Motor coil nose forming and manufacturing method and motor coil thereof

Abstract

The invention relates to a coil of a motor and a manufacturing method, the coil is formed by winding a long wire into multiple turns, the coil is externally wrapped with a main insulator, a large-deformation part of the coil is wrapped with a high-performance insulating material, the main insulator of the wire turn is suitable for an organic silicon system, and mica tapes and polyimide film tapes are used for wrapping in a sequential or staggered sequence. And the insulation grade of the coil is 200 DEG C or better. According to the invention, the high-performance material is bound between the coil and the main insulator at the part with larger deformation, so that when the coil deforms, the stress of the main insulator can be shared, and the main insulator is prevented from being torn and deformed. And the device is suitable for a small-span two-dimensional coil of 80-150 mm, and the shape of the two-dimensional coil is closer to that of a final coil due to the similar hexagonal design, so that the deformation amount of the coil is smaller. In addition, the main insulation part adopts an organic silicon insulation system, a heating process is not needed, and the binding operation efficiency is higher.

Description

Technical Field

[0001] The invention relates to the technical field of motor manufacturing, and in particular to a motor coil nose forming manufacturing method and a motor coil thereof. Background Art

[0002] The stator of the traction motor generally adopts a formed coil with a three-dimensional centerline. During the manufacturing process of this type of coil, due to the irregular bending of the nose of the three-dimensional stator coil, it is difficult to perform automated wrapping during the manufacturing process. Since the nose of the formed coil is a non-effective part of the coil electromagnetic induction and is far away from the iron core, the number of insulation layers and the overlap rate are usually lower than the straight part of the coil in the iron core area. In the traditional process, due to the irregular bending of the nose, the overlap rate is based on the outside during insulation wrapping, which will cause the insulation material on the inside to accumulate and be much thicker than the insulation thickness on the outside. When the process of first wrapping and then expanding is adopted, when the coil with the initial shape of insulation is formed into a three-dimensional shape, the deformation at the nose of the coil is large, and the possibility of stress and deformation of the insulation material is also greater. In order to solve this problem, the main means of the existing technology is to increase the overlap rate of the insulation material or increase the number of wrapping layers of the insulation material. When the coil is wrapped in a simple initial shape and then subjected to the final three-dimensional forming, the deformation at the nose is large, and the mechanical properties of the insulation materials such as mica tape are poor, and there are problems such as sliding and tearing, which affect the overall insulation performance of the coil. The search did not find the same technical solution as the present invention, but only found some related comparative technical documents, mainly the following: 1. Patent application number 201180044120.6 discloses a method for forming an electric mechanical insulated coil, forming a continuous insulation-coated wire into a generally flat long closed loop with a circumference and an outer surface. A permanent insulation layer is then applied to the outer surface of the closed loop, preferably by spirally winding an insulation tape around the circumference of the closed loop with a tape winding machine. The insulation tape has a catalytic compound including at least a portion of a multi-part epoxy resin. The closed loop is formed into a rigid conductive coil by applying pressure so that the coil conforms to the desired contour. Applying a permanent insulation layer to the closed loop before final forming allows mechanical insulation tape to be wound on a larger portion of the coil circumference, thereby reducing the need for slower and more expensive manual tape winding. It includes heating the closed loop before the forming step, and during the forming step, winding the wire around at least two winding pins with a diameter of 6 inches (150 mm).

[0003] 2. The patent with application number 201880048294.1 provides a shaped coil that is pre-wound with mica tape, and is formed into a flat coil by a certain number of turns of wire, and the certain number of turns of wire are collectively wound by a certain number of layers of mica tape, and the wound flat coil is subsequently constructed into a three-dimensional shaped coil, and a certain number of layers of cover tape are wound on the certain number of layers of mica tape. Among them, the mica tape has a bending stiffness of less than 50N / m according to EN 60371-2 2005 version, and has a static friction coefficient of less than 0.7 according to DIN ENISO 8295 2004 version directly on the top and bottom sides of the mica tape." "The cover tape has a static friction coefficient of less than 0.7 according to DIN ENISO 8295 2004 version between its top and bottom sides, and / or the cover tape and the mica tape are coordinated with each other. The cover tape itself has two layers, a fabric and a film, the fabric being made of glass fibers or a first high-performance polymer (which may be polyimide, but is preferably aromatic polyamide), and the film being made of a second high-performance polymer (polyimide).

