Insulation wrapping and sealing method for multi-turn annular coil

Abstract

The invention discloses a multi-turn annular coil insulation wrapping and sealing method which comprises the following steps: S1, an electromagnetic coil is sintered after being wrapped with a thin film, and the electromagnetic coil is wound into a multi-turn annular coil; s2, carrying out insulation binding on the series connection wire: tightly wrapping the series connection wire of the multi-turn annular coil by adopting a thin film, and binding and fixing after insulation binding; s3, carrying out insulation wrapping on the multi-layer coil; and S4, carrying out insulation binding on the whole coil for one time so as to realize fixation, and after insulation binding is completed, putting the whole coil into an oven for sintering so as to ensure the insulativity of the coil. According to the binding method, coil turn-to-turn insulation and connection point sealing are achieved, good sealing of insulation points can be achieved after sintering, and the method has the advantages of being simple in structure and convenient to operate.

Description

Technical Field

[0001] The invention belongs to the technical field of motor coil winding, and in particular relates to an insulation wrapping and sealing method for a multi-turn annular coil. Background Art

[0002] Linear motors are designed to be slender in structure to obtain sufficient torque, so the magnetic flux of the stator winding will directly determine the lifting force of the motor. In order to maximize the power density of the motor, the coil of a motor stator currently uses a multi-turn annular coil, and the motor winding uses a double-layer multi-turn annular coil cake structure, which is matched with a disc core. Compared with the scattered winding, the motor slot full rate is higher, so the motor torque density is greater. The insulation process is one of the key factors in the performance and life of the motor, and it is of great significance to improve the reliability and safety of the motor.

[0003] In the existing technical solutions, most linear motors have a loose winding structure. The electromagnetic wire itself has a layer of paint film with insulation performance. The electromagnetic wire is inserted into the core slot by embedding or penetration, and the stator with winding is then insulated (dip varnish or potting). This process requires the completion of winding embedding, end shaping, insulation treatment and other processes. The design and manufacturing process of linear motors with a loose winding structure is more complicated, requiring precise calculation and arrangement of each winding component, but in a limited space, the space utilization rate is low, and the insulation sealing effect of the loose winding structure is poor.

[0004] The existing patent publication number CN114825813A discloses a method for automatically and continuously winding multiple alpha coils, including: S1, winding the electromagnetic wire in a wire storage drum; S2, installing the winding mold and the wire storage drum on a rotating mechanism; S3, controlling the rotation of the rotating mechanism to make the electromagnetic wire in the wire storage drum wind the coil cake on the winding mold. Although it can achieve efficient production of coils and ensure the consistency of coil performance, the disadvantage of this patent is that it does not provide effective insulation and sealing protection for the formed coils. Summary of the invention

[0005] The present invention is mainly aimed at the problem that the design and manufacturing process of the linear motor using the scattered winding structure in the prior art is more complicated, and requires precise calculation and arrangement of each winding element, but the space utilization rate is low within the limited space; the insulation sealing effect of the scattered winding structure is poor, and a method for insulating and wrapping a multi-turn annular coil is provided.

[0006] In view of the above technical problems, the technical solutions of the present invention are as follows:

[0007] A method for insulating and sealing a multi-turn annular coil, comprising the following steps:

[0008] S1, wrapping the electromagnetic wire with a film and then sintering it, and then winding it into a multi-turn annular coil after cooling;

[0009] S2. Insulation wrapping of the series connection wire: Wrap the series connection wire of the multi-turn annular coil tightly with a film so that the length of the insulation wrapping meets the insulation requirements, and tie and fix the multi-turn annular coil;

[0010] S3. Insulation wrapping of multi-layer coils: using the film to wrap the coil cake from the required starting point, wrapping from bottom to top clockwise to the overlapping point on the opposite side of the lead wire, and covering the lead wire insulation position, and tying the end position tightly after wrapping;

[0011] S4. The entire coil is then insulated and wrapped. After the insulation wrapping is completed, the entire coil is placed in a baking furnace for sintering to ensure that the insulation performance reaches the preset standard.

[0012] Furthermore, the film is a polyimide composite film.

[0013] Furthermore, the multi-turn annular coil is wrapped with at least 4 layers.

[0014] Furthermore, in step S3, the inner circle of the multi-turn annular coil is wrapped in a half-overlapping manner, and the outer circle is wrapped in a overlapping manner.

[0015] Furthermore, in step S3, the overlapping length between the end position and the starting point meets the insulation requirement.

[0016] Furthermore, in the step S3, after packing, the end position is tied tightly with a polyimide adhesive tape or a cable tie.

[0017] Furthermore, in the step S3, during the insulation wrapping process of the multi-layer coil, the insulation overlap method of the coil cake and the insulation overlap method of the series wire includes the following steps:

[0018] S3.1. Lift the outermost electromagnetic wire first, and then overlap the lower coil cake;

[0019] S3.2, after overlapping the lower coil cake once, overlap another layer of film to the outermost electromagnetic wire;

[0020] S3.3, repeat the above steps S3.1 and S3.2 once, and then wrap the lower layer of coil cake to a symmetrical position;

[0021] S3.4. Perform a cross-sealing bandage.

