23 within the coating layer 22 based on pinholes or damage, and the electrostatic capacitance C2 of the portion between the defective portion 23 and the wire core 21 are connected in series. These series-connected electrostatic capacitors C1 and C2, the electrostatic capacitance C3 at the normal portion of the coating layer 22, the electrostatic capacitance C4 (the electrostatic capacitance of the coupling capacitor 11) connected in series within the detection device 10, and the detection impedance 12 are connected in parallel and subjected to an AC voltage.

[0071] When a discharge occurs from the wire core 21 toward the discharge detection electrode 5, the generated discharge charge is released to the grounding point through a closed circuit consisting of electrostatic capacitors C1, C2, and C4 and the detection impedance 12. When the discharge charge flows through the detection impedance 12, a voltage is generated across it, which is detected by the discharge detector 13. No voltage is generated when no discharge charge flows through the detection impedance 12.

[0072] In addition, the voltage (voltage signal) detected by the discharge detector 13 becomes the discharge signal detected by the detection device 10.

[0073] When the impedance of the detection impedance 12 is set to Z and the discharge charge flowing through it is set to q, the detected generation voltage ΔV is expressed by the following formula.

[0074] ΔV=Z·q

[0075] However, the core 21 of the electromagnetic wire 2 at the voltage application point is heated by the heating device 7A. This heating reduces the air density between the core 21 and the discharge detection electrode 5 at the voltage application point, lowering the discharge initiation voltage generated from the core 21 via the defect 23 of the cladding layer 22. In other words, the heating device 7A lowers the discharge initiation voltage, thus promoting discharge. Furthermore, the heating device 7A heats the core 21 at a temperature not exceeding the heat resistance temperature of the cladding layer 22, i.e., the heat resistance temperature of the cladding layer material.

[0076] In this way, the discharge initiation voltage decreases, thereby suppressing the voltage applied by the discharge detection electrode 5 to a low voltage, and allowing the generated voltage ΔV due to the discharge to be observed at a low voltage. That is, the defect 23 of the sheathing layer 22, which is an insulation abnormality of the electromagnetic wire 2, can be detected with high precision at a low voltage. As a result, the insulation characteristics of the electromagnetic wire can be reliably checked before winding without damaging the normal electromagnetic wire sheathing layer.

[0077] Figure 6 This is a waveform diagram showing the temperature-dependent characteristics of the discharge initiation voltage.

[0078] In this case, the discharge initiation voltage is shown when the coating film thickness is 2E-05m (20μm), and the temperature of the discharge detection section between the voltage application point wire core 21 and the discharge detection electrode 5 is increased from 25°C to 200°C in 25°C increments. Furthermore, at 25°C before heating, the discharge initiation voltage is 500V, and the air pressure of the discharge detection section is 101330Pa (1atm). It can be seen that as the temperature increases, the air density decreases, and therefore, the discharge initiation voltage decreases.

[0079] Figure 7 This is a flowchart illustrating the operation of the inspection device 100 for the electromagnetic wire coating layer.

[0080] In the inspection device 100, firstly, the delivery device 3 and the winding device 4 cause the electromagnetic wire 2 before winding to travel at a constant speed along the wire direction. As a result, the aforementioned travel path 1 is formed (step S1).

[0081] At a fixed point (voltage application point) within the travel path 1, the discharge detection electrode 5 applies an AC voltage to the electromagnetic wire 2, and the detection device 10 detects the discharge signal (step S2).

[0082] The detected discharge signal is sent to the control device 30, where it is converted by the A / D converter 31 at a constant sampling frequency and then stored in the storage unit 32. The calculation unit 33 retrieves the discharge signal from the storage unit 32 and performs the following processing.

[0083] First, for a preset reference charge signal strength, such as 100 picocoulombs, signals below this reference charge signal strength are removed from the discharge signal, thereby eliminating unwanted weak noise, i.e., discharge noise. This removes discharge noise unrelated to discharges caused by pinholes or damage-related defects 23 within the coating layer 22. In this case, the removed discharge noise also includes discharges from the normal surface of the coating layer 22, as well as discharges caused by the environment of the inspection work area of ​​the inspection device 100, such as discharges caused by instability in the grounding potential of the wire core 21, the AC power supply 6, or the discharge detector 13 (step S3).

[0084] To reduce the computational load on the computing unit 33, discharge noise removal, which is part of step S3, can be performed simultaneously when the discharge signal is stored in the storage unit 32. In this case, the storage unit 32 pre-stores a reference charge signal strength, and signals below that reference charge signal strength, i.e., discharge noise, are removed from the detected discharge signal.

[0085] The calculation unit 33 further smooths the discharge signal after removing discharge noise. For example, the smoothing process can be performed using a moving average method (step S4).

[0086] Figure 8 This is a waveform diagram of the discharge signal detected by the detection device 10. Figure 9 This is a waveform diagram of the discharge signal after smoothing. Figure 9 The example shown is an example of using a moving average with 9 points. Figure 8 The discharge signal waveform 15 shown becomes, after smoothing, as follows: Figure 9 The smooth discharge signal waveform shown is 16.

[0087] In the smoothing process, noise based on external interference that could not be removed in the discharge noise removal in step S3 can be further removed. Furthermore, when using the moving average method, smoothing can be performed through simple calculations.

[0088] In addition, the removal of discharge noise, which is the process in step S3, and the smoothing process, which is the process in step S4, can be performed simultaneously. In this case, during the smoothing process, discharge signals below the reference charge signal strength can be ignored.

[0089] Then, for the smoothed discharge signal, the calculation unit 33 calculates characteristic quantities. In the calculation of characteristic quantities, for example, the peak discharge charge, discharge duration, or total discharge charge of the detected discharge can be used. One of these calculation objects can be used, or multiple can be selected and combined (step S5).

[0090] The determination unit 35 obtains the calculation result, i.e. the feature quantity, from the calculation unit 33 and determines whether its value is above or above a preset upper limit value (step S6). If it is above or above the upper limit value, it determines that there is a defect 23 in the electromagnetic wire coating layer (step S7).

[0091] If the value of the characteristic quantity is less than the upper limit value in step S6, it is determined that the electromagnetic wire coating layer has no defects (step S8).

[0092] As described above, in this embodiment, the inspection device 100 moves the covered electromagnetic wire 2 at a constant speed along the wire direction before winding (corresponding to the first step of this application). At a designated location within the travel path 1, an alternating voltage is applied through the discharge detection electrode 5, and discharge charge generated from the core 21 of the electromagnetic wire 2 is collected (corresponding to the second step of this application). Discharge detection is performed based on this discharge charge (corresponding to the third step of this application). Furthermore, a heating device 7A is arranged close to the discharge detection electrode 5, and the discharge detection is performed simultaneously with heating the core 21 of the electromagnetic wire 2 at the voltage application point (corresponding to the fourth step of this application). By heating, the air density is reduced, thereby suppressing the voltage applied for discharge detection to a low voltage. That is, defects 23 in the covering layer 22 that constitute insulation abnormalities of the electromagnetic wire 2 can be detected with high accuracy at a low voltage. Thus, the insulation characteristics of the electromagnetic wire 2 can be reliably inspected before winding without damaging the normal electromagnetic wire covering layer.

