Coil, stator, forming method, generator, and wind turbine generator system

Abstract

The present application relates to a kind of coil, stator, forming method, generator and wind turbine unit, coil, comprising: conductor group, including at least one conductive unit;Protection body, at least partially covers conductor group setting, protection body includes inner insulating layer, outer insulating layer and the guide layer between inner insulating layer and outer insulating layer, inner insulating layer is between conductor group and guide layer;Wherein, guide layer includes support frame and filling body, support frame is set between inner insulating layer and outer insulating layer and has the channel along the length direction of conductor group, filling body is filled in channel.This embodiment of the present application provides a kind of coil, stator, forming method, generator and wind turbine unit, the insulation effect of coil is good, it is beneficial to meet the demand of generator to high voltage development.

Description

Technical Field

[0001] This invention relates to the field of electric motor technology, and in particular to a coil, stator, forming method, generator, and wind turbine generator set. Background Technology

[0002] Generators may use enameled wire insulation or wrapped insulation, typically on the winding coils, relying on the enamel film for insulation and reinforcement.

[0003] The selection of generator windings is based on the generator's power and specific operating conditions. Small generators often use loosely wound windings, while large generators tend to use shaped windings. These shaped winding coils typically employ multi-adhesive molding systems or vacuum pressure impregnation insulation methods. As voltage levels increase and insulation thickness increases, it becomes increasingly difficult for vacuum pressure impregnation insulation to penetrate the insulation layer, easily leading to defects such as incomplete penetration and poor insulation performance. Summary of the Invention

[0004] This invention provides a coil, a stator, a forming method, a generator, and a wind turbine generator set. The coil has good insulation performance, which helps to meet the generator's demand for high voltage development.

[0005] On one hand, according to an embodiment of the present invention, a coil is provided, comprising: a conductor group including at least one conductive unit; a protective body at least partially covering the conductor group, the protective body including an inner insulating layer, an outer insulating layer, and a guiding layer located between the inner insulating layer and the outer insulating layer, the inner insulating layer being located between the conductor group and the guiding layer; wherein, the guiding layer includes a support frame and a filler, the support frame being disposed between the inner insulating layer and the outer insulating layer and having a channel extending along the length direction of the conductor group, and the filler filling the channel.

[0006] According to one aspect of the present invention, the support frame includes an inner support plate, an outer support plate, and a plurality of support bridges connected between the outer support plate and the inner support plate, wherein the inner support plate, the outer support plate, and the support bridges enclose a channel.

[0007] According to one aspect of the present invention, the inner support plate, the outer support plate and the support bridge are an integral structure.

[0008] According to one aspect of the present invention, the inner support plate includes a plurality of first plate units distributed around the conductor group, and the outer support plate includes a plurality of second plate units distributed around the conductor group, each first plate unit being disposed opposite to one of the second plate units and supported by at least one support bridge between them to form a support unit.

[0009] According to one aspect of the present invention, the support unit is an integral structure.

[0010] According to one aspect of the present invention, the thickness of the inner support plate ranges from 1.2 mm to 1.5 mm, and / or the thickness of the outer support plate ranges from 1.2 mm to 1.5 mm.

[0011] According to one aspect of the present invention, the inner support plate is provided with a through hole, and / or the outer support plate is provided with a through hole.

[0012] According to one aspect of the present invention, the thickness of the guide layer ranges from 4 mm to 6 mm.

[0013] According to one aspect of the present invention, the inner insulating layer and the outer insulating layer each comprise a mica tape layer.

[0014] According to one aspect of the present invention, the thermal conductivity of the guiding layer is greater than that of the inner insulating layer and the outer insulating layer.

[0015] According to one aspect of the present invention, the average thermal conductivity of the guiding layer is not less than 0.6 W / (m·K).

[0016] According to one aspect of the present invention, the thermal conductivity of the support frame ranges from 0.5 W / (m·K) to 0.8 W / (m·K), and the thermal conductivity of the filler ranges from 1 W / (m·K) to 1.5 W / (m·K).

[0017] According to one aspect of the present invention, the support frame includes at least one of unsaturated polyester resin, epoxy resin, modified epoxy resin, and benzoxazine.

[0018] According to one aspect of the present invention, the filler includes at least one of silicone, polyurethane resin and epoxy resin.

[0019] On the other hand, according to an embodiment of the present invention, a method for forming a coil is provided, comprising:

[0020] A conductor assembly is provided, the conductor assembly comprising at least one conductive unit;

[0021] An inner insulation layer, a support frame, and an outer insulation layer are sequentially arranged around the outside of the conductor group to form a primary coil module. The support frame has a channel extending along the length of the conductor group.

[0022] The primary coil module is immersed in a liquid and cured, the liquid including insulating varnish;

[0023] A first fluid is injected into a primary coil module with cured insulating varnish and cured to form a filler located within the channel, wherein the thermal conductivity of the support frame and the filler as a whole is greater than the thermal conductivity of the inner insulation layer and the outer insulation layer.

[0024] In another aspect, a stator is provided according to an embodiment of the present invention, comprising:

[0025] Stator support with receiving groove;

[0026] The aforementioned coil is disposed in a receiving groove.

[0027] According to another aspect of the present invention, the coil includes a straight section and a bent section, both of which are covered with an inner insulating layer. The inner insulating layer of the straight section is further covered with a guide layer and an outer insulating layer in sequence. The straight section is configured to cooperate with and protrude from the receiving groove, and the bent section is connected to the stator support through a potting body.