[0004] 3. The patent with application number 201880048322.X discloses a coil with a covering tape made of a high-performance material, wherein the coil is composed of a plurality of turns, and the turns are wound together with a plurality of layers of mica tape, and a plurality of layers of covering tape are wound on the plurality of layers of mica tape, wherein the covering tape has a sequence of two layers, a fabric and a film, "the fabric is composed of glass fiber or a first high-performance polymer (preferably aramid), and the film is composed of a second high-performance polymer (preferably polyimide)", "the layers of the mica tape are stacked one above the other and / or the layers of the covering tape are stacked one above the other and have an offset relative to each other, and the offset is produced by first winding the coil into a two-dimensional coil, then winding it with layers of mica tape and covering tape, and then forming it into a three-dimensional formed coil.

[0005] Through the analysis of the above patents, it can be found that the existing technology mainly solves the problem that the stator coil insulation material is easily torn and deformed during the molding process by increasing the overlapping rate of the insulation material or increasing the number of wrapping layers of the insulation material. Increasing the overlapping rate or increasing the number of wrapping layers will lead to a large consumption of insulation material. At the same time, there is a situation where the insulation material is locally accumulated or even forms voids. Therefore, it is very necessary to improve this. Summary of the invention

[0006] The technical problem to be solved by the present invention is: to provide a method for forming a motor coil nose and a motor coil thereof, which can solve the problem that the stator coil insulation material is easily torn and deformed during the forming process.

[0007] The technical solution proposed by the present invention is: a method for manufacturing a motor coil, firstly arranging the wire harness of the motor coil into a hexagonal two-dimensional coil, then embedding the two-dimensional coil into the iron wire slot of the motor stator, and then arranging it into a three-dimensional coil; comprising the following steps: Step 1: Make a hexagonal two-dimensional coil, the angle between each adjacent side is preferably ≥90°, and the coil span is 80~150mm; Step 2: In a two-dimensional coil of a simple shape, the position where the final coil is most deformed is pre-determined according to the shape and size after forming, and a high-performance insulating material is applied here for wrapping, and then the main insulation is wrapped. When wrapping, the number of wrappings is first determined according to the product voltage level, and then the mica tape and polyimide film tape are used for wrapping according to the determined number of wrappings. The wrapping is carried out in a sequential or staggered order; Step 3: Place the two-dimensional coil on the expansion device, position it with the noses at both ends, position the inner side of the nose with pins, and clamp it with the splints on both sides; Step 4: Clamp the two sides of the two-dimensional coil with two clamps respectively, stretch it outward, and twist it at the same time or successively to form two straight lines with clamped feet of the three-dimensional coil. The nose clamp lifts the two ends of the coil so that the nose is higher than the straight lines. Step 5: The top arc device top arcs the four oblique sides of the coil to form the final curvature of the oblique sides of the three-dimensional coil.

[0008] Furthermore, the two-dimensional coil refers to a coil formed by bending the wire harness on the same plane to form the required hexagonal coil. When forming, the size change caused by the deformation of the two-dimensional coil must be considered, and it should be 3-15mm larger than the actual pitch of the three-dimensional coil; the three-dimensional coil refers to a coil formed by embedding the three-dimensional coil into the stator core slot of the motor and shaping the nose.

[0009] Furthermore, the high-performance insulating material can be wrapped in a flat package, a stacked package, or a rolled package. In order to improve the working efficiency and minimize the insulation gap, the rolled package is preferably used.

[0010] Furthermore, the expansion equipment is an expansion machine, a forming machine or a CNC expansion machine; the top arc device is a top arc mold or a top arc component inside the expansion machine.