[0093] Furthermore, the inspection device 100 calculates a characteristic quantity based on the detected discharge signal, and determines an abnormality in the electromagnetic wire sheathing layer based on this characteristic quantity (corresponding to step 5 of this application). Therefore, the insulation characteristics of the electromagnetic wire 2 can be inspected easily and with high accuracy.

[0094] In addition, in the above embodiment, the inspection device 100 has a control device 30 that monitors the detected discharge signal and makes an anomaly determination. However, the control device 30 may also be set separately from the inspection device 100 to receive the discharge signal.

[0095] In addition, such as Figure 10 As shown, the delivery device 3 and winding device 4 in the above embodiment can also be configured to place the rolls 3B and 4B on the turntable 19 respectively.

[0096] Furthermore, in the above embodiment, the diagram shows an inspection device 100 in which the heating device 7A is provided only upstream of the voltage application point of the discharge detection electrode 5. However, as... Figure 11As shown, heating devices 7A and 7B, which serve as discharge promotion devices, can also be provided on the upstream and downstream sides, respectively. This ensures temperature stability at the voltage application point of the discharge detection electrode 5, improving the inspection accuracy of the inspection device 100. In this case, each heating device 7A and 7B is also provided for heating the core 21 of the electromagnetic wire 2 at the voltage application point, and therefore is positioned close to the discharge detection electrode 5. Furthermore, each heating device 7A and 7B heats the core 21 at a temperature not exceeding the heat resistance temperature of the coating layer 22 of the electromagnetic wire 2, i.e., the heat resistance temperature of the coating layer material.

[0097] Implementation Method 2

[0098] Figure 12 This is a diagram showing the structure of the inspection device for the electromagnetic wire coating layer according to Embodiment 2.

[0099] like Figure 12 As shown, the inspection device 100A for the electromagnetic wire coating layer in Embodiment 2 is provided with thermometers 41A and 41B as thermometer measuring units and temperature display devices 42A and 42B, respectively, in the electromagnetic wire coating layer inspection device 100 of Embodiment 1. Thermometer 41A is disposed near the downstream side of heating device 7A between heating device 7A and discharge detection electrode 5, and thermometer 41B is disposed near the upstream side of heating device 7B between heating device 7B and discharge detection electrode 5. Furthermore, the temperature of the electromagnetic wire 2 measured by each thermometer 41A and 41B is displayed on the temperature display devices 42A and 42B.

[0100] The other structures and operations are the same as in Implementation Method 1 described above.

[0101] In this embodiment, thermometers 41A and 41B and temperature display devices 42A and 42B are provided, thus enabling the operator of the inspection device 100A to be prompted to adjust the output of the heating devices 7A and 7B. Specifically, the operator visually confirms the temperature display on the temperature display devices 42A and 42B, and adjusts the output of the heating devices 7A and 7B to reduce the output of the heating devices 7A and 7B in a manner that does not exceed the heat resistance temperature of the coating material when the temperature of the electromagnetic wire 2 rises to near the heat resistance temperature of the coating material. This prevents damage to the coating layer 22 of the electromagnetic wire 2 and allows for a more reliable inspection of the insulation characteristics of the electromagnetic wire 2.

[0102] Furthermore, in the above embodiment 2, thermometers 41A and 41B are shown to be disposed between the heating devices 7A and 7B and the discharge detection electrode 5, but this is not a limitation. For example, thermometer 41A may be disposed near the upstream side of the heating device 7A, and thermometer 41B may be disposed near the downstream side of the heating device 7B.

[0103] Furthermore, thermometers 41A and 41B and temperature display devices 42A and 42B are provided along with heating devices 7A and 7B. Therefore, it is also possible to configure heating device 7A to have thermometer 41A and temperature display device 42A, and heating device 7B to have thermometer 41B and temperature display device 42B.

[0104] Furthermore, such as Figure 13 As shown, alarm devices 43A and 43B can also be provided instead of temperature display devices 42A and 42B. In this case, when the temperature of the electromagnetic wire 2 measured by each thermometer 41A and 41B reaches a preset upper temperature limit, an alarm is issued by alarm devices 43A and 43B. Thus, similar to Embodiment 2 described above, the same effect can be achieved by prompting the operator to adjust the output of heating devices 7A and 7B.

[0105] In addition, for example, Figure 14 As shown, the thermometers 41A and 41B used in Embodiment 2 above can also be components formed by bonding thermocouples 45 to a ring-shaped metal film 44 made of iron, copper, aluminum, etc., through welding or the like. In this case, the inner diameter of the ring of the metal film 44 can be made to match the outer diameter of the electromagnetic wire 2, so that the metal film 44 and the electromagnetic wire 2 are in contact.

[0106] Implementation Method 3

[0107] Figure 15 This is a diagram showing the structure of the inspection device for the electromagnetic wire coating layer according to Embodiment 3.

[0108] like Figure 15 As shown, the inspection device 100B for the electromagnetic wire coating layer in Embodiment 3 is provided with the same thermometers 41A and 41B as those in Embodiment 2 in the inspection device 100 for the electromagnetic wire coating layer in Embodiment 1. Furthermore, the control device 30 has a temperature adjustment unit 36 ​​that controls and adjusts the temperature of the heating devices 7A and 7B.

[0109] The outputs of thermometers 41A and 41B, i.e., the temperature signals of the electromagnetic wire 2, are sent to the control device 30. After A / D conversion by the A / D converter 31 at a constant sampling frequency, the signals are input to the temperature regulation unit 36. The temperature regulation unit 36 ​​adjusts the outputs of the heating devices 7A and 7B to ensure that the temperature of the electromagnetic wire 2 is within a preset range. The preset range is set to effectively detect discharge at a temperature not exceeding the heat resistance temperature of the coating material.

[0110] The other structures and operations are the same as in Implementation Method 1 described above.

[0111] Therefore, the heating devices 7A and 7B can be automatically adjusted to maintain the desired temperature of the electromagnetic wire 2, easily and reliably preventing damage to the sheathing layer 22 of the electromagnetic wire 2. Furthermore, the discharge detection accuracy can be improved by reducing the air density through heating with high precision. Thus, the insulation characteristics of the electromagnetic wire 2 can be checked with even greater reliability.

[0112] Furthermore, the temperature signal of the electromagnetic wire 2 sent to the control device 30, after A / D conversion, is not only used by the temperature regulation unit 36 ​​but can also be stored in the storage unit 32. Both the detected discharge signal and temperature signal are stored in the storage unit 32, allowing the operator to read this signal information at any time and use it flexibly as a quality record during inspection. For example, the operator can use the read signal information to confirm the correlation between the discharge detection frequency and the temperature change of the electromagnetic wire 2, and to confirm whether the set travel speed of the electromagnetic wire 2 or the output conditions of the heating devices 7A and 7B are appropriate.