[0028] In another aspect, according to an embodiment of the present invention, a method for forming a stator includes:

[0029] A conductor assembly is provided, the conductor assembly comprising at least one conductive unit;

[0030] An inner insulation layer, a support frame, and an outer insulation layer are sequentially arranged around the conductor group to form a primary coil module. The support frame has a channel extending along the length of the conductor group.

[0031] A stator support is provided, which has multiple receiving slots in which a primary coil module is embedded;

[0032] The stator support and primary coil module are immersed in a liquid and cured, the liquid including insulating varnish;

[0033] The stator support and primary coil module, which are impregnated with insulating varnish, are filled with a first fluid and cured to form a filler located in the channel. The thermal conductivity of the support and the filler as a whole is greater than that of the inner insulation layer and the outer insulation layer.

[0034] In another aspect, according to the present invention, a generator includes the aforementioned coil, or the aforementioned stator.

[0035] In another aspect, according to the present invention, a wind turbine generator set includes the aforementioned generator.

[0036] According to embodiments of the present invention, the coil, stator, forming method, generator, and wind turbine generator set include a coil comprising a conductor group and a protective body. The protective body at least partially covers the conductor group, providing protection for the conductor group and ensuring the safety of the coil. Since the protective body includes an inner insulation layer, an outer insulation layer, and a guiding layer located between the inner and outer insulation layers, and the guiding layer includes a support frame and a filler, the filler can be omitted before vacuum pressure impregnation of the coil. This allows the insulating varnish to enter the space between the inner and outer insulation layers through the channel and be guided to the inner and outer insulation layers by the support frame, ensuring thorough impregnation. After impregnation, a filler liquid is poured into the channel and solidified to form the filler, ensuring the strength and insulation effect of the protective body. This structure can be formed using a vacuum impregnation process, ensuring thorough varnish penetration and good insulation protection, enabling the coil to meet the application requirements of higher voltage generators. Attached Figure Description

[0037] The features, advantages and technical effects of exemplary embodiments of the present invention will now be described with reference to the accompanying drawings.

[0038] Figure 1 This is a schematic diagram of the structure of a coil according to an embodiment of the present invention;

[0039] Figure 2 yes Figure 1 A cross-sectional view along the AA direction;

[0040] Figure 3 This is a schematic diagram of the structure of the guide layer according to an embodiment of the present invention;

[0041] Figure 4 This is a schematic diagram of the support frame according to an embodiment of the present invention;

[0042] Figure 5 This is a schematic diagram of the support frame according to another embodiment of the present invention;

[0043] Figure 6 yes Figure 5 An exploded view of the support frame shown;

[0044] Figure 7 This is a schematic diagram of the stator structure according to an embodiment of the present invention;

[0045] Figure 8 This is a partial schematic diagram of the coil and stator support in one embodiment of the present invention;

[0046] Figure 9 This is a partial structural schematic diagram of the stator according to an embodiment of the present invention;

[0047] Figure 10This is a schematic diagram of the structure of a wind turbine generator set according to an embodiment of the present invention;

[0048] Figure 11 This is a schematic flowchart of a coil forming method according to an embodiment of the present invention;

[0049] Figure 12 This is a schematic flowchart of a stator forming method according to an embodiment of the present invention.

[0050] 101-Stator; 1011-Stator support; 1011a-Receiving groove;

[0051] 1-Coil; 10-Conductor group; 11-Conductive unit; 1a-Straight section; 1b-Bent section;

[0052] 20-Protective body; 21-Inner insulation layer; 22-Outer insulation layer; 23-Guiding layer; 231-Support frame; 2311-Channel; 2312-Inner support plate; 2312a-First plate unit; 2313-Outer support plate; 2313a-Second plate unit; 2314-Support bridge; 2315-Through hole; 231a-Support unit; 232-Infill body;

[0053] 100 - Generator; 200 - Tower; 300 - Nacelle; 400 - Impeller;

[0054] Y-Zhou Xiang.

[0055] In the accompanying drawings, the same parts use the same reference numerals. The drawings are not drawn to scale. Detailed Implementation

[0056] The features and exemplary embodiments of various aspects of the present invention will now be described in detail. Numerous specific details are set forth in the following detailed description in order to provide a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without requiring some of these specific details. The following description of embodiments is merely intended to provide a better understanding of the invention by illustrating examples of the invention. In the accompanying drawings and the following description, at least some well-known structures and techniques have not been shown in order to avoid unnecessarily obscuring the invention; and, for clarity, the dimensions of some structures may be exaggerated. Furthermore, the features, structures, or characteristics described below may be combined in any suitable manner in one or more embodiments.

[0057] The directional terms used in the following description refer to the directions shown in the figures and are not intended to limit the specific structures of the coils, stators, forming methods, generators, and wind turbine generator sets of the present invention. In the description of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to direct connections or indirect connections. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

[0058] Common small generators may use enameled wire insulation or wrapped insulation, which is generally used on loosely wound coils. This type of insulation relies on the enamel film for insulation and reinforcement.

[0059] Larger generators typically use shaped coils (coil-type coils). The selection of motor windings is based on the generator's power and specific operating conditions. Small generators often use loosely wound coils, while large generators, especially high-voltage generators such as those around 10kV, tend to use shaped windings. These shaped windings generally use vacuum pressure impregnation (VPI) insulation.

