Preparation method of motor winding

Abstract

A preparation method of a motor winding comprises the following steps that S1, conductor line segment cutting and insulation paste caulking and fixing are completed on a prefabricated copper plate blank workpiece, and the relative positions of a segmented wire body and a visual positioning hole are kept consistent; s2, conductor lead wire and short circuit wire cutting; S3, conductor lead wire and short circuit wire caulking fixation with insulation glue; s4, carrying out secondary thermocuring on the UV photocuring adhesive on the workpiece to obtain a final joint filling and fixing effect; s5, removing residual glue on the conductor copper plate; s6, cutting internal and external electric connection points of the conductor copper plate, and performing laser cutting on the internal and external electric connection points of the conductor to form independent electric connection points; winding hot pressing and electrical connection point connection are carried out, multi-layer stacking is carried out on the conductor copper plates and the PP sheets, internal and external electrical connection points connected with each other are aligned, the stacked conductor copper plates and the PP sheets are fixed, and the conductor copper plates and the PP sheets are placed in a vacuum hot press for bonding pressing of the conductor copper plates and the PP sheets and electrical connection of the upper and lower electrical connection points at the corresponding positions.

Description

Technical Field

[0001] The present invention belongs to the technical field of motor manufacturing, and in particular relates to a method for preparing a motor winding. Background Art

[0002] In the current motor manufacturing process, motor windings are usually wound by enameled wire winding, braiding or PCB printing. Enameled wire windings waste space and materials in the motor structure, i.e., the winding slots are low, the end wires are too long, and the carbon emissions during the production of the winding raw material enameled wire are large. Among them, annealing, painting, baking, cooling and other processes and hazardous waste treatment require more electricity and auxiliary materials. PCB printed windings require lamination, exposure, development, etching and stripping to produce winding wires. Chemicals such as acids, alkalis and inks are involved, which also require additional energy consumption for hazardous waste treatment.

[0003] The above existing technologies lack effective technical measures for reducing raw materials and carbon emissions in the overall production of traditional motor windings. Summary of the Invention

[0004] In view of this, facing the shortcomings of the existing technology, the purpose of this application is to provide a method for preparing motor windings, overcoming the technical problems of space utilization and material waste in traditional motor structures and large carbon emissions during the production process. The motor winding preparation method of the present invention uses laser cutting and hot pressing to obtain a motor winding with optimized small size and excellent electrical and mechanical properties, and the flat wire winding has the advantages of short winding ends, high power density and strong heat dissipation capacity.

[0005] To achieve the above-mentioned and other related purposes, the present application provides a method for preparing motor windings, which uses pure copper sheet material and is mainly prepared by a laser cutting process and multi-layer stacking pressing, and includes the following steps:

[0006] S1: For the prefabricated copper sheet blank, the conductor segments are cut and fixed with insulating glue. The conductor bodies on the copper sheet are segmented by laser cutting, and the cut seams are filled with insulating glue. The glue is cured and bonded to the conductor bodies on both sides of the cut seams, so that the relative positions of the segmented conductor bodies and the visual positioning holes are consistent.

[0007] S2, conductor lead and short-circuit cutting, cutting the winding lead or short-circuit according to the needs of the circuit schematic;

[0008] S3, the conductor leads and short-circuit wires are fixed with insulating glue. The cut seam is filled with insulating glue and the glue is cured to bond the conductor leads or short-circuit wires on both sides of the cut seam, so that the relative position of the separated conductor leads or short-circuit wires is consistent with the visual positioning hole;

[0009] S4, curing the insulating adhesive on the workpiece to obtain the final caulking and fixing effect; resin adhesive or UV light curing adhesive can meet the needs of this application;

[0010] S5, cleaning the residual glue on the conductor copper plate, grinding and cleaning the residual glue on the surface of the cut copper plate, so that there is no conductive impurities intercalated between the conductors cut on the copper plate;

[0011] S6, cutting the inner and outer pads of the conductor copper plate, and performing laser cutting and separation on the inner and outer pads of the conductor, i.e., the connection points, to form independent electrical connection points;

[0012] S7, hot pressing of the winding and connection of the electrical connection points, stacking the conductor copper plates and PP sheets in multiple layers and aligning the internal and external electrical connection points that are connected to each other, fixing the stacked conductor copper plates and PP sheets, and placing them in a vacuum hot press to bond and press the conductor copper plates and PP sheets and electrically connect the upper and lower electrical connection points at corresponding positions.