[0113] Implementation Method 4

[0114] In this embodiment 4, the heating devices 7A and 7B used in each of the embodiments 1 to 3 will be described. Figure 16 This is a diagram showing the structure of the heating device. Figure 17 This is a diagram showing the operation of the heating device.

[0115] like Figure 16 As shown, each heating device 7A and 7B is, for example, composed of a heating wire coil 46 formed by shaping a nickel-chromium alloy wire or other heating wire into a coil shape and a DC power supply 47. Furthermore, as... Figure 17 As shown, the electromagnetic wire 2 travels through an electric heating wire coil 46 in which a DC voltage is applied from a DC power supply 47. A DC current flows through the electric heating wire coil 46, enabling the electromagnetic wire 2 to heat up through thermal conduction 48, which is based on its resistance.

[0116] Furthermore, when applied to embodiments 2 and 3 above, the output adjustment of heating devices 7A and 7B can be achieved by adjusting the output voltage of the DC power supply 47.

[0117] Alternatively, the inner diameter of the heating wire coil 46 can be made to match the outer diameter of the electromagnetic wire 2, so that the heating wire coil 46 and the electromagnetic wire 2 are in contact. Or, in order to avoid friction of the coating layer 22 caused by contact, the inner diameter of the heating wire coil 46 can be made larger, with a margin of about 10μm to 100μm from the outer diameter of the electromagnetic wire 2.

[0118] Implementation Method 5

[0119] In this fifth embodiment, another aspect of the heating devices 7A and 7B used in each of the above embodiments 1 to 3 will be described. Figure 18 This is a diagram showing the structure of the heating device. Figure 19 This is a diagram showing the operation of the heating device.

[0120] like Figure 18 As shown, each heating device 7A and 7B is constructed using an induction heating coil, which consists of a wire coil 49 formed by coiling wires and a high-frequency power supply 50. Furthermore, as... Figure 19 As shown, the electromagnetic line 2 travels through the induction heating coil, i.e., the wire coil 49, which is subjected to a high-frequency voltage from the high-frequency power supply 50.

[0121] In addition, a temperature setting device 51 connected to the high-frequency power supply 50 can be provided to optimize the heating of the electromagnetic wire 2.

[0122] When a high-frequency current flows through the conductor coil 49, an alternating magnetic flux 52 is generated around the conductor coil 49. Eddy currents 53 flow through the metal part (core 21) of the electromagnetic wire 2 inside the conductor coil 49, heating the core 21 through resistance heating. Due to the skin effect, the density of eddy currents 53 is higher closer to the surface of the core 21, and therefore the temperature near the surface of the core 21 rises faster. Therefore, when a voltage is applied from the discharge detection electrode 5, charge can be efficiently discharged from the vicinity of the surface of the core 21 for discharge detection.

[0123] The oscillation frequency of the high-frequency power supply 50 can be variably adjusted, thereby obtaining optimal heating efficiency. For example, the optimal oscillation frequency can be determined in advance through experiments based on the wire diameter of the core 21 and stored in the temperature setting device 51. Then, when checking the insulation characteristics, the wire diameter of the core 21 of the electromagnetic wire 2 being checked is input into the temperature setting device 51, and the temperature setting device 51 extracts the optimal oscillation frequency and adjusts the oscillation frequency of the high-frequency power supply 50.

[0124] Alternatively, the operator can set the optimal oscillation frequency to be predetermined based on the wire diameter of the core 21.

[0125] Furthermore, when applying Embodiment 3 described above, the temperature regulating unit 36 ​​regulates the high-frequency power output from the high-frequency power supply 50 to the wire coil 49, thereby enabling output regulation of the heating devices 7A and 7B. In this case, the temperature regulating unit 36 ​​can also be configured to function as a temperature setting device 51.

[0126] Alternatively, the inner diameter of the induction heating coil, i.e., the wire coil 49, can be made to match the outer diameter of the electromagnetic wire 2, so that the wire coil 49 and the electromagnetic wire 2 are in contact. Or, in order to avoid friction of the coating layer 22 caused by contact, the inner diameter of the wire coil 49 can be made larger, with a margin of about 10μm to 100μm from the outer diameter of the electromagnetic wire 2.

[0127] Implementation Method 6

[0128] In this embodiment 6, the guiding structure of the electromagnetic wire in the inspection device for the electromagnetic wire coating layer will be described. Figure 20 ( Figure 20 A, Figure 20 B. Figure 20 C) is a diagram illustrating the guide block of the electromagnetic wire in embodiment 6.

[0129] As described above, in the inspection devices 100, 100A, and 100B for the electromagnetic wire coating, an AC voltage is applied to the discharge detection electrode 5 at a designated location within the travel path 1 while the core 21 of the electromagnetic wire 2 is heated, detecting discharges caused by defects 23 in the coating 22. The instability of the travel path 1 is a factor hindering high-precision discharge detection. The contact state or distance between the electromagnetic wire 2 and the discharge detection electrode 5 sometimes varies due to slight serpentine movement or minor vibrations in the travel path 1. While a good and stable contact state, or an appropriately maintained distance, allows for stable detection of high-intensity discharges, conversely, without stable maintenance, the discharge becomes unstable and of low intensity, making high-precision discharge detection impossible.

[0130] To eliminate the instability of the travel path 1, in this embodiment 6, the voltage application point within the travel path 1 is configured at a fixed position. Figure 20 A shows a guide block 60, which serves as a guide for the electromagnetic wire 2. Furthermore, the guide block 60 is a component that stabilizes the travel path 1 of the electromagnetic wire 2, and together with the delivery device 3, the winding device 4, and the guide block 60, it constitutes a travel path forming apparatus. Moreover, this guide block 60 can also be applied to each of the embodiments 1 to 5 described above.

[0131] In this case, the guide block 60, which is roughly cubic in shape and made of resin material, is provided with a through hole 61 for the electromagnetic wire 2 to pass through and a groove 62 for accommodating the discharge detection electrode 5, such as... Figure 20 As shown in Figure B, the discharge detection electrode 5 is housed in the slot 62, as follows. Figure 20 As shown in C, the electromagnetic wire 2 is traveled in a manner that passes through the through hole 61.

[0132] The through-hole 61 penetrates the two opposing surfaces of the discharge detection electrode 5, separated by a circular surface, and its center point coincides with the center point of the discharge detection electrode 5. Its diameter is approximately 10 μm to 100 μm larger than the outer diameter of the electromagnetic wire 2. Furthermore, the electromagnetic wire 2 enters the guide block 60 through the through-hole 61 on the upstream end face of the guide block 60, approaches the discharge detection electrode 5, maintains stable contact with the discharge detection electrode 5 or at an appropriate distance, passes through the voltage application point, and exits from the through-hole 61 on the downstream end face of the guide block 60.

[0133] Thus, in this embodiment, the electromagnetic wire 2 is guided by the guide block 60, and the travel path 1 is stable, thereby enabling stable detection of high-intensity discharges. Consequently, the characteristic quantities of the discharge signal can be calculated with high precision in the calculation unit 33, improving the accuracy of discharge detection.