[0060] As voltage levels increase and insulation layer thickness increases, VPI (Voltage Impregnation) becomes increasingly difficult to penetrate, creating a bottleneck in the insulation treatment process. There is no absolute thickness boundary; generally, VPI is no longer used when the insulation layer thickness exceeds 3mm. This thickness typically corresponds to a voltage level of around 13kV, meaning VPI is generally applicable to voltages lower than this. If VPI technology is applied to higher voltage generators, the increasing thickness of the insulation layer further complicates VPI penetration, resulting in poorer insulation performance and limiting the generator's voltage level requirements.

[0061] Based on this, this application provides a new type of coil with good insulation performance, which is beneficial to meeting the needs of generators for high voltage development.

[0062] like Figures 1 to 4 As shown, the coil 1 provided in this embodiment includes a conductor group 10 and a protective body 20. The conductor group 10 includes at least one conductive unit 11. The protective body 20 at least partially covers the conductor group 10.

[0063] The protective body 20 includes an inner insulating layer 21, an outer insulating layer 22, and a guide layer 23 located between the inner insulating layer 21 and the outer insulating layer 22. The inner insulating layer 21 is located between the conductor group 10 and the guide layer 23. The guide layer 23 includes a support frame 231 and a filler 232. The support frame 231 is disposed between the inner insulating layer 21 and the outer insulating layer 22 and has a channel 2311 extending along the length direction of the conductor group 10. The filler 232 fills the channel 2311.

[0064] The conductor group 10 may include one conductive unit 11, or it may include two or more conductive units 11. When it includes two or more conductive units 11, the two or more conductive units 11 may be stacked on top of each other, and adjacent conductive units 11 may be insulated from each other.

[0065] The protective body 20 is configured to partially cover the conductor group 10. Of course, it can also be configured to completely cover the conductor group 10. When the conductor group 10 is completely covered, the inner insulation layer 21 of the protective body 20 can completely cover the protective body 20.

[0066] The support frame 231 can have two or more channels 2311, which are spaced apart from each other and can extend along the length of the conductor.

[0067] The coil 1 provided in this application embodiment has a protective body 20 that at least partially covers the conductor group 10, which can provide protection for the conductor group 10 and ensure the safety of the coil 1. Since the protective body 20 includes an inner insulation layer 21, an outer insulation layer 22, and a guide layer 23 located between the inner insulation layer 21 and the outer insulation layer 22, and the guide layer 23 includes a support frame 231 and a filler 232, the filler 232 can be omitted before vacuum pressure impregnation of the coil 1. This allows the insulating varnish to enter between the inner insulation layer 21 and the outer insulation layer 22 through the channel 2311 and be guided to the inner insulation layer 21 and the outer insulation layer 22 through the channel 2311 of the support frame 231, so that the insulating varnish can penetrate to the correct position. After impregnation is completed, the filler liquid is poured into the channel 2311 and solidified to form the filler 232, ensuring the strength and insulation effect of the protective body 20. This structure can be formed using the vacuum impregnation process and ensures that the varnish penetrates to the correct position, resulting in good insulation protection. This allows the coil 1 to meet the application requirements of higher voltage generators.

[0068] Furthermore, the inner insulation layer 21 and outer insulation layer 22 of this type of protective body 20 can be formed by vacuum impregnation process, which can improve production efficiency while meeting the insulation requirements of the formed coil 1, and help ensure the high voltage development requirements of the generator.

[0069] In some alternative embodiments, the support frame 231 of the coil 1 provided in this application embodiment can be a machined part or a drawn part; considering cost, a drawn part is preferred. The material can be selected based on heat resistance.

[0070] In some alternative embodiments, the support frame 231 of the coil 1 provided in this application embodiment can be either an integral structure or a split structure.

[0071] In some optional embodiments, the coil 1 provided in this application may include an inner support plate 2312, an outer support plate 2313, and a plurality of support bridges 2314 connected between the outer support plate 2313 and the inner support plate 2312, wherein the inner support plate 2312, the outer support plate 2313, and the support bridges 2314 enclose a channel 2311.

[0072] Both the inner support plate 2312 and the outer support plate 2313 can be a complete ring structure surrounding the conductor group 10. Of course, the inner support plate 2312 and the outer support plate 2313 can also be a ring structure formed by splicing multiple plate-shaped bodies.

[0073] The coil 1 provided in this embodiment adopts the above-described structure for its support frame 231. When supported between the inner insulation layer 21 and the outer insulation layer 22, the inner support plate 2312 is stacked with the inner insulation layer 21, and the outer support plate 2313 is stacked with the outer insulation layer 22. This ensures support for both the inner and outer insulation layers 21 and guarantees the formation of the channel 2311. During vacuum impregnation of the inner and outer insulation layers 21 and 22, the insulating varnish can enter through the channel 2311 and be guided to the inner insulation layer 21 through the inner support plate 2312, and to the outer insulation layer 22 through the outer support plate 2313. This ensures the penetration effect of the inner and outer insulation layers 21 and 22, and also provides a channel 2311 for the installation of the filler 232.

