An electrical penetration part and its design method, a high temperature resistant coil and its manufacturing method
Through the mechanical seal design and finite element analysis and optimization of electrical penetration, the problem of difficult to guarantee the sealing performance of high-temperature coils is solved, and effective sealing and heat resistance assessment in an environment above 450°C are achieved.
Patent Information
- Application Number
- CN202411346138.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-26
- Publication Date
- 2024-12-10
- Estimated Expiration
- 2044-09-26
AI Technical Summary
The prior art cannot effectively seal the coil in a high temperature environment above 450°C, resulting in coil failure, and conventional sealing methods cannot withstand long-term impacts from high temperature and high humidity environments.
The electrical through-piece design is adopted, including end plates, connectors, insulated isolation parts, annular limiting parts and seals. Mechanical sealing is achieved through locking mechanisms and elastic parts, and the gap fit is optimized in combination with finite element analysis to ensure sealing performance.
The coil is effectively sealed under high temperature conditions, avoiding seal failure between the lead wire and the end plate of the coil frame, and ensuring the heat resistance and electrical performance of the coil.
Smart Images
Figure CN118866527B_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the field of electromechanical product manufacturing, in particular to an electrical penetration component and a design method thereof, a high temperature resistant coil and a manufacturing method thereof. Background Art
[0002] A single-winding or multi-winding coil is composed of a coil frame 2, an outer cylinder 22, a winding wire 3, a lead wire 5, a filler 4, etc. (such as Figure 1 ), the lead wire is a structure of twisted wire of multiple nickel-plated round copper wires with an additional insulation layer and silicone impregnation varnish packaging. The way to assemble it in the coil is to directly pass through the wire threading hole of the skeleton end plate and fill and seal it with sealant 6 (such as resin, silicone rubber and other organic materials). This sealing method is feasible for the temperature resistance level requirement of about 230℃.
[0003] However, the design of high-temperature resistant single-winding or multi-winding coils requires a temperature resistance level of not less than 450°C. When the temperature resistance level is increased to above 450°C, during use, due to the decomposition and volatilization of organic materials, environmental moisture will pass through the twisted wire gaps inside the lead wire, and the sealing solution will fail, resulting in failure of the seal between the lead wire and the coil skeleton end plate, and moisture inside the coil, resulting in coil failure. Other conventional mechanical seals, organic paint filling seals, rubber ring seals, etc. cannot withstand the long-term impact of high temperatures above 450°C and 98% humidity environments.
[0004] Therefore, the sealing performance between the lead wire and the coil frame end plate determines the electrical performance of the coil and also determines whether the heat resistance assessment is qualified, which has always been a key factor in the development of such products. Summary of the invention
[0005] The purpose of the present invention is to provide an electrical penetration and a design method thereof, a high-temperature resistant coil and a manufacturing method thereof in response to the above-mentioned problems, aiming to solve the problems of connection between the lead wires of the high-temperature resistant coil and the winding wires, high temperature resistance, and sealing, as well as the technical difficulty that the sealing performance of the lead wires is extremely difficult to ensure or even impossible to ensure when the coils are subjected to high and low temperature thermal shocks during aging tests and working operation.
[0006] The technical solution adopted by the present invention is as follows: an electrical penetration component, including an end plate and a connecting piece, the end plate is provided with a through hole, the two ends of the connecting piece are respectively a locking end and a sealing end, the sealing end is located inside the through hole, and the locking end is located outside the through hole; a first insulating isolation piece is sleeved on the connecting piece, and radially extending annular limit plates are provided on the hole wall of the through hole, the sealing end and the first insulating isolation piece, a sealing piece is provided between adjacent annular limit plates, and the annular limit plate on the first insulating isolation piece is located between the other two annular limit plates; a locking mechanism for locking the three annular limit plates together is provided at the locking end, and a second insulating isolation piece is provided between the locking mechanism and the end plate.
[0007] Furthermore, the locking mechanism includes an external thread arranged on the locking end, a locking nut is connected to the external thread, and the second insulating spacer is located between the locking nut and the end plate.
[0008] Furthermore, an elastic member is provided between the locking nut and the second insulating spacer.
[0009] Furthermore, a gasket is provided between the elastic member and the locking nut.
[0010] Furthermore, the connecting member, the first insulating spacer, the second insulating spacer, the elastic member, the gasket and the through hole are coaxially assembled and are clearance-matched in the radial direction.