[0011] According to the above-mentioned motor coil, the present invention also relates to a motor coil manufactured according to the above-mentioned motor coil manufacturing method, the motor coil is composed of a long wire wound with multiple turns, the outside of the coil is wrapped with main insulation, and the local area of ​​the coil with larger deformation is wrapped with high-performance insulating material. The main insulation of the wire turns is suitable for silicone system, and is wrapped with mica tape and polyimide film tape in sequence or staggered order, so that the coil has an insulation level of more than 200°C.

[0012] Furthermore, the organic silicon material is formed by high-pressure impregnation and curing after forming the stator, so the coil does not need to be heated, debonded, or hardened.

[0013] Furthermore, the high-performance insulating material has an insulation level not lower than the main insulation of the coil, and has mechanical properties such as good ductility and a large compression ratio. It can better perform conformal filling at the coil deformation point and reduce the stress and extension of the main insulation through its own compression.

[0014] Furthermore, the high-performance insulating material is preferably polyaramid fiber felt.

[0015] Furthermore, the coil has a three-dimensional centerline in its final shape. Before forming the three-dimensional shape, a simple circular, long closed ring or hexagonal two-dimensional coil is first formed. In order to facilitate the formation of a small diameter nose size of the final coil, a hexagonal shape is preferably used.

[0016] Furthermore, when the coil adopts a hexagonal two-dimensional coil shape, in order to facilitate mechanized insulation wrapping, the angle between each two adjacent sides is preferably ≥90°.

[0017] Furthermore, the two-dimensional coil span of the coil is 80-150 mm, which is conducive to controlling the size of the nose when forming into the final shape, and is also convenient for mechanized insulation wrapping of the coil.

[0018] The beneficial effects of the present invention are as follows: (1) By using high-performance materials to wrap between the coil and the main insulation at the part with larger deformation, when the coil is deformed, the force of the main insulation can be shared to prevent the main insulation from tearing and deformation. (2) It is suitable for small-span two-dimensional coils of 80-150mm. The hexagonal design makes the shape of the two-dimensional coil closer to the final coil, making the deformation of the coil smaller. (3) The main insulation part adopts an organic silicon insulation system, which does not require a heating process and has a higher efficiency in the wrapping operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic diagram of the coil insulation structure provided by an embodiment of the present invention.

[0020] Figure 2 It is a schematic diagram of a two-dimensional coil structure.

[0021] Description of reference numerals: coil 1, high-performance insulating material 2, main insulation 3; DETAILED DESCRIPTION

[0022] The following describes the embodiments of the present invention by specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments only illustrate the basic concept of the present invention in a schematic manner, and the following embodiments and features in the embodiments can be combined with each other without conflict.

[0023] Among them, the drawings are only used for illustrative explanations, and they only represent schematic diagrams rather than actual pictures, and should not be understood as limitations on the present invention. In order to better illustrate the embodiments of the present invention, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of actual products. For those skilled in the art, it is understandable that some well-known structures and their descriptions in the drawings may be omitted.

[0024] The same or similar numbers in the drawings of the embodiments of the present invention correspond to the same or similar parts; in the description of the present invention, it should be understood that if the terms "upper", "lower", "left", "right", "front", "rear", etc. indicate the orientation or position relationship, they are based on the orientation or position relationship shown in the drawings, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, the terms describing the position relationship in the drawings are only used for illustrative purposes and cannot be understood as limiting the present invention. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0025] like Figure 1-2 As shown, a coil of a motor, the coil 1 is composed of a long wire wound with multiple turns, the coil 1 is wrapped with a main insulation 3 on the outside, and a high-performance insulating material 2 is wrapped in a part of the coil 1 with greater deformation. The main insulation 3 of the wire turn is suitable for a silicone system, and is wrapped with mica tape and polyimide film tape in a sequential or staggered order, so that the coil 1 has an insulation grade of 200°C or better.

[0026] Furthermore, the organic silicon material is formed by high-pressure impregnation and curing after forming the stator, so the coil does not need to be heated, debonded, or hardened.