[0022] Furthermore, in step S3.4, four areas are divided according to the positions of the coil cake, lead wire and series wire, the left and right sides of the series wire are area two and area one respectively, and the left and right sides of the lead wire are area three and area four respectively.

[0023] Furthermore, the film is first passed through from area one and inserted into area three; the composite film is passed through from area two and inserted into area one, and finally the film is passed through from area four, so that the cross-sealing wrapping of the coil cake can be completed.

[0024] Furthermore, the overlap length between the coil cake and the series wire is greater than the length of the insulation standard.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] 1. The present invention performs multi-layer insulation wrapping on a multi-turn annular coil, and performs insulation wrapping on the coil cake and the series connection line, and wraps clockwise from bottom to top to the overlapping point of each layer on the left side, and covers the insulation position of the series connection line. After wrapping, the end position is tied tightly, and the end position overlaps the starting position to meet the insulation requirements; after the multi-layer coil is wrapped, the entire coil is placed in a baking furnace for sintering, thereby ensuring that all insulation layers can be tightly combined to achieve the best insulation effect; the method has a simple structure and is easy to operate, and can achieve good sealing of the insulation points for the coil turn insulation and the connection points after sintering.

[0027] 2. The present invention performs insulation wrapping on the multi-turn annular coil and then sintering the entire coil to achieve the best insulation and sealing effect; the coil can be directly assembled with the iron core, and the assembled winding stator does not need to be insulated again, which simplifies the stator insulation process and has higher heat resistance, sealing and environmental adaptability. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the structure of multiple multi-turn annular coils of the present invention;

[0029] Figure 2 The insulation wrapping length of the series connection wire with the coil cake in the present invention;

[0030] Figure 3 It is a schematic diagram of the insulation wrapping of a multi-layer coil of the present invention;

[0031] Figure 4 It is a schematic diagram of the cross seal of the present invention.

[0032] In the above figure, 1 to 5 are the order of inserting and piercing the film in the cross seal; 20. First coil cake; 21. Lead wire; 22. Series wire; 23. Second coil cake; L1, L2: Lap length with the series wire. 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] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0036] In the present application, unless otherwise clearly specified and limited, a first feature "above" or "below" a second feature may be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. In the description of this specification, reference terms; descriptions of "one embodiment", "some embodiments", "examples", "specific examples" or "some examples" etc. mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in an appropriate manner in any one or more embodiments or examples.

[0037] Example 1

[0038] like Figures 1 to 4 As shown, a method for insulating and sealing a multi-turn annular coil comprises the following steps:

[0039] S1, wrapping the electromagnetic wire with a film and then sintering it, and then winding it into a multi-turn annular coil after cooling;

[0040] S2. Insulation wrapping of the series connection wire 22: Wrap the series connection wire 22 of the multi-turn annular coil tightly with a film so that the length of the insulation wrapping meets the insulation requirements. After the insulation wrapping, the multi-turn annular coil is tied and fixed;

[0041] S3. Insulation wrapping of multi-layer coils: Use the film to wrap the coil cake from the required starting point, wrap it clockwise from bottom to top to the left overlap point, and cover the lead wire insulation position. After wrapping, tie the end position tightly; Figure 3 As shown, the left overlap point is located on the opposite side of the lead-out line, at position S3.1;

[0042] S4. Insulate the coil once more. After the insulation wrapping is completed, put the entire coil into a baking furnace for sintering, so that all insulation layers are tightly combined to achieve the best insulation effect.

[0043] like Figure 3 As shown, in this embodiment, the multi-turn annular coil is insulated and wrapped in two layers: a polyimide composite film is used to wrap the coil from the required starting point on the coil cake, and the inner circle of the coil cake is wrapped in an overlapping manner, and the outer circle is wrapped in an overlapping manner, and the wrapping is performed clockwise from bottom to top to the overlapping point of each layer on the left, and the lead insulation position is covered, and the lead insulation is overlapped to meet the insulation requirements.

[0044] Then wrap the multi-turn annular coil with one layer of insulation: Use polyimide composite film to wrap from the required starting point on the coil cake, wrap the inner circle of the coil cake in an overlapping manner, and wrap the outer circle in an overlapping manner. Wrap clockwise from bottom to top to the third layer of overlapping point on the left side, and completely cover the lead wire insulation position. The insulation of the coil cake and the insulation overlap of the series wire 22 are as follows Figure 3 As shown, the method comprises the following steps: (1) firstly lifting the outermost electromagnetic wire, and then overlapping the lower coil cake with a composite film; (2) after overlapping the lower coil cake once, overlapping another layer of film to the outermost electromagnetic wire; (3) after repeating the above steps 1 and 2 once, wrapping the lower coil cake to a symmetrical position; (4) Figure 4 As shown, the coil cake is cross-sealed and wrapped ten times with a composite film.