[0134] Furthermore, the guide block 60 is formed of a resin material, thus preventing damage to the electromagnetic wire 2 due to friction. As the resin material, fluoropolymers such as PTFE (Polytetrafluoroethylene) with a low coefficient of friction are preferred.

[0135] Alternatively, the guide block 60 can be formed using metal materials such as iron, aluminum, or copper. In this case, instead of housing the discharge detection electrode 5 in the guide block 60, the guide block 60 itself, which has a through hole 61 forming the travel path 1 of the electromagnetic wire 2, serves as the discharge detection electrode. In this case, the through hole 61 is also adjusted to have a diameter approximately 10 μm to 100 μm larger than the outer diameter of the electromagnetic wire 2.

[0136] In addition, the guide block 60 can also remain on the platform within the travel path 1 (not shown).

[0137] Furthermore, the guiding structure of the guiding electromagnetic wire 2 can be guided by maintaining a stable contact state or an appropriate distance between the electromagnetic wire 2 and the discharge detection electrode 5 through the voltage application point, and is not limited to the structure shown in Embodiment 6 above.

[0138] Implementation Method 7

[0139] Figure 21 ( Figure 21 A, Figure 21 B. Figure 21 C) is a diagram illustrating the guide block of the electromagnetic wire in embodiment 7.

[0140] Regarding the factors that hinder the inspection device 100 for inspecting the electromagnetic wire coating from performing high-precision discharge detection, a factor different from that described in Embodiment 6 above is the deviation in the distance between the heating devices 7A and 7B and the discharge detection electrode 5. When there is a deviation in the distance between the heating devices 7A and 7B and the discharge detection electrode 5, even if the heating devices 7A and 7B heat the electromagnetic wire 2 with a constant output, the temperature of the electromagnetic wire 2 at the voltage application point is unstable, and the discharge quantity deviates due to the decrease in air density, thus degrading the accuracy of discharge detection.

[0141] To eliminate instability in travel path 1 and temperature instability of electromagnetic wire 2 at voltage application point, in this embodiment 7, a [missing information - likely a configuration or arrangement] is provided within travel path 1. Figure 21 A shows a guide block 60A, which serves as the guide portion for the electromagnetic wire 2. Furthermore, the travel path forming apparatus comprises a delivery device 3, a winding device 4, and the guide block 60A. Moreover, this guide block 60A can be applied to the inspection device 100 shown in Embodiment 1 above.

[0142] In this case, the guide block 60A, which is roughly rectangular in shape and made of high heat-resistant resin material, is provided with a through hole 61 for the electromagnetic wire 2 to pass through, a slot 62 for housing the discharge detection electrode 5, and slots 63A and 63B for housing the heating devices 7A and 7B, respectively. The slots 63A and 63B for the heating devices 7A and 7B are parallel to the slot 62 for the discharge detection electrode 5, and are arranged at equal distances on both sides of the slot 62.

[0143] As heating devices 7A and 7B, the electric heating wire coil 46 of Embodiment 4 or the wire coil 49 of Embodiment 5 are housed in slots 63A and 63B. Furthermore, the electric heating wire coil 46 is connected to a DC power supply 47, and the wire coil 49 is connected to a high-frequency power supply 50.

[0144] Moreover, such as Figure 21 As shown in Figure B, the discharge detection electrode 5 is housed in tank 62, and the heating devices 7A and 7B are housed in tanks 63A and 63B respectively. Figure 21 As shown in C, the electromagnetic wire 2 is traveled in a manner that passes through the through hole 61.

[0145] Thus, the guide block 60A is provided with multiple (in this case, three) slots 62, 63A, and 63B, respectively, to accommodate the discharge detection electrode 5 and the heating devices 7A and 7B. Furthermore, the discharge detection electrode 5 and the heating devices 7A and 7B are respectively housed in the three slots 62, 63A, and 63B, and fixed in their respective fixed positions, with the center points of the heating devices 7A and 7B aligned with the center point of the discharge detection electrode 5. Therefore, the distance between the heating devices 7A and 7B and the discharge detection electrode 5 remains constant and without deviation.

[0146] The through-hole 61 penetrates the two opposing surfaces of the discharge detection electrode 5, separated by a circular surface, and its center point coincides with the center point of the discharge detection electrode 5. Furthermore, its diameter is formed to be approximately 10 μm to 100 μm larger than the outer diameter of the electromagnetic wire 2. In addition, the electromagnetic wire 2 enters the guide block 60A from the inlet of the through-hole 61 on the upstream end face of the guide block 60A, passes through the coil of the heating device 7A, approaches the discharge detection electrode 5, maintains a stable contact state or an appropriate distance from the discharge detection electrode 5, passes through the voltage application point, and then exits the guide block 60A from the outlet of the through-hole 61 on the downstream end face of the guide block 60A through the coil of the heating device 7B.

[0147] In this embodiment, the electromagnetic wire 2 is guided by the guide block 60A to stabilize the travel path 1, and the distance between the heating devices 7A and 7B and the discharge detection electrode 5 is kept constant. Therefore, the temperature of the electromagnetic wire 2 at the voltage application point can be stabilized, and the discharge caused by the decrease in air density can be detected stably and with high intensity under constant temperature conditions. Consequently, the characteristic quantities of the discharge signal can be calculated with high precision in the calculation unit 33, improving the accuracy of discharge detection.

[0148] Furthermore, the guide block 60A is formed of a high heat-resistant resin material, thus preventing damage to the electromagnetic wire 2 due to friction and providing heat resistance for heating the heating devices 7A and 7B. As a high heat-resistant resin material, fluoropolymers such as PTFE with a heat resistance temperature of 200°C or higher are preferred.

[0149] Alternatively, a slot can be added to the guide block to accommodate the thermometers 41A and 41B shown in Embodiment 2 above, which will be explained below.

[0150] Figure 22 ( Figure 22 A, Figure 22 B) is a diagram illustrating another example of an electromagnetic wire guide block in Embodiment 7. This guide block 60B can be applied to the inspection devices 100A and 100B shown in Embodiments 2 and 3 above.

[0151] In this case, the guide block 60B, which is roughly rectangular in shape and made of high heat-resistant resin material, is provided with a through hole 61 for the electromagnetic wire 2 to pass through, a slot 62 for housing the discharge detection electrode 5, slots 63A and 63B for housing the heating devices 7A and 7B respectively, and slots 64A and 64B for housing the thermometers 41A and 41B respectively. The slots 63A and 63B for the heating devices 7A and 7B are parallel to the slot 62 for the discharge detection electrode 5 and are equidistant from each other on both sides of the slot 62. Furthermore, the slots 64A and 64B for the thermometers 41A and 41B are parallel to the slot 62 at positions between the slots 63A and 63B and the slot 62, and are equidistant from each other on both sides of the slot 62.

