Alpha coil insulation wrapping and sealing method

Abstract

The present invention discloses an Alpha coil insulation wrapping and sealing method, comprising the following steps: S1. Winding electromagnetic wire with a polyimide composite film and then sintering; S2. Half-wrapping all the series wires and lead wires in the Alpha coil with the composite film, insulating and wrapping them, and then binding and securing them; S3. Wrapping all Alpha coil cakes with a single layer of the composite film; S4. Starting the second layer of insulation wrapping at the external lead wires of the Alpha coil, the composite film is continuously wrapped around the coil cakes and series wires; S5. Placing the Alpha coil in an oven for sintering; S6. Applying third and fourth layers of insulation wrapping to the Alpha coil; S7. Placing the entire Alpha coil in an oven for sintering, and immersing the coil in insulating oil after insulation wrapping. This method simplifies the stator insulation process and improves the insulation and sealing properties of the Alpha coil.

Description

Technical Field

[0001] The present invention relates to the technical field of motor coils, and in particular to an alpha coil insulation wrapping and sealing method. Background Art

[0002] Submersible motors for oil production feature simple structure, energy conservation, environmental protection, and online control. They are suitable for production in horizontal, directional, and low-permeability wells. Due to wellhead limitations, submersible motors are typically designed with a slender structure to achieve sufficient torque. Therefore, the magnetic flux of the stator winding directly determines the motor's lifting force. Submersible pump motors mostly use a loose-wound structure. The electromagnetic wire, coated with a varnish for insulation, is embedded or threaded into the core slots. The stator with the windings is then insulated (either by varnishing or potting). This process requires winding embedding, end shaping, and insulation treatment. The design and manufacturing process of submersible motors using a loose-wound structure is more complex, requiring precise calculation and layout of each winding component. However, this results in low space utilization within limited space. The loose-wound structure can introduce additional electromagnetic interference, particularly in the high-pressure, high-humidity environments of underground wells, potentially impacting the electromagnetic compatibility of the motor and associated equipment.

[0003] Patent application number CN202210569555.2 discloses a method for automatically and continuously winding multiple Alpha coils, comprising: S1. Winding electromagnetic wire onto a wire storage reel; S2. Mounting a winding die and the wire storage reel on a rotating mechanism; S3. Controlling the rotating mechanism to rotate the electromagnetic wire in the wire storage reel to form a coil cake on the winding die. While this method achieves efficient coil production and ensures consistent coil performance, the patent's disadvantage is that it lacks effective insulation protection for the finished coils. Summary of the Invention

[0004] The main problem solved by the present invention is that the design and manufacturing process of the submersible motor using a scattered winding structure in the prior art is more complicated, requiring precise calculation and arrangement of each winding component, and the space utilization rate is low within a limited space. The scattered winding structure may introduce additional electromagnetic interference, especially in the high-pressure and high-humidity environment underground, which may affect the electromagnetic compatibility performance of the motor and supporting equipment. A method for insulating and wrapping the alpha coil is provided.

[0005] In view of the above technical problems, the technical solutions of the present invention are as follows:

[0006] An Alpha coil insulation wrapping and sealing method comprises the following steps:

[0007] S1, wrapping the electromagnetic wire with the composite film and sintering it, and then winding it into an alpha coil after cooling;

[0008] S2. Half-wrap all the series wires and lead wires in the Alpha Coil with the composite film. The half-wrap direction is from the previous coil to the corresponding length of the next coil, maintaining electrical connection and insulation between the coils. After insulation wrapping, tie and secure the Alpha Coil.

[0009] S3. Wrap all the Alpha coil cakes with the composite film in a layer, with the inner coil of the Alpha coil being wrapped in a half-folded manner and the outer coil of the Alpha coil being wrapped in a lapped manner;

[0010] S4. The starting point of the second layer of insulation wrapping is located at the external lead wire of the Alpha Coil. The composite film is used to continuously wrap the coil cake and the string wire until it reaches the external lead wire at the other end of the coil cake. During the wrapping process from the lead wire to the coil cake, the intersection between the lead wire and the coil cake is filled and wrapped. During the wrapping process from the coil cake to the string wire, the intersection between the coil cake and the string wire is filled and wrapped.