[0027] Furthermore, the high-performance insulating material 2 has an insulation level not lower than that of the main insulation 3 of the coil 1, and has mechanical properties such as good ductility and a large compression ratio. It can better perform conformal filling at the deformation of the coil 1 and reduce the stress and extension of the main insulation 3 through its own compression.

[0028] Furthermore, the high-performance insulating material 2 is preferably polyaramid fiber felt.

[0029] Furthermore, the coil 1 has a three-dimensional center line in its final shape. Before forming the three-dimensional shape, a simple circular, long closed ring or hexagonal two-dimensional coil 1 is first formed. In order to facilitate the formation of a small diameter nose size of the final coil 1, a hexagonal shape is preferably used.

[0030] Furthermore, when the coil 1 adopts a hexagonal two-dimensional coil 1 shape, in order to facilitate mechanized insulation wrapping, the angle between each two adjacent sides is preferably ≥90°.

[0031] Furthermore, the two-dimensional coil 1 of the coil 1 has a span of 80-150 mm, which is conducive to controlling the size of the nose when forming into the final shape, and is also convenient for mechanized insulation wrapping of the coil 1.

[0032] According to the above-mentioned motor coil, the present invention also relates to a method for manufacturing the motor coil, firstly arranging the wire harness of the motor coil into a hexagonal two-dimensional coil, then embedding the two-dimensional coil into the motor stator iron wire slot, and then arranging it into a three-dimensional coil; comprising the following steps: Step 1: Make a hexagonal two-dimensional coil, the angle between each adjacent side is preferably ≥90°, and the coil span is 80~150mm; Step 2: In a two-dimensional coil of a simple shape, the position where the final coil is most deformed is pre-determined according to the shape and size after forming, and a high-performance insulating material is applied here for wrapping, and then the main insulation is wrapped. When wrapping, the number of wrappings is first determined according to the product voltage level, and then the mica tape and polyimide film tape are used for wrapping according to the determined number of wrappings. The wrapping is carried out in a sequential or staggered order; Step 3: Place the two-dimensional coil on the expansion device, position it with the noses at both ends, position the inner side of the nose with pins, and clamp it with the splints on both sides; Step 4: Clamp the two sides of the two-dimensional coil with two clamps respectively, stretch it outward, and twist it at the same time or successively to form two straight lines with clamped feet of the three-dimensional coil. The nose clamp lifts the two ends of the coil so that the nose is higher than the straight lines. Step 5: The top arc device top arcs the four oblique sides of the coil to form the final curvature of the oblique sides of the three-dimensional coil.

[0033] Furthermore, the two-dimensional coil refers to a coil formed by bending the wire harness on the same plane to form the required hexagonal coil. When forming, the size change caused by the deformation of the two-dimensional coil must be considered, and it should be 3-15mm larger than the actual pitch of the three-dimensional coil; the three-dimensional coil refers to a coil formed by embedding the three-dimensional coil into the stator core slot of the motor and shaping the nose.

[0034] Furthermore, the high-performance insulating material 2 can be wrapped in a flat package, a stacked package, or a rolled package. In order to improve the work efficiency and minimize the insulation gap, the rolled package is preferably used.

[0035] Furthermore, the high-performance insulating material 2 is wound around the position of the final coil 1 where the deformation is the greatest.

[0036] Furthermore, the expansion equipment is an expansion machine, a forming machine or a CNC expansion machine.

[0037] Furthermore, the top arc device is a top arc component inside a top arc mold or an expansion machine.

[0038] The beneficial effects of the present invention are as follows: (1) By using high-performance materials to wrap between the coil and the main insulation at the part with larger deformation, when the coil is deformed, the force of the main insulation can be shared to prevent the main insulation from tearing and deformation. (2) It is suitable for small-span two-dimensional coils of 80-150mm. The hexagonal design makes the shape of the two-dimensional coil closer to the final coil, making the deformation of the coil smaller. (3) The main insulation part adopts an organic silicon insulation system, which does not require a heating process and has a higher efficiency in the wrapping operation.

[0039] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution, which should be included in the scope of the claims of the present invention.