[0074] In some optional embodiments, the coil 1 provided in this application can have an inner support plate 2312 and an outer support plate 2313 that are both ring-shaped structures surrounding the conductor. Multiple support bridges 2314 are supported between the inner support plate 2312 and the outer support plate 2313 and are integrally formed with the inner support plate 2312 and the outer support plate 2313, that is, the support frame 231 can be an integrally formed structure.

[0075] The coil 1 provided in this embodiment ensures the overall strength of the support frame 231 by making it an integrally formed structure. Of course, this is an optional embodiment and is not limited to the above method.

[0076] like Figures 5 to 6As shown, the inner support plate 2312 may include a plurality of first plate units 2312a distributed around the conductor group 10, and the outer support plate 2313 may include a plurality of second plate units 2313a distributed around the conductor group 10. Each first plate unit 2312a is disposed opposite to one of the second plate units 2313a and is supported by a support bridge 2314 between them to form a support unit 231a.

[0077] The support frame 231 may include multiple support units 231a. For example, when the support frame 231 is in the form of a square structure, it may have four support units 231a, with two units per group, and the support units 231a in each group may be spaced apart and symmetrically arranged.

[0078] The coil 1 provided in this application embodiment, by adopting the form of multiple support units 231a for its support frame 231, facilitates installation between the inner insulation layer 21 and the outer insulation layer 22, and reduces installation difficulty.

[0079] like Figures 1 to 6 As shown, in some optional embodiments, the thickness d1 of the inner support plate 2312 of the coil 1 provided in this application embodiment ranges from 1.2mm to 1.5mm.

[0080] Optionally, the thickness of the inner support plate 2312 may refer to its thickness dimension in the radial arrangement direction relative to the outer support plate 2313.

[0081] The thickness of the inner support plate 2312 can be any value between 1.2mm and 1.5mm, including both 1.2mm and 1.5mm. It can be selected as 1.3mm to 1.5mm, and in some optional embodiments, 1.4mm, etc., can be used.

[0082] The coil 1 provided in this application embodiment allows the thickness of the inner support plate 2312 to be any value between 1.2mm and 1.5mm. This ensures the guiding effect of the varnish during the impregnation of the inner insulation layer 21 with insulating varnish, while also reducing the probability of deformation of the inner support plate 2312 or the filling liquid entering the inner insulation layer 21 when the filling liquid is injected into the channel 2311 to form the filling body 232.

[0083] In some optional embodiments, the thickness d2 of the outer support plate 2313 of the coil 1 provided in this application embodiment ranges from 1.2mm to 1.5mm.

[0084] Optionally, the thickness of the outer support plate 2313 may refer to its thickness dimension in the radial arrangement direction of the outer support plate 2313.

[0085] The thickness of the outer support plate 2313 can be any value between 1.2mm and 1.5mm, including both 1.2mm and 1.5mm. It can be selected as 1.3mm to 1.5mm, and in some optional embodiments, 1.4mm, etc., can be used.

[0086] The coil 1 provided in this application embodiment allows the thickness of the outer support plate 2313 to be any value between 1.2mm and 1.5mm. This not only ensures the guiding effect of the varnish during the impregnation of the outer insulation layer 22 with insulating varnish, but also reduces the probability of deformation of the outer support plate 2313 or the filling liquid entering the outer insulation layer 22 when the filling liquid is injected into the channel 2311 to form the filling body 232.

[0087] In one of the following optional embodiments, the coil 1 provided in this application embodiment has a through hole 2315 on the inner support plate 2312.

[0088] The through hole 2315 can be set through the inner support plate 2312 along the radial arrangement direction of the inner support plate 2312 and the outer support plate 2313.

[0089] The number of through holes 2315 on the inner support plate 2312 can be one or more. When there are more than two, the two or more through holes 2315 are distributed at intervals.

[0090] The coil 1 provided in this embodiment of the application has through holes 2315 on the inner support plate 2312, which helps to guide the insulating varnish liquid to the inner insulation layer 21 and the outer insulation layer 22 during the impregnation of insulating varnish, thus ensuring the penetration effect of the inner insulation layer 21.

[0091] In some optional embodiments, the coil 1 provided in this application embodiment has a through hole 2315 on the outer support plate 2313.

[0092] The through hole 2315 can be set through the outer support plate 2313 along the radial arrangement direction of the inner support plate 2312 and the outer support plate 2313.

[0093] The number of through holes 2315 on the outer support plate 2313 can be one or more. When there are more than two, the two or more through holes 2315 are distributed at intervals.

[0094] The coil 1 provided in this embodiment of the application has through holes 2315 on the outer support plate 2313, which helps to guide the insulating varnish to the outer insulation layer 22 during the impregnation of the inner insulation layer 21 and the outer insulation layer 22, thus ensuring the penetration effect of the insulating varnish to the outer insulation layer 22.

[0095] In some optional embodiments, the thickness d3 of the guide layer 23 of the coil 1 provided in this application embodiment ranges from 4mm to 6mm.

[0096] The thickness of the guide layer 23 can be any value between 4mm and 6mm, including both 4mm and 6mm. It can be selected from 4.5mm to 5.5mm, and in some optional embodiments, 5mm can be used.

[0097] The coil 1 provided in this embodiment ensures the dimensions of the channel 2311 by making the thickness of the guiding layer 23 range from 4mm to 6mm. This, in turn, ensures the guiding effect of the insulating varnish when the inner insulating layer 21 and the outer insulating layer 22 are immersed. Secondly, it facilitates the flow of the filling liquid and ensures the formation of the filling body 232 within the channel 2311.