[0152] Moreover, such as Figure 22 As shown in Figure B, the discharge detection electrode 5 is housed in the slot 62, and the heating devices 7A and 7B are housed in the slots 63A and 63B respectively. Furthermore, the thermometers 41A and 41B are housed in the slots 64A and 64B respectively, so that the electromagnetic wire 2 can travel through the through hole 61.

[0153] In this way, by using the guide block 60B which is further provided with slots 64A and 64B for thermometers 41A and 41B, the distance between the temperature measuring position of the electromagnetic wire 2 and the discharge detection electrode 5 can be kept constant, the output adjustment accuracy of the heating devices 7A and 7B is improved, and thus the accuracy of discharge detection is further improved.

[0154] Implementation Method 8

[0155] Figure 23 This is a diagram showing the structure of the inspection device for the electromagnetic wire coating layer according to Embodiment 8. Furthermore, Figure 24 This is a partially enlarged view showing the winding device and stator core connected to the inspection device for the electromagnetic wire coating. Additionally, Figure 23 Point A inside and Figure 24 Connect point A within the range.

[0156] In this embodiment 8, the inspection device 100C for the electromagnetic wire coating layer is applied to the winding process of the armature, i.e., the stator, of a rotary or linear motor. This embodiment 8 can be applied to each of the embodiments 1 to 7 described above; however, the illustration here shows the application to embodiment 3, and only the different parts are described.

[0157] like Figure 23 , Figure 24 As shown, the inspection device 100C does not have a winding device 4 for winding the electromagnetic wire 2, and feeds the electromagnetic wire 2 to the winding device 70 located on the downstream side of the travel path 1. The electromagnetic wire 2 is wound onto the stator core 72 through the nozzle 71 of the winding device 70.

[0158] Furthermore, the inspection device 100C has an output unit 37 within the control device 30, and a display device 38 for externally displaying output information. The output unit 37 displays desired output information, such as the waveform image of the detected discharge signal, together with the determination result of the determination unit 35 on the display device 38. At this time, the cumulative number of discharge signals determined to have a defect 23 in the electromagnetic wire coating layer can also be displayed simultaneously.

[0159] In this embodiment, the inspection device 100C performs a discharge detection-based inspection on the electromagnetic wire 2 before winding, and continuously with this inspection, the winding device 70 winds the electromagnetic wire 2 onto the stator core 72. Moreover, throughout the series of processes, the operator can use the display device 38 to check the detection status of the defective portion 23 that is an insulation abnormality in the electromagnetic wire sheath.

[0160] Furthermore, in the control device 30, the measuring unit 34 operates as a timer to measure the travel time of the electromagnetic wire 2. Additionally, the calculation unit 33 calculates the time T until the defect 23 in the electromagnetic wire sheath reaches the stator core 72 in the winding, and the measuring unit 34 acquires this time information (T).

[0161] In the calculation unit 33, the traveling speed S of the electromagnetic wire 2 and the travel path length L from the discharge detection electrode 5 to the winding device 70 are preset, and the calculation time T (=L / S) is calculated. Then, the measurement unit 34 starts the timer from the point when the determination unit 35 determines that a defective part 23 exists, and measures for time T. As a result, the stator core 72 that is in the winding operation at the point when the measurement unit 34 completes the measurement is determined, that is, the stator core 72 with the defective part 23 covered by the electromagnetic wire coating is determined.

[0162] In addition, the winding operation for the stator core 72 continues regardless of whether there is a defect or not, part 23.

[0163] Furthermore, before the measurement unit 34 completes the measurement, the movement of the electromagnetic wire 2 may sometimes stop due to the winding device 70 stopping. The measurement unit 34 detects whether the electromagnetic wire 2 is moving, and if it detects that the movement has stopped, it interrupts the measurement of the movement time. Then, when the winding device 70 starts winding again and the electromagnetic wire 2 starts moving again, the measurement of the measurement unit 34 also resumes.

[0164] As described above, the inspection device 100C identifies stator cores 72 with insulation defects in the electromagnetic wire 2 wound with the cladding layer 22. The identified stator cores 72, or stators containing such stator cores 72, are not allowed to proceed to subsequent processes. They are distinguished from qualified products as non-conforming products by means of conveyors, trolleys, or other means for discharging non-conforming products.

[0165] In addition, these defective stator cores can be re-inspected separately using known methods such as surge voltage application (pulse voltage application) tests.

[0166] Figure 25 This is a diagram showing the structure of the stator after winding. As shown in the figure, after the stator core 72, on which the electromagnetic wire 2 is wound, is formed into a circle, the frame 74 is installed to form the stator 75.

[0167] also, Figure 26 This is a diagram showing the structure of an electric motor using a wound stator. As shown, the rotary motor 90, as an electric motor, has a stator 75 and a rotor 91 formed as described above.

[0168] The rotary motor 90 is manufactured using a stator core 72 that is confirmed by an inspection device 100C to have no insulation defects in the coating layer 22 of the wound electromagnetic wire 2. This results in a highly reliable rotary motor 90 that uses electromagnetic wire 2 with excellent insulation properties.

[0169] In addition, Figure 26 In the example of an electromechanical device, a rotary motor 90 is shown; however, it could also be a linear motor. The iron core for winding the electromagnetic wire 2 is not limited to the stator core 72.

[0170] Furthermore, when the electromagnetic wire sheathing layer is inspected using the inspection devices 100, 100A, and 100B of Embodiments 1 to 7 described above, the inspected electromagnetic wire 2, which is confirmed to have no insulation defects, can be wound onto the iron core to manufacture electric machinery. In this case, a highly reliable electric machinery using electromagnetic wire 2 with good insulation properties can also be obtained.

[0171] Implementation Method 9

[0172] In the above embodiments 1 to 8, heating devices 7A and 7B were used as discharge promotion devices to promote discharge generation by reducing the discharge start voltage. However, in this embodiment 9, a pressure reduction device for reducing the pressure around the electromagnetic wire 2 is used as the discharge promotion device.

[0173] Figure 27 This is a diagram showing the structure of the inspection device for the electromagnetic wire coating layer according to Embodiment 9. Figure 27 As shown, similar to Embodiment 8 above, the inspection device 100D for the electromagnetic wire coating layer is applied to the winding process of the armature, i.e., the stator, of a rotary motor or linear motor. Figure 27 Point A inside is the same as shown in Embodiment 8 above. Figure 24 Connect point A within the range.

[0174] That is, the inspection device 100D has a feeding device 3 on the upstream side of the travel path 1 of the electromagnetic wire 2. The feeding device 3 has a feeder 3A and a reel 3B for feeding the electromagnetic wire 2, but it does not have a winding device 4 for winding the electromagnetic wire 2. The electromagnetic wire 2 is fed to the winding device 70 located on the downstream side of the travel path 1. The electromagnetic wire 2 is wound onto the stator core 72 through the nozzle 71 of the winding device 70.

[0175] In addition, the inspection device 100D for the electromagnetic wire coating layer includes a discharge detection device consisting of a discharge detection electrode 5 and a detection device 10, and a pressure reduction device 9 provided at a voltage application point in the travel path 1 to reduce the pressure around the electromagnetic wire 2.