[0013] The technical solution provided in this application also includes the following technical features:

[0014] Preferably, in one embodiment of the present application, the prefabricated copper plate blank workpiece in S1 is obtained by the following steps: blanking the copper plate blank to obtain the copper plate workpiece, shaping the copper plate workpiece, completing the visual positioning hole and process hole cutting of the copper plate, and deburring the copper plate workpiece;

[0015] Copper plate shaping, flatness shaping of uneven copper plate blanks to achieve the required flatness.

[0016] Visual positioning holes and process holes are cut by laser cutting. Visual positioning holes are used for visual positioning recognition and discrimination.

[0017] Deburring of copper plate workpieces, cleaning of surface bonding residual slag on the upper and lower surfaces of cutting;

[0018] The insulating glue is transparent and colorless UV light curing glue or resin glue;

[0019] The electrical connection method is a physical welding connection method such as reflow soldering and laser welding.

[0020] Preferably, in one embodiment of the present application, after the copper plate is shaped in S1, the flatness tolerance does not exceed 0.1 mm.

[0021] Preferably, in one embodiment of the present application, the secondary thermal curing parameter in S4 is: curing the insulating glue on the workpiece by heating at 110° C. within 6 minutes.

[0022] Preferably, in one embodiment of the present application, step S7 is included:

[0023] Deburring, removing slag and conductive impurities from the electrical connection points, split seams, and upper and lower surfaces;

[0024] Pre-treatment of the conductor electrical connection points, grinding and cleaning the conductor pad connection surface to remove oxide scale, oil stains and other unfavorable welding substances;

[0025] Scrape and apply solder paste, and screen print the solder paste on the surface of the electrical connection points to make the solder paste full;

[0026] Pre-treatment of solder paste at electrical connection points, low-temperature baking and dehydration of solder paste on conductor copper plates.

[0027] Preferably, in one embodiment of the present application, solder paste is scraped and applied in S7, and the thickness of the screen-printed steel mesh is 0.2 mm.

[0028] Preferably, in one embodiment of the present application, step S8 is included:

[0029] Winding hot pressing and electrical connection of electrical connection points: The conductor copper plates and PP sheets that have been pre-treated with solder paste are stacked in multiple layers and the internal and external electrical connection points that are connected to each other are aligned. The stacked conductor copper plates and PP sheets are fixed and placed in a vacuum hot press to bond and press the conductor copper plates and PP sheets and reflow the solder paste to electrically connect the upper and lower electrical connection points at the corresponding positions.

[0030] Preferably, in one embodiment of the present application, step S9 is included:

[0031] Visual inspection and quality control: Visual inspection of the semi-finished windings that have been pressed and bonded. The gaps between the pads are checked for solder overflow and adhesion or conductive impurities. Minor defects are cleaned with lasers for quality control.

[0032] Preferably, in one embodiment of the present application, step S10 is included:

[0033] Sealing the electrical connection points with glue, filling the gaps between the internal and external electrical connection points with insulating glue to ensure the electrical connection point positions and the insulation between the internal and external ring strength and the pad connection points;

[0034] The inner and outer process edges are milled and cleared by using a CNC milling machine, and there is no sticky copper chips between the inner and outer pads and the gap is clear. The CNC milling machine can also be a CNC multi-axis machine tool, which includes a milling machine processing technology.

[0035] Preferably, in one embodiment of the present application, step S11 is included:

[0036] Winding lead pretreatment: welding and insulation treatment of phase winding leads of pressed motor windings;

[0037] Winding electrical performance testing, including phase winding resistance testing, phase-to-phase insulation testing, current carrying testing, etc.

[0038] The whole is packaged and the outer surface of the winding is sealed with insulating glue. Thus, a complete laser-cut, stacked and pressed motor winding preparation is completed.