[0098] In some optional embodiments, the coil 1 provided in this application embodiment includes a mica tape layer for the inner insulation layer 21 and the outer insulation layer 22.

[0099] For the mica tape layer, low-resin mica tape can be selected, as it has a higher mica content. Glass fiber reinforcement of low-resin mica tape is preferred due to the good wettability of glass fiber. A mica content of 180 g / m³ can be chosen. 2 The above measures improve the long-term durability of coil 1.

[0100] The coil 1 provided in this application embodiment, by including a mica tape layer in the inner insulation layer 21 and the outer insulation layer 22, can improve the overall insulation capability of the coil 1 by utilizing the characteristics of the mica tape.

[0101] In some optional embodiments, the thickness of the inner insulation layer 21 and the outer insulation layer 22 of the coil 1 provided in this application embodiment does not exceed 3 mm, and can be selected as 2 mm. When the coil 1 is used in the stator 101, a low-resistance strip / low-resistance coating can be provided on the outer insulation layer 22 near the stator support. The thickness of this part can be selected as 0.1 mm-0.2 mm to achieve good contact and uniform electric field.

[0102] In some alternative embodiments, the thermal conductivity of the coil 1 and the guiding layer 23 provided in the above embodiments of this application is greater than that of the inner insulation layer 21 and the outer insulation layer.

[0103] In existing technologies, the thickness of the main insulation is increased by using multi-adhesive molding in the motor, and then reasonable anti-corona treatment is applied to the ends. In principle, this can increase the voltage. However, the insulation system is too thick and has poor thermal conductivity, which means that the electrical density design of the motor conductor needs to be reduced again to reduce the heat generation of the conductor group 10. However, reducing the electrical density design is not conducive to the high voltage development of the coil 1.

[0104] Furthermore, as the voltage increases, the heat generated by conductor group 10 cannot be dissipated, leading to heat accumulation. In addition, the insulation material will be subjected to severe thermomechanical stress, and the heat dissipation is very slow. Even if high thermal conductivity mica tape is used as the raw material, the thermal conductivity of the insulation system after molding still needs to be improved, which affects the safety of coil 1 and the motor it is in.

[0105] The coil 1 provided in this embodiment has a thermal conductivity of the guiding layer 23 that is greater than that of the inner insulation layer 21 and the outer insulation layer 22. This allows the guiding layer 23 to not only guide the inner insulation layer 21 and the outer insulation layer 22 when they are impregnated with insulating varnish, but also to conduct heat, quickly dissipating heat from the conductor group 10 and other components, thus improving the safety performance of the coil 1.

[0106] In some optional embodiments, the coil 1 provided in this application has an average thermal conductivity of the guide layer 23 of not less than 0.6 W / (m·K). The thermal conductivity of mica tape is approximately 0.26 W / (m·K). By ensuring that the average thermal conductivity of the guide layer 23 is not less than 0.6 W / (m·K), its thermal conductivity is more than twice that of mica tape. Compared to a protective layer that is entirely composed of mica tape, the coil 1 provided in this application has stronger thermal conductivity, higher safety, and is more conducive to meeting the heat dissipation requirements of high-voltage motors.

[0107] In some optional embodiments, the thermal conductivity of the coil 1 and the support frame 231 provided in this application embodiment ranges from 0.5 W / (m·K) to 0.8 W / (m·K), and the thermal conductivity of the filler 232 ranges from 1 W / (m·K) to 1.5 W / (m·K).

[0108] The thermal conductivity of the support frame 231 can be any value between 0.5 W / (m·K) and 0.8 W / (m·K), including the two extreme values ​​of 0.5 W / (m·K) and 0.8 W / (m·K), and can be selected as 0.55 W / (m·K) to 0.75 W / (m·K). In some optional embodiments, 0.6 W / (m·K) and 0.7 W / (m·K) can be used.

[0109] The thermal conductivity of the filler 232 can be any value between 1 W / (m·K) and 1.5 W / (m·K), including the two extreme values ​​of 1 W / (m·K) and 1.5 W / (m·K), and can be selected as 1.1 W / (m·K) to 1.4 W / (m·K). In some optional examples, 1.2 W / (m·K) and 1.3 W / (m·K) can be used.

[0110] The coil 1 provided in this application embodiment ensures that the average thermal conductivity of the guide layer 23 is not less than 0.6 W / (m·K) by making the thermal conductivity of the support frame 231 range from 0.5 W / (m·K) to 0.8 W / (m·K) and the thermal conductivity of the filler 232 range from 1 W / (m·K) to 1.5 W / (m·K). This also facilitates the selection of materials for the support frame 231 and the filler 232, makes molding easier, and meets the functional requirements of the coil 1.

[0111] In some alternative embodiments, the coil 1 and support frame 231 provided in this application embodiment include at least one of unsaturated polyester resin, epoxy resin, modified epoxy resin, and benzoxazine.

[0112] The above settings help to ensure the required support strength and drainage.

[0113] In some alternative embodiments, the coil 1 provided in this application has a filler 232 comprising at least one of silicone, polyurethane resin, and epoxy resin.