[0176] The discharge detection electrode 5 and the detection device 10 operate in the same manner as in Embodiment 1 described above. The pressure reducing device 9 is provided as a discharge promoting device to promote the discharge generated from the core of the electromagnetic wire 2, and has a pressure reducing tank 8 arranged in a manner that surrounds the electromagnetic wire 2 at the voltage application point, and a pressure reducing pump 8A for reducing the pressure in the pressure reducing tank 8.

[0177] Furthermore, the inspection device 100D includes a control device 30 and a display device 38 that displays output information externally. The control device 30 monitors the discharge signal from the detection device 10 and determines an abnormality in the electromagnetic wire coating layer based on the discharge signal. Similar to Embodiment 8 described above, the control device 30 includes an A / D (analog-to-digital) converter 31, a storage unit 32, a calculation unit 33, a measurement unit 34, a determination unit 35, and an output unit 37. It also includes a pressure regulating unit 39 that controls and regulates the pressure reducing device 9.

[0178] Figure 28 This is a diagram showing the structure of the pressure reducing device 9.

[0179] As shown in the figure, the pressure reducing device 9 includes a pressure reducing tank 8 formed into a roughly cubic shape from an insulating resin panel such as acrylic resin, and a pressure reducing pump 8A for reducing pressure within the pressure reducing tank 8. Through holes 65A and 65B of approximately 1 mm diameter are provided on the resin panels of two opposing sides of the pressure reducing tank 8, allowing the electromagnetic wire 2 to pass perpendicularly through these two surfaces. The through holes 65A and 65B are arranged such that they pass through their respective centers and are aligned with a centerline perpendicular to the opening surface. Furthermore, a pressure gauge 68 is provided to measure the pressure within the pressure reducing tank 8.

[0180] In addition, in order to maintain the pressure inside the pressure relief groove 8, the inner diameter side of the through holes 65A and 65B can be covered with a rubber material such as silicone rubber.

[0181] The discharge detection electrode 5 is arranged in a ring around the electromagnetic wire 2, which is located within the travel path 1 of the electromagnetic wire 2, inside the pressure reducing groove 8, and is connected to the AC power supply 6 via the voltage application part 6A. The discharge detection electrode 5 is held and fixed by the holding part 66 in such a way that the center line of the discharge detection electrode 5 is aligned with the center lines of the through holes 65A and 65B.

[0182] Furthermore, the electromagnetic wire 2 enters the pressure reducing tank 8 through the through hole 65A on the upstream end face of the pressure reducing tank 8, approaches the discharge detection electrode 5, maintains a stable contact state or an appropriate distance from the discharge detection electrode 5, and passes through the voltage application point, traveling out of the pressure reducing tank 8 through the through hole 65B on the downstream end face of the pressure reducing tank 8. During the travel of the electromagnetic wire 2 in the pressure reducing tank 8, the pressure reducing pump 8A reduces the pressure in the pressure reducing tank 8 to a specified pressure.

[0183] In addition, such as Figure 29 As in another example shown, a guide roller 67 for guiding the electromagnetic wire 2 can also be provided in the pressure reducing groove 8 to stabilize the movement of the electromagnetic wire 2.

[0184] In addition, the resin panel forming the pressure relief groove 8 is preferably transparent, so that the travel status of the electromagnetic wire 2 can be visually confirmed.

[0185] The output of pressure gauge 68 is a signal indicating the pressure inside pressure reducing tank 8. This signal is sent to control device 30, where it is converted to digital value by A / D converter 31 at a constant sampling frequency, and then input to pressure regulating unit 39. Pressure regulating unit 39 regulates the output of pressure reducing pump 8A to keep the pressure inside pressure reducing tank 8 within a preset range.

[0186] As described above, when there is a defect 23 in the sheath 22 of the electromagnetic wire 2 based on pinholes or damage, a discharge occurs from the wire core 21 at the voltage application point through the defect 23 in the sheath 22 toward the discharge detection electrode 5. The discharge charge is collected by the discharge detection electrode 5 and sent to the detection device 10.

[0187] The area around the electromagnetic wire 2 at the voltage application point is depressurized by the pressure reducing device 9. This pressure reduction decreases the air density between the wire core 21 and the discharge detection electrode 5 at the voltage application point, thus reducing the discharge initiation voltage generated from the wire core 21 via the defect 23 of the cladding layer 22. In other words, the pressure reducing device 9 lowers the discharge initiation voltage, thereby promoting discharge.

[0188] In this way, the discharge initiation voltage decreases, thereby suppressing the voltage applied by the discharge detection electrode 5 to a low voltage, and allowing the generated voltage ΔV due to the discharge to be observed at a low voltage. That is, the defect 23 of the sheathing layer 22, which is an insulation abnormality of the electromagnetic wire 2, can be detected with high precision at a low voltage. As a result, the insulation characteristics of the electromagnetic wire can be reliably checked before winding without damaging the normal electromagnetic wire sheathing layer.

[0189] Figure 30 It is a graph showing the relationship between the pressure around the electromagnetic wire and the discharge initiation voltage.

[0190] In this case, the pressure in the pressure reducing tank 8 is varied within the range of 0.002 MPa to 0.1 MPa by the pressure reducing pump 8A, and the discharge start voltage from the core 21 through the defect portion 23 of the covering layer 22 is measured. Figure 30 The horizontal axis represents the pressure surrounding the electromagnetic wire 2, i.e., the pressure inside the pressure-reducing tank 8. The vertical axis represents the discharge initiation voltage ratio obtained by dividing the discharge initiation voltage at each surrounding pressure by the discharge initiation voltage at 0.1 MPa (atmospheric pressure).

[0191] As shown in the figure, the pressure around the electromagnetic wire 2 is reduced to a pressure range not exceeding the discharge start voltage at atmospheric pressure, i.e., below 0.1 MPa, thereby reducing the discharge start voltage. Furthermore, in pressure regions below 0.005 MPa, the discharge start voltage changes drastically with pressure, making proper control of the pressure reducing pump 8A difficult. Therefore, it is preferable that the pressure regulating range of the pressure reducing device 9 is between 0.005 MPa and 0.1 MPa.

[0192] In this embodiment, similar to Embodiment 8 described above, the inspection device 100D performs a discharge detection-based inspection on the electromagnetic wire 2 before winding, and continuously with this inspection, the winding device 70 winds the electromagnetic wire 2 onto the stator core 72. Moreover, throughout the series of processes, the operator can use the display device 38 to check the detection status of the defective portion 23 that is an insulation abnormality in the electromagnetic wire sheath.

[0193] Furthermore, in the control device 30, the measuring unit 34 operates as a timer to measure the travel time of the electromagnetic wire 2. Additionally, the calculation unit 33 calculates the time T until the defective portion 23 of the electromagnetic wire coating reaches the stator core 72 during winding, and the measuring unit 34 acquires this time information (T). Moreover, it determines the stator core 72 in the winding operation at the point when the measuring unit 34 completes its measurement; that is, it identifies the stator core 72 with the defective portion 23 of the electromagnetic wire coating.