[0039] The beneficial effects of this application are:

[0040] 1. Suitable for the production of stacked high-power motor windings;

[0041] 2. No harmful waste gas is emitted during the production and preparation process and from raw materials;

[0042] 3. Achieve low-carbon production throughout the entire process;

[0043] 4. The preparation method can be easily automated throughout the entire process. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 This is a flow chart of a method for preparing a motor winding according to the present invention; DETAILED DESCRIPTION

[0045] The following further describes the specific embodiments of the present application in conjunction with the accompanying drawings. These embodiments are only used to illustrate the present application and are not intended to limit the present invention.

[0046] In the description of the present invention, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer" and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0047] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0048] Furthermore, in the description of the present invention, unless otherwise specified, “plurality” means two or more.

[0049] like Figure 1 A method for preparing a motor winding comprises the following steps 1-21:

[0050] 1. Blanking of copper sheet blanks: Blanking of copper sheet blanks is carried out according to the process size of the winding blanks to be prepared;

[0051] 2. Copper plate shaping, flattening the uneven copper plate blank to achieve the required flatness;

[0052] 3. Laser cutting is used to cut the visual positioning holes and process holes. The visual positioning holes are completely cleaned to facilitate subsequent visual positioning recognition and identification.

[0053] 4. Deburring and cleaning the upper and lower surfaces of the cutting to remove residual slag from the surface;

[0054] 5. Conductor segment cutting and UV light curing glue filling and fixing: Use laser cutting method to cut the conductor body on the copper plate, and use UV light curing glue to fill the cut seam and cure the glue to bond the conductor bodies on both sides of the cut seam, so that the relative position of the cut conductor body and the visual positioning hole are consistent;

[0055] 6. Conductor lead and short-circuit cutting: cut the winding lead or short-circuit according to the needs of the circuit schematic;

[0056] 7. The conductor leads and short-circuit wires are fixed with UV light-curing glue. The cut seams are filled with UV light-curing glue and the glue is cured to bond the conductor leads or short-circuit wires on both sides of the cut seams, so that the relative positions of the separated conductor leads or short-circuit wires and the visual positioning holes are consistent;

[0057] 8. Secondary thermal curing of UV light curing adhesive to achieve the final caulking and fixing effect;

[0058] 9. Remove residual glue from the conductor copper plate. Grind and remove the residual glue on the surface of the cut copper plate, and ensure that there are no conductive impurities mixed in between the conductors separated on the copper plate.

[0059] 10. Cutting of inner and outer pads of conductor copper plate, laser cutting and dividing the inner and outer pads of conductor, i.e. connection points, to form independent electrical connection points;

[0060] 11. Deburr, remove slag and conductive impurities from the pad split seam and upper and lower surfaces;

[0061] 12. Pre-treatment of conductor pads: polish and clean the surface of conductor pads to remove oxide scale, oil stains and other unfavorable welding substances;

[0062] 13. Scrape and apply solder paste, screen print solder paste on the pad position to ensure that the solder paste is full;

[0063] 14. Pretreatment of solder paste on pads, low-temperature baking and dehydration of solder paste on conductor copper plates;

[0064] 15. Hot pressing of windings and electrical connection of pads: stack the conductor copper plates and PP sheets that have been pre-treated with solder paste and align the inner and outer pads that are connected to each other. Fix the stacked conductor copper plates and PP sheets and place them in a vacuum hot press to bond and press the conductor copper plates and PP sheets and reflow solder paste to connect the upper and lower pads in corresponding positions.

[0065] 16. Visual inspection and quality control: Visual inspection of the semi-finished windings that have been pressed and bonded. Check for solder overflow and adhesion or conductive impurities in the gaps between pads. Laser cleaning and other quality control measures will be performed for minor defects.

[0066] 17. Seal the pad connection parts and fill the gaps between the inner and outer pads with UV light curing glue to ensure the pad position and the strength of the inner and outer circles and the insulation between the pad connection points;

[0067] 18. Milling and clearing of internal and external process edges: use CNC milling machine to mill and clear internal and external process edges, and ensure that there is no adhesion of copper chips between the internal and external pads and the gap is clear;

[0068] 19. Pre-treatment of winding leads: welding and insulation treatment of phase winding leads of pressed motor windings;

[0069] 20. Winding electrical performance test, including phase winding resistance test, phase insulation test, current carrying test, etc.;

[0070] 21. Overall packaging, the entire outer surface of the winding is encapsulated with UV light curing glue, thus completing the preparation of a complete laser cutting, stacking and pressing motor winding.