[0011] Among them, the two intersection positions are divided into four quadrants according to the separation of the coil cake, lead wire and series wire, the left and right sides of the series wire are the first quadrant and the second quadrant respectively, and the left and right sides of the lead wire are the third quadrant and the fourth quadrant respectively; in the process of wrapping the lead wire to the coil cake, a gap is formed between the second and third quadrants, first pass through the composite film from the third quadrant, insert the composite film from the second quadrant, then pass through the composite film from the first quadrant, insert the composite film from the second quadrant, and finally pass through the composite film from the fourth quadrant, the coil cake can be wrapped, and the process of passing through the composite film from the third quadrant and inserting the composite film into the second quadrant is gap filling.

[0012] S5. After the second layer of insulation wrapping is completed, the entire Alpha coil is placed in a baking oven for sintering, so that the insulation of the Alpha coil reaches a predetermined standard;

[0013] S6. After the Alpha Coil has cooled, performing a third and a fourth insulation wrapping on the Alpha Coil, wherein the insulation wrapping method of the third and fourth layers is the same as the insulation wrapping method of the second layer;

[0014] S7. After the fourth layer of insulation wrapping is completed, the entire Alpha coil is placed in a baking oven for sintering until all insulation layers are tightly bonded to achieve the best insulation effect. After the Alpha coil is insulation wrapped, it is immersed in insulating oil. The insulating oil is heated to a certain temperature, and the stator is sealed as a whole and cooled to room temperature.

[0015] Furthermore, the composite film is a polyimide composite film.

[0016] Furthermore, in step S3, the length of the package is controlled to be between 3 mm and 4 mm.

[0017] Furthermore, in step S4, the composite film is used for wrapping, the inner circle of the coil cake is half-overlapped, and the outer circle is overlapped, and the overlapped length is controlled between 3mm-4mm. At the same time, the lead wire and the series wire are both wrapped in a half-overlapping manner, and the coil cake, the lead wire and the series wire form an insulating whole.

[0018] Furthermore, in step S4, during the wrapping process from the coil cake to the string line, after the lead wire of the coil cake is wrapped, the coil cake is wrapped again, wherein the inner circle of the coil cake is wrapped in a half-overlap manner, and the outer circle of the coil cake is wrapped in a overlapping manner, and the length of the overlapping is in the range of 3mm-4mm. When the wrapping process reaches the intersection position of the coil cake and the string line, filling and wrapping are performed.

[0019] Furthermore, during the filling and wrapping, when the next string of wires is located on the left side of the previous string of wires, a gap is formed between the second quadrant and the third quadrant. The composite film is first wrapped six times at the intersection of the coil cake and the string of wires in a penetration-insertion manner, and then the composite film is penetrated from the first quadrant.

[0020] Furthermore, the third and fourth penetration-insertion of the composite film are both penetrated from the third quadrant and then inserted from the second quadrant, and the third and fourth penetration-insertion of the composite film are gap filling.

[0021] Furthermore, during the filling and wrapping, when the next string of wires is located on the right side of the previous string of wires, a gap is formed between the first quadrant and the fourth quadrant. The composite film is first wrapped eight times at the intersection of the coil cake and the string of wires in a penetration-insertion manner, and then the composite film is penetrated from the first quadrant.

[0022] Furthermore, the fourth and fifth penetration-insertion of the composite film are both penetrated from the fourth quadrant and then inserted from the first quadrant, and the fourth and fifth penetration-insertion of the composite film are gap filling.