[0194] In addition, the winding operation for the stator core 72 continues regardless of whether there is a defect or not, part 23.

[0195] As described above, the inspection device 100D identifies stator cores 72 with insulation defects in the electromagnetic wire 2 wound with the cladding layer 22. The identified stator core 72, or a stator containing the identified stator core 72, is then not allowed to proceed to subsequent processes.

[0196] Furthermore, a rotating motor 90 is manufactured by using an inspection device 100D to confirm that there are no insulation defects in the coating layer 22 of the wound electromagnetic wire 2. Thus, a highly reliable rotating motor 90 using electromagnetic wire 2 with good insulation properties can be obtained.

[0197] Furthermore, the control device 30 used in each of the embodiments 1 to 9 described above can, for example, have Figure 26 The hardware structure shown is implemented using a processor 80 and a storage device 81.

[0198] Storage device 81 includes volatile storage devices such as RAM (Random Access Memory) (not shown), and non-volatile auxiliary storage devices such as HDD (Hard Disk Drive) and SSD (Solid State Drive) (not shown). Alternatively, flash memory can be used as a non-volatile auxiliary storage device instead of HDD.

[0199] The processor 80 executes the control program input from the storage device 81.

[0200] The storage device 81 includes an auxiliary storage device and a volatile storage device. The control program 82 is input from the auxiliary storage device to the processor 80 via the volatile storage device.

[0201] The processor 80 outputs the calculation results and other data 83 to the volatile storage device of the storage device 81, and saves these data 83 to the auxiliary storage device via the volatile storage device as needed.

[0202] This application describes various exemplary embodiments and examples; however, the various features, methods and functions described in one or more embodiments are not limited to the application of a particular embodiment and can be applied to the embodiment alone or in various combinations.

[0203] 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.

[0204] Label Explanation

[0205] 1: Travel path; 2: Electromagnetic wire; 3: Delivery device; 4: Winding device; 5: Discharge detection electrode; 7A, 7B: Heating device; 8: Pressure reducing tank; 8A: Pressure reducing pump; 9: Pressure reducing device; 10: Detection device; 21: Wire core; 22: Coating layer; 23: Defect section; 30: Control device; 32: Storage section; 33: Calculation section; 34: Measurement section; 35: Judgment section; 36: Temperature regulation section; 39: Pressure regulation section; 41A, 41B: Thermometer; 46: Heating wire coil; 47: DC power supply; 49: Conductor coil; 50: High frequency power supply; 60, 60A, 60B: Guide block; 61: Through hole; 62, 63A, 63B: Slot; 70: Winding device; 72: Stator core; 90: Rotary motor; 100, 100A, 100B, 100C, 100D: Inspection device.

Claims

1. An electromagnetic wire coating layer inspection device, comprising: a traveling path forming device that forms a traveling path in which a coated electromagnetic wire travels at a constant speed in a wire direction before being wound; a discharge detection device that has a discharge detection electrode that applies an alternating voltage to the electromagnetic wire at a prescribed position within the traveling path and collects a discharge charge generated from a core of the electromagnetic wire, and a detection device that detects a discharge signal from the discharge charge of the discharge detection electrode; and a discharge promoting device that promotes discharge from the core of the electromagnetic wire at a voltage application point that is the prescribed position within the traveling path, wherein the electromagnetic wire coating layer inspection device has a heating device as the discharge promoting device, the heating device being provided at least one of an upstream side and a downstream side of the voltage application point within the traveling path, and heating the core of the electromagnetic wire at the voltage application point.

2. The electromagnetic wire coating layer inspection device according to claim 1, wherein the heating device heats at a temperature that does not exceed a heat resistance temperature of a coating material of the electromagnetic wire.

3. The electromagnetic wire coating layer inspection device according to claim 1 or 2, wherein the heating device has an electric heating wire coil and a direct current power source.

4. The electromagnetic wire coating layer inspection device according to claim 1 or 2, wherein the heating device has an induction heating coil that is constituted by a wire coil and a high frequency power source.

5. The electromagnetic wire coating layer inspection device according to any one of claims 1 to 4, wherein the heating device has a temperature measuring portion that measures a temperature of the electromagnetic wire, and the heating device is capable of heating adjustment according to a measurement result of the temperature measuring portion.

6. The electromagnetic wire coating layer inspection device according to any one of claims 1 to 5, wherein the electromagnetic wire coating layer inspection device has a control device that has a storage portion that stores the discharge signal, a calculation portion that calculates a characteristic quantity from the stored discharge signal, and a determination portion that determines an abnormality of an electromagnetic wire coating layer from the characteristic quantity.

7. The electromagnetic wire coating layer inspection device according to claim 6, wherein the control device has a temperature adjustment portion, and the control device controls the heating device in such a manner that a temperature of the electromagnetic wire is within a range that is set in advance.

8. The electromagnetic wire coating layer inspection device according to any one of claims 1 to 5, wherein the discharge detection electrode is disposed in a ring shape around the electromagnetic wire at the voltage application point, and the traveling path forming device has a guide portion that guides the electromagnetic wire to a fixed position of the voltage application point within the traveling path.

9. The electromagnetic wire coating layer inspection device according to claim 8, wherein the guide portion is provided with a through hole through which the electromagnetic wire passes, the guide portion is constituted by a guide block, the guide block is constituted by a resin material, and the discharge detection electrode is housed in the guide block. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ 10. The electromagnetic wire coating layer inspection apparatus according to claim 9, wherein the guide block is provided with a plurality of grooves that respectively receive the discharge detection electrode and the heating device, and the guide block fixes the discharge detection electrode and the heating device to respective fixed positions.

11. An electromagnetic wire coating layer inspection apparatus, comprising: travel path forming means for forming a travel path in which a coated electromagnetic wire travels at a constant speed in a wire direction before being wound; discharge detection means having a discharge detection electrode that applies an alternating voltage to the electromagnetic wire at a prescribed position within the travel path and collects a discharge charge generated from a wire core of the electromagnetic wire, and detection means that detects a discharge signal based on the discharge charge from the discharge detection electrode; and discharge promotion means for promoting discharge from the wire core of the electromagnetic wire at a voltage application point that is the prescribed position within the travel path, the discharge detection electrode being disposed in a ring shape around the electromagnetic wire at the voltage application point.

12. The electromagnetic wire coating layer inspection apparatus according to claim 11, wherein the electromagnetic wire coating layer inspection apparatus has control means having a storage section that stores the discharge signal, a calculation section that calculates a characteristic quantity based on the stored discharge signal, and a determination section that determines an abnormality of an electromagnetic wire coating layer based on the characteristic quantity.