Claims

1. A method for manufacturing a motor coil, characterized in that: First, the wire harness of the motor coil is arranged into a hexagonal two-dimensional coil, and then the two-dimensional coil is embedded in the motor stator iron wire slot, and then reshaped into a three-dimensional coil; the following steps are included: Step 1: Make a hexagonal two-dimensional coil, the angle between each adjacent side is preferably ≥90°, and the coil span is 80~150mm; Step 2: In a two-dimensional coil of a simple shape, the position where the final coil is most deformed is pre-determined according to the shape and size after forming, and a high-performance insulating material is applied here for wrapping, and then the main insulation is wrapped. When wrapping, the number of wrappings is first determined according to the product voltage level, and then the mica tape and polyimide film tape are used for wrapping according to the determined number of wrappings. The wrapping is carried out in a sequential or staggered order; Step 3: Place the two-dimensional coil on the expansion device, position it with the noses at both ends, position the inner side of the nose with pins, and clamp it with the splints on both sides; Step 4: Clamp the two sides of the two-dimensional coil with two clamps respectively, stretch it outward, and twist it at the same time or successively to form two straight lines with clamped feet of the three-dimensional coil. The nose clamp lifts the two ends of the coil so that the nose is higher than the straight lines. Step 5: The top arc device top arcs the four oblique sides of the coil to form the final curvature of the oblique sides of the three-dimensional coil.

2. The method for manufacturing a motor coil according to claim 1, characterized in that: The two-dimensional coil refers to a coil formed by bending the wire harness on the same plane to form the required hexagonal shape. During the process of forming, the size change caused by the deformation of the two-dimensional coil must be considered, and it should be 3-15mm larger than the actual pitch of the three-dimensional coil. The three-dimensional coil refers to a coil formed by embedding the three-dimensional coil into the stator core slot of the motor and shaping the nose.

3. The method for manufacturing a motor coil according to claim 1, characterized in that: The high performance insulating material (2) can be wrapped in a flat package, a stacked package or a rolled package. In order to improve the work efficiency and minimize the insulation gap, the rolled package is preferably used.

4. A motor coil manufactured by the method for manufacturing a motor coil according to claim 1, characterized in that: The high-performance insulating material (2) is wound around the largest deformed portion of the final coil (1) for one circle.

5. A motor coil manufactured by the method for manufacturing a motor coil according to claim 1, characterized in that: The expansion equipment is an expansion machine, a forming machine or a CNC expansion machine; the top arc device is a top arc mold or a top arc component in the expansion machine.

6. A motor coil manufactured by the method for manufacturing a motor coil according to claim 1, characterized in that: The coil (1) is composed of a long wire wound with multiple turns. A high-performance insulating material (2) is wrapped around a part of the coil (1) where deformation is greater. A main insulation (3) is then wrapped around the high-performance insulating material (2). The main insulation (3) is wrapped around the outermost layer of the coil (1). The main insulation (3) is a silicone material and is wrapped with a mica tape and a polyimide film tape in a sequential or staggered order, so that the coil (1) has an insulation level of more than 200°C.

7. The coil of a motor according to claim 6, characterized in that: The high-performance insulating material (2) is preferably polyaramid fiber felt.

8. The coil of a motor according to claim 6, characterized in that: The coil (1) has a three-dimensional shape in its final shape, and before forming the three-dimensional shape, a simple circular, long closed ring or hexagonal two-dimensional coil (1) is first formed. In order to facilitate the formation of a small diameter nose size of the final coil (1), a hexagonal shape is preferably used.

9. The motor coil according to claim 8, characterized in that: When the coil (1) is in the shape of a two-dimensional hexagonal coil (1), in order to facilitate mechanized insulation wrapping, the angle between each two adjacent sides is preferably ≥90°.

10. The motor coil according to claim 6, characterized in that: The two-dimensional coil (1) of the coil (1) has a span of 80 to 150 mm, which is conducive to controlling the size of the nose when forming into the final shape, and is also convenient for mechanized insulation wrapping of the coil (1).

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