[0023] Furthermore, in step S6, the insulation wrapping method of the third and fourth layers of the alpha coil is the same as the insulation wrapping method of the second layer.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. During the wrapping process, the present invention performs special filling and wrapping at the intersection of the lead wire and the coil cake, as well as the intersection of the coil cake and the series wire, to ensure the stability of the coil cake and the reliability of the overall structure. The alpha coil adopts a continuous winding structure of multiple alpha coils to avoid problems such as poor contact, dimensional deviation, and poor sealing caused by coil short circuit.

[0026] 2. After the Alpha coil is wrapped with four layers of insulation, it can achieve both insulation and sealing effects. The Alpha coil can be directly assembled with the disc-shaped iron core. The assembled stator with windings does not need to be insulated again, which simplifies the stator insulation process, saves motor space, and maximizes the lifting force of the motor.

[0027] 3. The insulation wrapping and sealing method adopted in the present invention has the advantages of simple structure and easy wrapping operation. It adopts polyimide composite film for winding and sintering. Each layer of insulation layer is sintered after wrapping, so that the coil can withstand an AC voltage of more than 10KV, and at the same time can achieve higher heat resistance and environmental adaptability. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 A schematic diagram of the structure of multiple alpha coils of the present invention;

[0029] Figure 2 A schematic diagram of wrapping the lead wire to the coil cake in an Alpha coil insulation wrapping and sealing method;

[0030] Figure 3 A schematic diagram of a coil cake to string wire wrapping method 1 of an Alpha coil insulation wrapping and sealing method;

[0031] Figure 4 This is a schematic diagram of the second coil to string wire wrapping method of an Alpha coil insulation wrapping and sealing method.

[0032] In the figure, 1 to 17 are the order of inserting and removing the composite film; 20. First coil cake; 21. Lead wire; 22. Series wire; 23. Second coil cake. DETAILED DESCRIPTION

[0033] In order to clearly illustrate the technical features of the application scheme of the present invention, the present invention is described in detail below through specific implementation methods and in conjunction with the accompanying drawings.

[0034] In the following description, many specific details are set forth to facilitate a full understanding of the present application. However, the present application may also be implemented in other ways different from those described herein. Therefore, the scope of protection of the present application is not limited to the specific embodiments disclosed below.

[0035] Example 1

[0036] like Figure 1 As shown, a method for insulating and sealing an Alpha coil comprises the following steps:

[0037] S1, wrapping the electromagnetic wire with the composite film and sintering it, and then winding it into an alpha coil after cooling;

[0038] S2. Half-wrap all the series wires and lead wires in the Alpha Coil with the composite film. The half-wrap direction is from the previous coil to the corresponding length of the next coil, maintaining electrical connection and insulation between the coils. After the coils are insulated and wrapped, they are tied and fixed.

[0039] S3. Wrap all the Alpha coil cakes with the composite film, with the inner coil of the Alpha coil being wrapped in a half-fold manner and the outer coil of the Alpha coil being wrapped in a lap manner;

[0040] S4. The starting point of the second layer of insulation is located at the external lead wire of the Alpha coil. The composite film is used to continuously wrap the coil cake and the string wire until it reaches the external lead wire at the other end of the coil cake. During the wrapping process of the lead wire to the coil cake, the intersection between the lead wire and the coil cake is filled and wrapped. During the wrapping process of the coil cake to the string wire, the intersection between the coil cake and the string wire is filled and wrapped.

[0041] Among them, the two intersection positions are divided into four quadrants according to the separation of the coil cake, lead wire and series wire, the left and right sides of the series wire are the first quadrant and the second quadrant respectively, and the left and right sides of the lead wire are the third quadrant and the fourth quadrant respectively; in the process of wrapping the lead wire to the coil cake, a gap is formed between the second and third quadrants, first pass through the composite film from the third quadrant, insert the composite film from the second quadrant, then pass through the composite film from the first quadrant, insert the composite film from the second quadrant, and finally pass through the composite film from the fourth quadrant, the coil cake can be wrapped, and the process of passing through the composite film from the third quadrant and inserting the composite film into the second quadrant is gap filling.