13. An electromagnetic wire coating layer inspection apparatus, comprising: travel path forming means for forming a travel path in which a coated electromagnetic wire travels at a constant speed in a wire direction before being wound; discharge detection means having a discharge detection electrode that applies an alternating voltage to the electromagnetic wire at a prescribed position within the travel path and collects a discharge charge generated from a wire core of the electromagnetic wire, and detection means that detects a discharge signal based on the discharge charge from the discharge detection electrode; discharge promotion means for promoting discharge from the wire core of the electromagnetic wire at a voltage application point that is the prescribed position within the travel path; and control means having a storage section that stores the discharge signal, a calculation section that calculates a characteristic quantity based on the stored discharge signal, and a determination section that determines an abnormality of an electromagnetic wire coating layer based on the characteristic quantity, the characteristic quantity calculated by the calculation section being at least one of a peak discharge charge amount, a discharge duration, and a total discharge charge amount.

14. An electromagnetic wire coating layer inspection apparatus, comprising: travel path forming means for forming a travel path in which a coated electromagnetic wire travels at a constant speed in a wire direction before being wound; discharge detection means having a discharge detection electrode that applies an alternating voltage to the electromagnetic wire at a prescribed position within the travel path and collects a discharge charge generated from a wire core of the electromagnetic wire, and detection means that detects a discharge signal based on the discharge charge from the discharge detection electrode; a discharge promoting device that promotes generation of a discharge from the core of the electromagnetic wire at a voltage application point that is the set position within the travel path; and a control device that has a storage section that stores the discharge signal, a calculation section that calculates a characteristic quantity from the stored discharge signal, and a determination section that determines an abnormality of the electromagnetic wire covering layer from the characteristic quantity, the control device performs smoothing processing of the discharge signal before calculating the characteristic quantity.

15. The electromagnetic wire covering layer inspection device according to claim 14, wherein the smoothing processing of the discharge signal is performed using a moving average method.

16. An electromagnetic wire covering layer inspection device, comprising: a travel path forming device that causes a covered electromagnetic wire to travel at a constant speed in a wire direction before being wound to form a travel path; a discharge detection device that has a discharge detection electrode that applies an alternating voltage to the electromagnetic wire at a set position within the travel path and collects a discharge charge generated from the core of the electromagnetic wire, and a detection device that detects a discharge signal from the discharge charge from the discharge detection electrode; a discharge promoting device that promotes generation of a discharge from the core of the electromagnetic wire at a voltage application point that is the set position within the travel path; a control device that has a storage section that stores the discharge signal, a calculation section that calculates a characteristic quantity from the stored discharge signal, and a determination section that determines an abnormality of the electromagnetic wire covering layer from the characteristic quantity; and a display device that displays a determination result of the determination section together with a waveform of the discharge signal.

17. The electromagnetic wire covering layer inspection device according to any one of claims 6, 7, 12 to 16, wherein the abnormality determined by the determination section is an insulation abnormality caused by a defective portion of the electromagnetic wire covering layer.

18. The electromagnetic wire covering layer inspection device according to any one of claims 6, 7, 12 to 17, wherein the control device removes a discharge noise of the discharge signal before calculating the characteristic quantity.

19. The electromagnetic wire covering layer inspection device according to any one of claims 1 to 18, wherein the travel path forming device has a feeding device that feeds out the electromagnetic wire on an upstream side of the travel path, and a winding device that winds up the electromagnetic wire on a downstream side of the travel path.

20. The electromagnetic wire covering layer inspection device according to any one of claims 1 to 18, wherein the travel path forming device has a feeding device that feeds out the electromagnetic wire on an upstream side of the travel path, and the travel path forming device feeds out the electromagnetic wire to a winding device provided on a downstream side of the travel path.

21. The electromagnetic wire covering layer inspection device according to any one of claims 6, 7, 12 to 18, wherein The travel path forming device has a sending device that is provided on an upstream side of the travel path and sends the electromagnetic wire, and sends the electromagnetic wire to a winding device provided on a downstream side of the travel path, The control device has a measurement unit that measures a travel time of the electromagnetic wire, and the control device can determine abnormal winding of the electromagnetic wire covering layer after winding based on a measurement result of the measurement unit and a determination result of the determination unit.

22. A method of manufacturing an electric machine, in which the electromagnetic wire, after being inspected by the inspection device for an electromagnetic wire covering layer according to any one of claims 1 to 21, is wound around a core to manufacture an electric machine.

23. An inspection method for an electromagnetic wire covering layer, the inspection method for an electromagnetic wire covering layer having the following steps: Step 1, causing the covered electromagnetic wire to travel at a constant speed in a wire direction before winding; Step 2, applying an alternating voltage to the electromagnetic wire by a discharge detection electrode at a predetermined position in a travel path of the electromagnetic wire and collecting discharge charges generated from a wire core of the electromagnetic wire; Step 3, detecting a discharge signal based on the discharge charges from the discharge detection electrode; and Step 4, promoting discharge from the wire core of the electromagnetic wire at a voltage application point that is the predetermined position in the travel path, In the Step 4, the wire core of the voltage application point is heated, and a discharge start voltage at which discharge starts from the wire core at the voltage application point is lowered.

24. An inspection method for an electromagnetic wire covering layer, the inspection method for an electromagnetic wire covering layer having the following steps: Step 1, causing the covered electromagnetic wire to travel at a constant speed in a wire direction before winding; Step 2, applying an alternating voltage to the electromagnetic wire by a discharge detection electrode at a predetermined position in a travel path of the electromagnetic wire and collecting discharge charges generated from a wire core of the electromagnetic wire; Step 3, detecting a discharge signal based on the discharge charges from the discharge detection electrode; and Step 4, promoting discharge from the wire core of the electromagnetic wire at a voltage application point that is the predetermined position in the travel path, In the Step 4, the wire core is heated by a heating device provided on at least one of an upstream side and a downstream side of the voltage application point, and the Step 2 is performed while the wire core is heated by the Step 4.

25. An inspection method for an electromagnetic wire covering layer, the inspection method for an electromagnetic wire covering layer having the following steps: Step 1, causing the covered electromagnetic wire to travel at a constant speed in a wire direction before winding; Step 2, applying an alternating voltage to the electromagnetic wire by a discharge detection electrode at a predetermined position in a travel path of the electromagnetic wire and collecting discharge charges generated from a wire core of the electromagnetic wire; Step 3, detecting a discharge signal based on the discharge charges from the discharge detection electrode; and Step 4, promoting discharge from the wire core of the electromagnetic wire at a voltage application point that is the predetermined position in the travel path, In the Step 4, the wire core is heated by a heating device provided on at least one of an upstream side and a downstream side of the voltage application point, and the Step 2 is performed while the wire core is heated by the Step 4. In the fourth step, the core is heated at a temperature not exceeding the heat resistance temperature of the covering layer material of the electromagnetic wire.

26. The electromagnetic wire covering layer inspection method according to any one of claims 23 to 25, wherein The electromagnetic wire covering layer inspection method has a fifth step in which a characteristic quantity is calculated from the discharge signal detected in the third step, and the abnormality of the electromagnetic wire covering layer is determined from the characteristic quantity.

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