[0114] The above-mentioned design facilitates bonding with the support frame 231 to form a unified structure. The strong adhesive force creates this integrated structure, which also possesses high toughness and good elongation. When used in a motor, it can expand and contract with the stator support and conductor assembly 10 due to thermal expansion and contraction, preventing cracking. It expands and contracts in sync with the thermal expansion and contraction of the core and conductors, ensuring a good fit and preventing cracking, thus guaranteeing the overall safety of the coil 1.

[0115] The coil 1 provided in the above embodiments of this application can be applied to a rod-shaped coil 1, and of course, it can also be applied to a coil-shaped coil 1.

[0116] like Figures 7 to 9 As shown, on the other hand, this application embodiment also provides a stator 101, including: a stator support 1011 and a coil 1 provided in the above embodiments. The stator support 1011 has a receiving groove 1011a, and the coil 1 is disposed in the receiving groove 1011a.

[0117] The stator support 1011 includes multiple receiving slots 1011a, which are spaced apart and evenly arranged on the circumferential Y direction of the stator support 1011. Each receiving slot 1011a can be equipped with a coil 1.

[0118] The stator 101 provided in this application embodiment includes the coil 1 provided in the above embodiments, which facilitates molding and can ensure the insulation strength requirements and improve safety performance.

[0119] In some optional embodiments, the stator 101 provided in this application includes a coil 1 comprising a straight section 1a and a bent section 1b. Both the straight section 1a and the bent section 1b are covered with an inner insulation layer 21. The inner insulation layer 21 of the straight section 1a is further covered with a guide layer 23 and an outer insulation layer 22 in sequence. The straight section 1a cooperates with and protrudes from the receiving groove 1011a. The bent section 1b is connected to the stator support 1011 through a potting body.

[0120] The stator 101 provided in this embodiment of the application includes a straight section 1a and a bent section 1b for the coil 1, which facilitates the engagement of the straight section 1a with the receiving groove 1011a of the stator support 1011. The inner insulating layer 21 provides insulation protection for both the straight section 1a and the bent section 1b. The inner insulating layer 21 of the straight section 1a is further covered by a guide layer 23 and an outer insulating layer 22, allowing the channel 2311 to be open along the length of the straight section 1a or along the axial direction of the stator support 1011, facilitating the entry of insulating varnish and fluid for molding the filler 232 into the channel 2311. Furthermore, the bent section 1b is connected to the stator support 1011 via a potting compound, ensuring the fixed position of the coil 1.

[0121] Optionally, the material of the infusion body can be the same as that of the filler 232, which ensures connection strength and good ductility, allowing it to deform with the deformation of the stator 101 without cracking. Furthermore, the infusion body and the filler 232 can be integrally molded, facilitating the molding of the stator.

[0122] In another aspect, the present application also provides a generator, including the coil 1 provided in the above embodiments or the stator 101 provided in the above embodiments. The generator may also include a rotor. The stator 101 and the rotor may be coaxially arranged and rotated together. It may be an outer rotor inner stator 101 generator, or of course, an outer stator 101 inner rotor generator.

[0123] The generator provided in this application embodiment, by including the coil 1 or stator 101 provided in the above embodiments, facilitates the generator's molding and provides good insulation. It also possesses a certain degree of thermal conductivity, which is beneficial for the high-voltage development of the generator.

[0124] like Figure 10As shown, in another aspect, this application embodiment also provides a wind turbine generator set, which includes the generator provided in the above embodiments, and may also include a tower 200, a nacelle 300 and an impeller 400. The nacelle 300 is disposed above the tower 200, and the generator may be located inside the nacelle 300 or outside the nacelle 300. The hub of the impeller 400 is directly or indirectly connected to the rotor of the generator. When wind energy acts on the impeller 400, it drives the impeller 400 to rotate, and then drives the rotor of the generator to rotate relative to the stator 101 through the impeller 400, thereby realizing the conversion of wind energy into electrical energy.

[0125] Because the wind turbine generator set provided in this application includes the generators provided in the above embodiments, the structure of coil 1 allows the generator to be manufactured as a high-voltage generator. This allows the generator to be directly connected to the substation of the wind farm after generating electricity, thus eliminating the need for a transformer in each wind turbine generator set. The transformer's capacity is comparable to the wind turbine's capacity, and it is expensive. If the generator can be directly connected to the wind farm substation, the transformer component can be saved. Furthermore, the low / medium voltage high-current cables between the generator and the transformer can be saved. These cables typically have large cross-sections, and with so many outgoing cables, they would be both expensive and space-consuming. Therefore, the wind turbine generator set provided in this application has advantages such as high cost and high power generation efficiency.

[0126] like Figure 11 As shown, on the other hand, this application also provides a method for forming coil 1, which can be used to form coil 1 provided in the above embodiments. The forming method includes:

[0127] S11. Provide a conductor group 10, which includes at least one conductive unit 11.

[0128] S12. An inner insulation layer 21, a support frame 231, and an outer insulation layer 22 are sequentially arranged around the outside of the conductor group 10 to form a primary coil module. The support frame 231 has a channel 2311 extending along the length of the conductor group 10.

[0129] S13. Immerse the primary coil module in a liquid and cure it, the liquid including insulating varnish.

[0130] S14. A first fluid is injected into the primary coil module, which is cured with insulating varnish, and then cured to form a filler 232 located in the channel 2311. The thermal conductivity of the entire structure formed by the support frame 231 and the filler 232 is greater than that of the inner insulation layer 21 and the outer insulation layer 22.