[0042] S5. After the second layer of insulation wrapping is completed, the entire Alpha coil is placed in a baking oven for sintering, so that the insulation of the Alpha coil reaches a predetermined standard;

[0043] S6. After the Alpha coil cools down, the Alpha coil is wrapped with a third and fourth layer of insulation.

[0044] S7. After the fourth layer of insulation wrapping is completed, the entire Alpha coil is placed in a baking furnace for sintering until all insulation layers are tightly bonded to achieve the best insulation effect. After the Alpha coil is insulation wrapped, it is immersed in insulating oil. The insulating oil is heated to a certain temperature, the stator is sealed as a whole, and then cooled to room temperature.

[0045] In this embodiment, the composite film is a polyimide composite film, and all the series wires and lead wires of the Alpha coil are wrapped with the polyimide composite film. The direction of the half-wrap is from the previous coil cake to the corresponding length of the next coil cake to maintain the electrical connection and insulation between the coils. After the insulation wrapping, the wires are tied and fixed.

[0046] All coil cakes are wrapped with a layer of polyimide composite film. The inner circle of the Alpha coil cake is half-overlapped, and the outer circle is overlapped. The length of the overlap is controlled between 3mm-4mm, in order to achieve the best insulation and fixation effect for the Alpha coil; the coil is then wrapped with a second layer. The starting point of the second layer of insulation wrapping is located at the external lead wire of the Alpha coil, and then the coil cake and the series wire are continuously wrapped until they extend to the external lead wire at the other end of the Alpha coil. During this wrapping process, polyimide composite film is used for wrapping. The inner circle of the coil cake is half-overlapped, and the outer circle is overlapped by 3mm-4mm. At the same time, the lead wire and the series wire are both wrapped in a half-overlapping manner, so that the coil cake, the series wire and the lead wire form an insulating whole, thereby ensuring the insulation of the Alpha coil.

[0047] In the process of wrapping the lead wire to the coil cake, special attention should be paid to the filling and wrapping at the intersection. Filling and wrapping at the intersection of the lead wire and the coil cake is more important. The purpose is to ensure the stability of the coil cake and the firmness of the overall structure. The specific method of filling and wrapping is as follows: Figure 2 As shown, a gap is formed between the second quadrant and the third quadrant. First, the film is passed through from position 1 of the third quadrant, and the film is inserted into position 2 of the second quadrant. Then, the film is passed through from position 3 of the first quadrant, and the film is inserted into position 4 of the second quadrant. Finally, the film is passed through from position 5 of the fourth quadrant. The process of passing through the film from position 1 of the third quadrant and inserting the film into position 2 of the second quadrant is gap filling.

[0048] After the lead wire of the coil cake is wrapped, the coil cake is then wrapped. The inner circle of the coil cake is half-wrapped and the outer circle is wrapped with a layer. The length of the wrapping range is 3mm-4mm. When the wrapping process reaches the position where the coil cake and the string line intersect, special filling and wrapping are required, such as Figure 3 As shown, when the next string of wires is located on the left side of the previous string of wires, a gap is formed between the second and third quadrants. The composite film is wrapped six times at the intersection of the coil cake and the string of wires in a penetration-insertion manner. Specifically, the film is first penetrated from position 1 of the third quadrant, inserted into position 2 of the first quadrant, then penetrated from position 3 of the fourth quadrant, and then inserted into position 4 of the first quadrant. Figure 3Mark the process of penetrating and inserting the composite film, and repeat the process of penetrating and inserting from position 5 of the third quadrant to position 6 of the second quadrant and from position 7 of the third quadrant to position 8 of the second quadrant for gap filling.