[0011] A method for designing an electrical penetration is used to design the electrical penetration and determine the fit clearance of a clearance fit, comprising the following steps:
[0012] A1: Create a 3D model and use modeling software to create a model of the electrical penetration;
[0013] A2: Material property input: according to the materials used in each component of the electrical penetration, input the material properties into each component in the model in the modeling software;
[0014] A3: Thermal stress analysis: use finite element analysis software to perform thermal stress analysis on the model;
[0015] A4: Gap optimization. Based on the results of the finite element analysis software, observe the expansion of each component in the model at different temperatures and the resulting stress distribution; adjust the fit clearance between the components in the model, and repeat steps A1-A3 until the best fit clearance with the most uniform stress distribution and the smallest stress concentration is found.
[0016] A high temperature resistant coil comprises a coil frame with a winding cavity and the electrical penetration member, wherein the end plate closes the winding cavity; a winding wire is arranged in the winding cavity, and the winding cavity is filled with filler; and the winding wire is connected to the sealed end.
[0017] Furthermore, the coil frame includes a winding core and an outer cylinder, the winding wire is wound on the winding core, the winding core and the outer cylinder are arranged coaxially and the winding core is located inside the outer cylinder; a sealing plate is fixedly and sealedly connected between the outer cylinder and the winding core; the sealing plate, the winding core and the outer cylinder form a winding cavity.
[0018] A method for manufacturing a high temperature resistant coil, comprising the following steps:
[0019] B1: Assemble electrical penetrations and assemble coil skeletons;
[0020] B2: Wind the winding wire on the winding core;
[0021] B3: Fill the winding cavity with filler material, and after sintering and solidification, fix the lead-out end of the winding wire to the sealed end of the connector;
[0022] B4: The end plate closes the winding cavity and is sealed and fixed.
[0023] Furthermore, the sealing and fixing method is welding.
[0024] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:
[0025] The present invention optimizes the lead-out method of the lead wires and adopts the electrical penetration piece of the present invention. The electrical penetration piece is a mechanical sealing method to achieve the connection between the winding wire inside the coil and the external lead wire, avoiding the problem that the gap between the lead wire strands cannot be sealed under high temperature conditions (not less than 450°C); it solves the problems of connection, high temperature resistance and sealing of the lead wires of the high-temperature resistant coil and the winding wires, as well as the technical difficulty that the sealing performance of the lead wire is extremely difficult to ensure or even cannot be ensured when the coil is subjected to high and low temperature thermal shock during aging tests and working operation. BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The present invention will now be described by way of example with reference to the accompanying drawings, in which:
[0027] Figure 1 is a schematic diagram of the existing structure of the coil;
[0028] Figure 2 It is a schematic diagram of the structure of the electrical penetration member disclosed in the present invention;
[0029] Figure 3 It is a structural schematic diagram of the high temperature resistant coil disclosed in the present invention;
[0030] Markings in the figure: 1-electrical penetration piece; 11-connector; 111-locking end; 112-sealing end; 113-annular limiting plate b; 12-end plate; 121-through hole; 122-annular limiting plate a; 13-sealing piece; 14-first insulating spacer; 141-annular limiting plate c; 15-second insulating spacer; 16-elastic piece; 17-gasket; 18-locking nut; 2-coil skeleton; 21-winding core; 22-outer cylinder; 23-sealing plate; 3-winding wire; 4-filling material; 5-lead wire; 6-sealant. DETAILED DESCRIPTION
[0031] In the description of this specification, it should be noted that if the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc. appear, the orientation or position relationship indicated is based on the orientation or position relationship shown in the drawings, or is the orientation or position relationship in which the product of this specification is usually placed when used. It is only for the convenience of describing this specification and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this specification.
[0032] In addition, if the terms "horizontal" or "vertical" appear in the description of this specification, it does not mean that the components are required to be absolutely horizontal or suspended, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but can be slightly tilted.
[0033] In the description of this specification, it should also be noted that, unless otherwise clearly stipulated and limited, the terms "set", "installed", "connected" and "connected" should be understood in a broad sense. For example, the connection can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be a connection between the internal parts of two elements.