[0131] In step S11, the conductive unit 11 included in the provided conductor group 10 can be one or more conductive units 11. When there are two or more conductive units 11, they can be insulated from each other. Specifically, each conductive unit 11 can have an insulating film layer on its exterior. When the number of conductive units 11 is two or more, the two or more conductive units 11 can be stacked on top of each other.

[0132] In step S12, if the formed coil is a rod-shaped coil, the inner insulation layer 21, the support frame 231, and the outer insulation layer 22 can cover the outer periphery of the conductor group 10 in its own length direction or axial direction. When the formed coil is a loop-shaped coil 1, only the inner insulation layer 21 covers the straight part and the end of the coil 1, and the support frame 231 and the outer insulation layer 22 cover the straight part of the coil 1, but do not need to cover its end part.

[0133] In step S13, the immersion liquid may include insulating varnish, the heat resistance grade of which is generally selected according to the design. The vacuum degree, immersion time, and pressure value of the immersion liquid can be adjusted according to the intrinsic properties of different types of insulating varnish.

[0134] In step S14, the components of the first fluid include, but are not limited to, at least one of organosilicon, polyurethane resin, and epoxy resin.

[0135] The coil 1 forming method provided in this application embodiment, by setting a support frame 231 between the inner insulation layer 21 and the outer insulation layer 22, and first immersing in insulating varnish, facilitates the insulating varnish liquid to enter between the inner insulation layer 21 and the outer insulation layer 22 through the channel 2311 and be guided to the inner insulation layer 21 and the outer insulation layer 22 through the support frame 231, so that the insulating varnish liquid can penetrate to the appropriate position. After the varnish is impregnated, a first fluid is injected into the channel 2311 and solidified to form a filler 232, which increases the thickness of the protective body 20 of the coil 1. Moreover, this structure can be formed by vacuum impregnation process, ensuring that the varnish liquid penetrates to the appropriate position, and has a good insulation protection effect, so that the coil 1 can meet the application requirements of motors with higher voltage levels.

[0136] like Figure 12 As shown, in another aspect, this application also provides a method for forming a stator 101, including:

[0137] S21. Provide a conductor group 10, which includes at least one conductive unit 11.

[0138] S22. An inner insulation layer 21, a support frame 231, and an outer insulation layer 22 are sequentially arranged around the conductor group 10 to form a primary coil module. The support frame 231 has a channel 2311 extending along the length of the conductor group 10.

[0139] S23. A stator support 1011 is provided, the stator support 1011 having a plurality of receiving slots 1011a, in which a primary coil module is embedded.

[0140] S24. Immerse the stator support 1011 and the primary coil module into a liquid and cure it, the liquid including insulating varnish.

[0141] S25. The stator support 1011 and primary coil 1 module, which are impregnated with insulating varnish, are filled with a first fluid and solidified to form a filler 232 located in the channel 2311. The thermal conductivity of the whole formed by the support 231 and the filler 232 is greater than that of the inner insulation layer 21 and the outer insulation layer 22.

[0142] In step S21, the conductor group 10 may include one or more conductive units 11. When there are two or more conductive units 11, they may be insulated from each other. Specifically, each conductive unit 11 may have an insulating film layer on its exterior. When there are two or more conductive units 11, they may be stacked on top of each other.

[0143] In step S22, if the formed primary coil module corresponds to a rod-shaped coil, the inner insulating layer 21, the support frame 231, and the outer insulating layer 22 can cover the outer periphery of the conductor group 10 in its own length direction or axial direction. If the formed primary coil module corresponds to a coil, only the inner insulating layer 21 covers the straight portion and ends of the entire conductor group 10, while the support frame 231 and the outer insulating layer 22 cover the straight portion of the coil 1, but do not need to cover its end portion.

[0144] In step S23, the multiple receiving slots 1011a of the stator support 1011 can be spaced apart and evenly arranged in its circumferential Y direction, and a primary coil module is provided in each receiving slot 1011a.

[0145] In step S24, the immersion liquid may include insulating varnish, the heat resistance grade of which is generally selected according to the design. The vacuum degree, impregnation time, and pressure value of the immersion liquid can be adjusted according to the intrinsic properties of different types of insulating varnish.

[0146] Step S25 may specifically include: placing the stator support 1011 impregnated with insulating varnish and the primary coil 1 module in reverse and upright, then injecting a first fluid, so that the first fluid first fills the gap between the end of the coil 1 located in the lower vertical direction and the stator support 1011, and then gradually rises into the channel 2311, filling the channel 2311 and continuing to rise and fill the gap between the end of the coil 1 and the stator support 1011 in the upper part, and solidifying to form an infusion body and a filling body 232.

[0147] The stator 101 forming method provided in this application embodiment can be used for the stator 101 provided in the above embodiments. This forming method, by setting a support frame 231 between the inner insulation layer 21 and the outer insulation layer 22, and first immersing in insulating varnish, facilitates the varnish liquid to enter between the inner insulation layer 21 and the outer insulation layer 22 through the channel 2311 and be guided to the inner insulation layer 21 and the outer insulation layer 22 through the support frame 231, so that the insulating varnish liquid can penetrate to the correct position. After the varnish is impregnated, a first fluid is injected into the channel 2311 and solidified to form a filler 232, which increases the thickness of the protective body 20 of the coil 1. Moreover, this structure can be formed by vacuum impregnation process, ensuring that the varnish liquid penetrates to the correct position, and has a good insulation protection effect, so that the coil 1 can meet the application requirements of higher voltage generators.