[0049] After completing the second layer of insulation wrapping, after sintering and cooling, continue to the third and fourth layers of insulation wrapping. The insulation wrapping method of the third and fourth layers is the same as that of the first layer. The purpose is to further consolidate and improve the insulation effect of the coil; when the fourth layer of insulation wrapping is completed, the entire coil is placed in the oven for sintering until all insulation layers are tightly bonded to achieve the best insulation effect; after the Alpha coil is insulation wrapped, it needs to be immersed in insulating oil and heated to a certain temperature. The stator is sealed as a whole and cooled to room temperature. Therefore, the stator coil is in a vacuum environment. In order to ensure that the insulation performance of the Alpha coil does not decrease, the insulation sealing must be ensured during the Alpha coil insulation wrapping process to prevent motor creepage and breakdown.

[0050] Example 2

[0051] like Figure 1 As shown, an Alpha coil insulation wrapping and sealing method includes step S4, the starting point of the second layer of insulation is located at the external lead wire of the Alpha coil, the composite film is used to continuously wrap the coil cake and the string wire until it extends to the external lead wire at the other end of the coil cake, and in the process of wrapping the lead wire to the coil cake, the intersection between the lead wire and the coil cake is filled and wrapped; in the process of wrapping the coil cake to the string wire, the intersection between the coil cake and the string wire is filled and wrapped. Figure 4 As shown, in this embodiment, when the wrapping process reaches the position where the coil cake and the string line intersect, special filling and wrapping are required, such as Figure 4 When the next string line is located on the right side of the previous string line, a gap is formed between the first and fourth quadrants. The composite film is wrapped six times at the intersection of the coil cake and the string line in a penetration-insertion manner. Specifically, the film is first penetrated from position 1 of the third quadrant, inserted into position 2 of the first quadrant, then penetrated from position 3 of the fourth quadrant, and then inserted into position 4 of the second quadrant. Figure 4 The composite film is inserted and removed from the coil, and this process is repeated. The process of inserting the composite film from position 7 in the fourth quadrant to position 8 in the first quadrant, and then from position 9 in the fourth quadrant to position 10 in the first quadrant, is called gap filling. This method completes the coil wrapping and ensures its insulation.

[0052] Example 3

[0053] like Figure 1Figure 1 shows an Alpha coil insulation wrapping and sealing method. In this embodiment, during the first layer of insulation wrapping, all coils are wrapped with a polyimide composite film. The inner coil is partially wrapped, while the outer coil is overlapped, with a 3mm overlap length. Simultaneously, during the second layer of wrapping from the coil to the string line, after the coil lead wires are wrapped, the coil is wrapped again. The inner coil is partially wrapped, and the outer coil is overlapped, with a 3mm overlap length, the same as the first layer. Similarly, the outer coils of the third and fourth layers are similarly overlapped, with a 3mm overlap length. This improves coil wrapping accuracy and consistency, maintaining coil stability.

[0054] Obviously, the above embodiments of the present invention are merely examples for the purpose of clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. Those skilled in the art will appreciate that other variations or modifications can be made based on the above description. It is not necessary and impossible to enumerate all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the claims of the present invention.