[0034] Example 1
[0035] like Figure 2-Figure 3As shown, an electrical penetration piece includes an end plate 12 and a lead piece 11, wherein a through hole 121 is formed on the end plate 12, and two ends of the lead piece 11 are respectively a locking end 111 and a sealing end 112, wherein the lead piece 11 passes through the through hole 121 and the sealing end 112 is located inside the through hole 121, and the locking end 111 is located outside the through hole 121; a first insulating spacer 14 is sleeved on the lead piece 11, and the first insulating spacer 14 is made of an insulating material, and is located between the locking end 111 and the sealing end 112. The end 112 is between the guide member 11 and the inner wall of the through hole 121 to prevent the guide member 11 from contacting the inner wall of the through hole 121, to prevent the end plate 12 from being charged, and thus to prevent the coil skeleton 2 of the coil from being charged; the hole wall of the through hole 121, the sealing end 112 and the first insulating isolation member 14 are all provided with a radially extending annular limiting plate, that is, the inner wall of the through hole 121 is coaxially sealed and welded with an annular limiting plate a122, and the sealing end 112 is also provided with an annular limiting plate b113, so that the sealing end 112 is a "cross" shaped structure, the first insulating spacer 14 has an annular limiting plate c141, so that the structure of the first insulating spacer 14 is a "T" shape; from the outside of the through hole 121 to the inside of the through hole 121 (from the outside of the coil to the inside of the coil), the annular limiting plate a122, the annular limiting plate c141, and the annular limiting plate b113 are arranged in sequence, and the annular limiting plate a122 and the annular limiting plate c141, the annular limiting plate c141 and the annular limiting plate a122 and the annular limiting plate c141 are arranged in sequence. A seal 13 is arranged between the annular limit plate b113, and the seal 13 is one or more of an O-ring and a sealing flat gasket; the seal 13 between the annular limit plate a122 and the annular limit plate c141 can seal the gap between the first insulating isolation piece 14 and the through hole 121; the seal 13 between the annular limit plate c141 and the annular limit plate b113 can seal the gap between the first insulating isolation piece and the guide piece 11.
[0036] In this embodiment, a locking mechanism is provided at the locking end 111, which can pull the connecting member 11 and the first insulating isolation member out of the hole 121, so that the annular limiting plate b113 squeezes the annular limiting plate c141, and the annular limiting plate squeezes the annular limiting plate a122, so that the sealing member 13 is compressed to ensure the sealing effect.
[0037] In this embodiment, a second insulating spacer 15 is arranged between the locking mechanism and the end plate 12. The second insulating spacer 15 is made of insulating material to isolate the locking mechanism from the end plate 12, preventing the connecting member 11 from causing the end plate 12 to be charged through the locking mechanism, thereby preventing the coil frame 2 of the coil from being charged.
[0038] It should be noted that there is an annular limiting plate c141 between the annular limiting plate a122 and the annular limiting plate b113, and the annular limiting plate c141 is actually a part of the first insulating isolation member, so there will be no electricity between the annular limiting plate a122 and the annular limiting plate b113.
[0039] It should be noted that the connector 11 is a transition piece that connects the winding wire 3 inside the coil and the external lead wire 5. Its material is preferably a high-temperature alloy rod, the resistivity of which is close to that of copper, which not only improves the temperature resistance of the electrical penetration piece 1, but also ensures the overall resistance value of the coil.
[0040] In summary, multiple sealing members 13 are added between the connector 11 and the end plate 12, which cooperate with the locking mechanism to effectively ensure the sealing performance of the electrical penetration member 1 at high temperature, thereby preventing the coil from getting damp; the first insulating isolation member 14 and the second insulating isolation member 15 can effectively prevent electricity from being passed between the connector 11 and the end plate 12.
[0041] Example 2
[0042] Based on Example 1, a specific implementation method of the "locking mechanism" is further proposed.
[0043] It can be known from Example 1 that the purpose of the locking mechanism is to provide pressure for the seal 13 so that the seal 13 remains in a compressed state; therefore, the locking mechanism only needs to be able to provide tension, such as a force-applying device in conjunction with a pull rope; of course, a simpler structure is the following structure.
[0044] The locking mechanism includes an external thread arranged on the locking end 111, and a locking nut 18 is connected to the external thread. The second insulating isolation member 15 is located between the locking nut 18 and the end plate 12. The second insulating isolation member 15 isolates the end plate 12 and the locking nut 18, restricts the locking nut 18, so that the locking nut 18 has a tendency to move out of the through hole 121 with the guide member 11, and further realizes that the seal 13 is tightened; in fact, the pre-tightening force between the locking nut 18 and the external thread is the pressure exerted on the seal 13.
[0045] Furthermore, it can be known from the above that the pre-tightening force between the locking nut 18 and the external thread is the pressure exerted on the seal 13. In order to increase the pressure and maintain the pressure for a long time, an elastic member 16 can be arranged between the locking nut 18 and the second insulating isolation member 15. Through the squeezing of the elastic member 16 by the locking nut 18, the elastic member 16 is deformed with elastic potential energy, thereby achieving the purpose of increasing the pre-tightening force between the locking nut 18 and the external thread and achieving the purpose of maintaining the pre-tightening force for a long time.