[0148] Although the invention has been described with reference to preferred embodiments, various modifications can be made and components can be replaced with equivalents without departing from the scope of the invention. In particular, the technical features mentioned in the various embodiments can be combined in any manner as long as there is no structural conflict. The invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A coil, characterized in that, include: A conductor assembly, comprising at least one conductive unit; A protective body, at least partially covering the conductor group, the protective body including an inner insulating layer, an outer insulating layer, and a guiding layer located between the inner insulating layer and the outer insulating layer, the inner insulating layer being located between the conductor group and the guiding layer; The guiding layer includes a support frame and a filler. The support frame is disposed between the inner insulation layer and the outer insulation layer and has a channel extending along the length of the conductor group. The channel is used to guide the insulating varnish into the inner insulation layer and the outer insulation layer along the length of the conductor group during the vacuum pressure impregnation process. The filler is filled in the channel.

2. The coil according to claim 1, characterized in that, The support frame includes an inner support plate, an outer support plate, and a plurality of support bridges connecting the outer support plate and the inner support plate. The inner support plate, the outer support plate, and the support bridges enclose the channel.

3. The coil according to claim 2, characterized in that, The inner support plate, the outer support plate, and the support bridge are an integral structure.

4. The coil according to claim 2, characterized in that, The inner support plate includes a plurality of first plate units distributed around the conductor group, and the outer support plate includes a plurality of second plate units distributed around the conductor group. Each first plate unit is disposed opposite to one of the second plate units and is supported by at least one of the support bridges between them to form a support unit.

5. The coil according to claim 4, characterized in that, The support unit is an integral structure.

6. The coil according to claim 2, characterized in that, The thickness of the inner support plate is in the range of 1.2mm to 1.5mm, and / or the thickness of the outer support plate is in the range of 1.2mm to 1.5mm.

7. The coil according to claim 2, characterized in that, The inner support plate is provided with through holes, and / or the outer support plate is provided with through holes.

8. The coil according to claim 1, characterized in that, The thickness of the guide layer ranges from 4mm to 6mm.

9. The coil according to claim 1, characterized in that, The inner insulation layer and the outer insulation layer each include a mica tape layer.

10. The coil according to claim 1, characterized in that, The thermal conductivity of the guiding layer is greater than that of the inner insulating layer and the outer insulating layer.

11. The coil according to claim 1, characterized in that, The average thermal conductivity of the guiding layer is not less than 0.6 W / (m•K).

12. The coil according to claim 11, characterized in that, The thermal conductivity of the support frame ranges from 0.5 W / (m•K) to 0.8 W / (m•K), and the thermal conductivity of the filler ranges from 1 W / (m•K) to 1.5 W / (m•K).

13. The coil according to claim 1, characterized in that, The support frame comprises at least one of unsaturated polyester resin, epoxy resin, and benzoxazine. And / or, the filler comprises at least one of silicone, polyurethane resin and epoxy resin.

14. A method for forming a coil, characterized in that, include: A conductor assembly is provided, the conductor assembly comprising at least one conductive unit; A primary coil module is formed by sequentially surrounding an inner insulating layer, a support frame, and an outer insulating layer on the outside of the conductor group. The support frame has a channel extending along the length of the conductor group. The primary coil module is immersed in a liquid and cured, the liquid including insulating varnish, and the channel is used to guide the insulating varnish liquid into the inner insulation layer and the outer insulation layer along the length of the conductor group during the vacuum pressure impregnation process; A first fluid is injected into the primary coil module, which is cured with insulating varnish, and then cured to form a filler located within the channel, wherein the thermal conductivity of the support frame and the filler as a whole is greater than the thermal conductivity of the inner insulation layer and the outer insulation layer.

15. A stator, characterized in that, include: Stator support with receiving groove; The coil as described in any one of claims 1 to 13, wherein the coil is disposed in the receiving groove.

16. The stator according to claim 15, characterized in that, The coil includes a straight section and a bent section, both of which are covered with the inner insulation layer. The inner insulation layer of the straight section is further covered with the guide layer and the outer insulation layer in sequence. The straight section mates with the receiving groove and protrudes from the receiving groove. The bent section is connected to the stator support through a potting body.

17. A method for forming a stator, characterized in that, include: A conductor assembly is provided, the conductor assembly comprising at least one conductive unit; An inner insulating layer, a support frame, and an outer insulating layer are sequentially arranged around the conductor group to form a primary coil module. The support frame has a channel extending along the length of the conductor group. A stator support is provided, the stator support having a plurality of receiving slots, in which the primary coil module is embedded; The stator support and the primary coil module are immersed in a liquid and cured. The liquid includes insulating varnish. The channel is used to guide the insulating varnish liquid into the inner insulation layer and the outer insulation layer along the length of the conductor group during the vacuum pressure impregnation process. The stator support and primary coil module, which are impregnated with the insulating varnish, are filled with a first fluid and cured to form a filler located in the channel, wherein the thermal conductivity of the support and the filler as a whole is greater than that of the inner insulation layer and the outer insulation layer.

18. A generator, characterized in that, It includes the coil as described in any one of claims 1 to 13, or the stator as described in claim 15 or 16.

19. A wind turbine generator set, characterized in that, Includes the generator as described in claim 18.

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