Claims

1. An Alpha coil insulation wrapping and sealing method, characterized in that: The steps include: S1, wrapping the electromagnetic wire with the composite film and then sintering it, and then winding it into an alpha coil after cooling; S2. Half-wrap all the series wires and lead wires in the Alpha Coil with the composite film. The half-wrap direction is from the previous coil to the corresponding length of the next coil, maintaining electrical connection and insulation between the coils. After insulation wrapping, tie and secure the Alpha Coil. S3. Wrap all the Alpha coil cakes with the composite film in a layer, with the inner coil of the Alpha coil being wrapped in a half-folded manner and the outer coil of the Alpha coil being wrapped in a lapped manner; S4. The starting point of the second layer of insulation wrapping is located at the external lead wire of the Alpha coil, and the composite film is then used to continuously wrap the coil cake and the string wire until it extends to the external lead wire at the other end of the coil cake; when wrapping the lead wire to the coil cake, the intersection between the lead wire and the coil cake is filled and wrapped; when wrapping the coil cake to the string wire, the intersection between the coil cake and the string wire is filled and wrapped; The two intersection positions are divided into four quadrants according to the separation of the coil cake, the lead wire and the series wire, the left and right sides of the series wire are the first quadrant and the second quadrant respectively, and the left and right sides of the lead wire are the third quadrant and the fourth quadrant respectively; in the process of wrapping the lead wire to the coil cake, a gap is formed between the second and third quadrants, and the composite film is first passed through the third quadrant, inserted into the second quadrant, then passed through the first quadrant, inserted into the second quadrant, and finally passed through the fourth quadrant to complete the wrapping of the coil cake, wherein the process of passing through the composite film from the third quadrant and inserting the composite film into the second quadrant is gap filling; S5. After the second layer of insulation wrapping is completed, the entire Alpha coil is placed in a baking oven for sintering, so that the insulation of the Alpha coil reaches a predetermined standard; S6. After the Alpha coil cools down, the Alpha coil is wrapped with a third and fourth layer of insulation. S7. After the fourth layer of insulation wrapping is completed, the entire Alpha coil is placed in a baking furnace for sintering until the insulation layers are tightly bonded. After the Alpha coil is insulation wrapped, it is immersed in insulating oil. The insulating oil is heated to a certain temperature, and the stator is sealed as a whole and cooled to room temperature.

2. The Alpha coil insulation wrapping and sealing method according to claim 1, characterized in that: The composite film is a polyimide composite film.

3. The Alpha coil insulation wrapping and sealing method according to claim 1, characterized in that: In step S3, the length of the package is controlled to be between 3 mm and 4 mm.

4. The Alpha coil insulation wrapping and sealing method according to claim 1, characterized in that: In step S4, the composite film is used for wrapping, the inner circle of the coil cake is half-overlapped, and the outer circle is overlapped, and the overlapped length is controlled between 3mm and 4mm. At the same time, the lead wire and the series wire are both wrapped in a half-overlapping manner, and the coil cake, the lead wire and the series wire form an insulating whole.

5. The Alpha coil insulation wrapping and sealing method according to claim 4, characterized in that: In step S4, during the wrapping process from the coil cake to the string line, after the lead wire of the coil cake is wrapped, the coil cake is wrapped again, wherein the inner circle of the coil cake is wrapped in a half-folded manner, and the outer circle of the coil cake is wrapped in a overlapping manner, and the length of the overlapping is in the range of 3mm-4mm. When the wrapping process reaches the intersection position of the coil cake and the string line, filling and wrapping are performed.

6. The Alpha coil insulation wrapping and sealing method according to claim 5, characterized in that: During the filling and wrapping, when the next string of wires is located on the left side of the previous string of wires, a gap is formed between the second quadrant and the third quadrant. First, the composite film is wrapped six times at the intersection of the coil cake and the string of wires in a penetration-insertion manner, and then the composite film is penetrated from the first quadrant.

7. The Alpha coil insulation wrapping and sealing method according to claim 6, characterized in that: The third and fourth penetration-insertion of the composite film are both penetration from the third quadrant and then insertion from the second quadrant, and the third and fourth penetration-insertion of the composite film are gap filling.

8. The Alpha coil insulation wrapping and sealing method according to claim 5, characterized in that: During the filling and wrapping, when the next string of wires is located on the right side of the previous string of wires, a gap is formed between the first quadrant and the fourth quadrant. First, the composite film is wrapped eight times at the intersection of the coil cake and the string of wires in a penetration-insertion manner, and then the composite film is penetrated from the first quadrant.

9. The Alpha coil insulation wrapping and sealing method according to claim 8, characterized in that: The fourth and fifth penetration-insertion of the composite film are both penetrated from the fourth quadrant and then inserted from the first quadrant, and the fourth and fifth penetration-insertion of the composite film are gap filling.

10. The Alpha coil insulation wrapping and sealing method according to claim 1, characterized in that: In step S6, the insulation wrapping method of the third and fourth layers of the alpha coil is the same as the insulation wrapping method of the second layer.

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