[0046] Preferably, the elastic member 16 is a disc spring or an elastic washer.
[0047] Furthermore, a gasket 17 is provided between the elastic member 16 and the locking nut 18 , and the gasket 17 isolates the locking nut 18 from the elastic member 16 , so as to prevent the locking nut 18 from damaging the elastic member 16 when being screwed and locked.
[0048] Example 3
[0049] Based on Example 2, a feasible specific implementation method is further proposed.
[0050] As can be seen from the above, the connecting member 11, the first insulating isolator 14, the second insulating isolator 15, the elastic member 16, the gasket 17 and the through hole 121 and other components are coaxially assembled, so these components are preferably clearance-fitted in the radial direction; for the convenience of explanation, taking the connecting member 11 and the first insulating isolator 14 as an example, there is a dimensional clearance fit tolerance between the outer diameter of the position where the first insulating isolator 14 is assembled on the connecting member 11 and the inner diameter of the first insulating isolator 14; the clearance fit tolerance provides space for the connecting member 11, the first insulating isolator 14, the second insulating isolator 15, the elastic member 16, the gasket 17 and the through hole 121 and other components to expand due to heat, thereby avoiding damage to the components due to obstruction of thermal expansion between the components, thereby affecting the sealing performance.
[0051] Example 4
[0052] A method for designing an electrical penetration 1, used for designing the electrical penetration 1 described in Embodiment 3, determining a fit clearance of a clearance fit, comprises the following steps:
[0053] A1: Establish a three-dimensional model and use modeling software to establish a model of the electrical penetration member 1, including models of components such as the connector 11, the first insulating spacer 14, the second insulating spacer 15, the elastic member 16, the gasket 17 and the through hole 121; the modeling software may be CAD or CAE software.
[0054] A2: Material property input. According to the materials used for each component in the electrical penetration 1, the material properties are input into each component in the model in the modeling software. The material properties include the thermal expansion coefficient, elastic modulus, thermal conductivity and other physical parameters of the material.
[0055] A3: Thermal stress analysis: Use finite element analysis software to perform thermal stress analysis on the model. Specifically, by setting different boundary conditions and initial temperatures in the finite element analysis software, simulate the temperature changes under different working conditions, and calculate the thermal stress and strain generated by each component.
[0056] A4: Gap optimization. Based on the results of the finite element analysis software, observe the expansion of each component in the model at different temperatures and the resulting stress distribution; adjust the fit clearance between the components in the model, and repeat steps A1-A3 until the best fit clearance with the most uniform stress distribution and the smallest stress concentration is found.
[0057] Example 5
[0058] A high temperature resistant coil comprises a coil frame 2 having a winding cavity and an electrical penetration piece 1 as described in any one of the embodiments 1-3, wherein an end plate 12 is sealed and welded to the winding cavity so that the end plate 12 closes the winding cavity; a winding wire 3 is arranged in the winding cavity, and a filler 4 is filled in the winding cavity; the winding wire 3 is connected to a sealed end 112 so that electricity is supplied to the winding wire 3 through a connector 11.
[0059] In this embodiment, the filler 4 is an inorganic filler 4, which plays a filling and solidifying role to ensure that the overall structure of the coil is firm and reliable.
[0060] In this embodiment, the electrical penetration 1 is a mechanical sealing method, which realizes the connection between the winding wire 3 inside the coil and the external lead wire 5, avoiding the problem that the gap between the strands of the lead wire 5 cannot be sealed under high temperature conditions (not less than 450°C); it solves the problems of connection, high temperature resistance and sealing between the high-temperature resistant coil lead wire 5 and the winding wire 3, as well as the technical difficulty that the sealing performance of the lead wire is extremely difficult to ensure or even impossible to ensure when the coil is subjected to high and low temperature thermal shock during aging tests and working operation.
[0061] In this embodiment, the coil skeleton 2 includes a winding core 21 and an outer cylinder 22, the winding wire 3 is wound on the winding core 21, the winding core 21 and the outer cylinder 22 are coaxially arranged and the winding core 21 is located inside the outer cylinder 22; a sealing plate 23 is fixedly and sealedly connected between the outer cylinder 22 and the winding core 21, that is, the sealing plate 23 is seal-welded to the winding core 21, and the sealing plate 23 is seal-welded to the outer cylinder 22; the sealing plate 23, the winding core 21 and the outer cylinder 22 form a winding cavity.