[0045] Example 2

[0046] like Figure 4 As shown, in this embodiment, four areas are divided according to the positions of the coil cake, the lead wire 21 and the series wire 22. The left and right sides of the series wire 22 are area two and area one respectively, and the left and right sides of the lead wire 21 are area three and area four respectively; first, the film is passed through area one, and the film is inserted into area three; the composite film is passed through area two, and the film is inserted into area one, and finally the film is passed through area four, so that the coil cake can be cross-sealed and wrapped; in the process of wrapping the third layer of the coil cake, the end position overlaps with the starting position to meet the insulation requirements, and the end position is tied tightly with a cable tie after wrapping.

[0047] After completing the third layer of coil insulation wrapping, the entire coil is insulated and wrapped once to achieve fixation. After the fourth layer of insulation wrapping is completed, the entire coil is placed in a baking oven for sintering to ensure that all insulation layers can be tightly combined to achieve the best insulation effect.

[0048] Example 3

[0049] In this embodiment, the method adopted is to seal the insulation between coil turns and the connection points. Regarding the problem of poor contact of electromagnetic wire: Since the electromagnetic wire itself is insulated, poor contact can be avoided by ensuring the lap rate and sintering the electromagnetic wire as a whole.

[0050] In this embodiment, the following methods can also be used: 1. By increasing the number of coil insulation layers; 2. Ensuring that the film fits snugly at the tapered overlap of a single coil cake to avoid sealing problems caused by film wrinkles; 3. After the coil insulation is wrapped, the entire coil is sintered at high temperature to ensure that the insulation layer and the coil are melted at high temperature to form a whole.

[0051] After the multi-turn annular coil is insulated and wrapped, it is immersed in insulating oil. After the insulating oil is heated to a certain temperature, the stator is sealed as a whole and cooled to room temperature. Therefore, the stator coil is always in a vacuum environment. In order to ensure that the insulation performance of the multi-turn annular coil does not decrease, the insulation sealing is ensured when the multi-turn annular coil is insulated and wrapped to prevent the motor from creeping and breaking through.

[0052] Obviously, the above-described embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention shall be included in the protection scope of the claims of the present invention.

Claims

1. A method for insulating and sealing a multi-turn annular coil, characterized in that: The following steps are involved: S1, wrapping the electromagnetic wire with a film and then sintering it, and then winding it into a multi-turn annular coil after cooling; S2. Insulation wrapping of the series connection wires: Wrapping the series connection wires and lead wires of the multi-turn annular coil tightly with a film so that the length of the insulation wrapping meets the insulation requirements, and tying and fixing the multi-turn annular coil; S3. Insulation wrapping of multi-layer coils: Use the film to wrap the coil cake from the required starting point, wrap it clockwise from bottom to top to the overlapping point on the opposite side of the lead wire, and cover the lead wire insulation position, and tie the end position tightly after wrapping; S4. The entire coil is then insulated and wrapped. After the insulation wrapping is completed, the entire coil is placed in a baking furnace for sintering to ensure that the insulation performance reaches the preset standard.

2. A method for insulating and sealing a multi-turn annular coil according to claim 1, characterized in that: The film is a polyimide composite film.

3. The method for insulating and sealing a multi-turn annular coil according to claim 1, characterized in that: The multi-turn annular coil is wrapped with at least 4 layers.

4. The method for insulating and sealing a multi-turn annular coil according to claim 1, characterized in that: In the step S3, the inner circle of the multi-turn annular coil is wrapped in a half-overlapping manner, and the outer circle is wrapped in a overlapping manner.

5. The method for insulating and sealing a multi-turn annular coil according to claim 1, characterized in that: In step S3, the overlapping length between the end position and the starting point meets the insulation requirement.

6. The method for insulating and sealing a multi-turn annular coil according to claim 1, characterized in that: In the step S3, after packing, the end position is tied tightly with a polyimide adhesive tape or a cable tie.

7. The method for insulating and sealing a multi-turn annular coil according to claim 1, characterized in that: In the step S3, in the insulation wrapping of the multi-layer coil, the insulation overlap method of the coil cake and the insulation overlap method of the series wire includes the following steps: S3.

1. Lift the outermost electromagnetic wire first and then overlap the lower coil cake; S3.2, after overlapping the lower coil cake once, overlap another layer of film to the outermost electromagnetic wire; S3.3, repeat the above steps S3.1 and S3.2 once, and then wrap the lower layer of coil cake to a symmetrical position; S3.

4. Perform a cross-sealing bandage.

8. The method for insulating and sealing a multi-turn annular coil according to claim 7, characterized in that: In step S3.4, four areas are divided according to the positions of the coil cake, lead wire and series wire. The left and right sides of the series wire are area two and area one respectively, and the left and right sides of the lead wire are area three and area four respectively.

9. The method for insulating and sealing a multi-turn annular coil according to claim 8, characterized in that: First, the film is passed through from area one, and the film is inserted into area three; the composite film is passed through from area two, and the film is inserted into area one, and finally the film is passed through from area four, so that the cross-sealing wrapping of the coil cake can be completed.

10. The method for insulating and sealing a multi-turn annular coil according to claim 1, characterized in that: The overlapping length of the coil cake and the series wire is greater than the length of the insulation standard.

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