[0062] Example 6
[0063] A method for manufacturing a high temperature resistant coil, manufacturing the high temperature resistant coil described in Example 5, comprising the following steps:
[0064] B1: Assembling electrical penetration 1 and assembling coil frame 2;
[0065] B2: Winding the winding wire 3 on the winding core 21;
[0066] B3: Filling the filling material 4 into the winding cavity, and after sintering and solidification, fixing the lead-out end of the winding wire 3 to the sealing end 112 of the lead-in member 11;
[0067] B4: The end plate 12 closes the winding cavity and is sealed and fixed.
[0068] Furthermore, the sealing and fixing method is welding, and the welding method adopts a welding method with a smaller heat-affected zone, such as self-contained welding, laser welding, Kovar alloy welding, etc.
[0069] The present invention is not limited to the above-mentioned specific embodiments, but extends to any new features or any new combination disclosed in this specification, as well as any new method or process steps or any new combination disclosed.
Claims
1. An electrical penetration, characterized in that: The invention comprises an end plate (12) and a guide member (11), wherein a through hole (121) is formed on the end plate (12), and two ends of the guide member (11) are respectively a locking end (111) and a sealing end (112), wherein the sealing end (112) is located inside the through hole (121), and the locking end (111) is located outside the through hole (121); a first insulating spacer (14) is sleeved on the guide member (11), and radially extending annular limiting plates are provided on the hole wall of the through hole (121), the sealing end (112) and the first insulating spacer (14), wherein a sealing member (13) is provided between adjacent annular limiting plates, and the annular limiting plate on the first insulating spacer (14) is located between the other two annular limiting plates; a sealing member (13) is provided at the locking end (111) for locking the three annular limiting plates. A locking mechanism for locking the plates together, wherein a second insulating spacer (15) is arranged between the locking mechanism and the end plate (12); the locking mechanism comprises an external thread arranged on the locking end (111), a locking nut (18) is connected to the external thread, and the second insulating spacer (15) is located between the locking nut (18) and the end plate (12); an elastic member (16) is arranged between the locking nut (18) and the second insulating spacer (15); a gasket (17) is arranged between the elastic member (16) and the locking nut (18); the guide member (11), the first insulating spacer (14), the second insulating spacer (15), the elastic member (16), the gasket (17) and the through hole (121) are coaxially assembled and clearance-matched in the radial direction.
2. A method for designing an electrical penetration, used for designing the electrical penetration according to claim 1, and determining the fit clearance of a clearance fit, characterized in that: The following steps are involved: A1: Create a three-dimensional model and use modeling software to create a model of the electrical penetration (1); A2: Input material properties. According to the materials used for each component in the electrical penetration (1), input material properties into each component in the model in the modeling software. A3: Thermal stress analysis: use finite element analysis software to perform thermal stress analysis on the model; A4: Gap optimization. Based on the results of the finite element analysis software, observe the expansion of each component in the model at different temperatures and the resulting stress distribution; adjust the fit clearance between the components in the model, and repeat steps A1-A3 until the best fit clearance with the most uniform stress distribution and the smallest stress concentration is found.
3. A high temperature resistant coil, characterized in that: The invention comprises a coil frame (2) having a winding cavity and the electrical penetration member as claimed in claim 1, wherein the end plate (12) closes the winding cavity; a winding wire (3) is arranged in the winding cavity, and the winding cavity is filled with a filling material (4); and the winding wire (3) is connected to a sealed end (112).
4. The high temperature resistant coil according to claim 3, characterized in that: The coil frame (2) comprises a winding core (21) and an outer cylinder (22), a winding wire (3) is wound on the winding core (21), the winding core (21) and the outer cylinder (22) are coaxially arranged and the winding core (21) is located inside the outer cylinder (22); a sealing plate (23) is fixedly and hermetically connected between the outer cylinder (22) and the winding core (21); and the sealing plate (23), the winding core (21) and the outer cylinder (22) form a winding cavity.
5. A method for manufacturing a high temperature resistant coil, characterized in that: The manufacturing method of the high temperature resistant coil according to claim 4 comprises the following steps: B1: Assembling electrical penetrations (1) and assembling coil bobbins (2); B2: Winding the winding wire (3) onto the winding core (21); B3: Filling the filling material (4) into the winding cavity, and after sintering and solidification, fixing the lead-out end of the winding wire (3) to the sealed end (112) of the connector (11); B4: The end plate (12) closes the winding cavity and is sealed and fixed.
6. The manufacturing method according to claim 5, characterized in that: The sealing and fixing method is welding.