[0071] Specifically, during implementation, the copper plate blank is first blanked according to the process size of the winding blank to be prepared; the copper plate is then shaped, and the uneven copper plate blank is shaped to achieve the required flatness tolerance of 0.1mm (when the flatness of the curled surface of the blank is higher than 0.5mm, which is visually noticeable, the cutting of the wire conductor and the electrical connection point will produce obvious position and shape errors. The conservative value of the flatness tolerance of the copper plate blank is obtained by verification processing to be below 0.1mm, which can control the shape and position error of the electrical connection point caused by thermal deformation by laser cutting to 0.01-0.02mm); then the blank visual positioning hole and process hole are cut, and the cutting is carried out by laser cutting method to ensure the integrity of the shape of the visual positioning hole and clean the impurities and oxide scale around it to facilitate subsequent visual positioning identification and discrimination; then deburring is performed, and the cutting Clean the residual slag from the surface bonding on the upper and lower surfaces; then cut the conductor segments and fix them with UV light-curing glue. Use laser cutting to segment the wire bodies on the copper plate, and use UV light-curing glue to fill the cut seams and cure the glue to bond the conductor bodies on both sides of the cut seams, so that the relative positions of the separated wire bodies and the visual positioning holes are consistent; then cut the conductor leads and short-circuit wires, and cut the winding leads or short-circuit wires according to the needs of the circuit schematic; then use UV light-curing glue to fill the cut seams of the conductor leads and short-circuit wires and fix them, and use UV light-curing glue to fill the cut seams and cure the glue to bond the conductor leads or short-circuit wires on both sides of the cut seams, so that the relative positions of the separated conductor leads or short-circuit wires and the visual positioning holes are consistent; then perform a secondary thermal curing of the UV light-curing glue, and bake at 110°C for 6 minutes to obtain the final filling and fixing effect;

[0072] This application has been verified through multiple tests that the UV light curing adhesive can be cured at 110°C within 6 minutes to obtain a high hardness without becoming sticky, and will not stick to impurities generated in the subsequent process;

[0073] Next, the residual glue on the surface of the conductor copper plate is removed, and the residual glue left on the surface of the copper plate after cutting is polished and removed, and it is ensured that there are no conductive impurities intermingled and embedded between the conductors separated on the copper plate; then the inner and outer pads of the conductor copper plate are cut and the mechanical fixing process holes are cut, and the inner and outer pads of the conductor, that is, the connection points, are laser cut and separated to form independent electrical connection points; then the cutting surface is deburred, and the slag and conductive impurities adhering to the pad separation seam and the upper and lower surfaces are removed; then the conductor pad is pre-treated, and the connection surface of the conductor pad is polished and cleaned of oxide scale, oil stains and other unfavorable welding substances;

[0074] Then scrape the solder paste with a thickness of 0.2mm (sample verification: scrape the solder paste with a diameter of 1mm for reflow soldering and solidification, the average height of the solder collapse is 0.16mm, scrape the same amount of solder paste on the two flat electrical connection pads, and the spacing after bonding is 0.2mm, which can meet the 0.5mm 2 (The above cross-sectional requirements) The steel mesh is used to screen print the solder paste on the pad position to ensure that the solder paste is full;

[0075] The solder paste on the conductor copper plate is then baked and dehydrated at a low temperature; the conductor copper plate and PP sheet that have been pre-treated with solder paste are then stacked and the inner and outer pads connected to each other are aligned, the stacked conductor copper plate and PP sheet are fixed, and placed in a vacuum hot press to bond the conductor copper plate and PP sheet and reflow the solder paste to connect the upper and lower pads at corresponding positions; visual inspection and quality processing are then carried out, and the semi-finished windings that have been pressed and bonded are visually inspected. If there is solder overflow and adhesion or conductive impurities in the gaps between the pads, laser cleaning and other quality treatments are performed on the minor defects; then the pad connection parts are inspected. The gaps between the inner and outer pads are filled with UV light-curing glue to ensure the pad position, the strength of the inner and outer circles, and the insulation and fixation between the pad connection points; then, a CNC milling machine is used to mill and remove the inner and outer process edges, and ensure that there is no adhesion of copper chips between the inner and outer pads and the gap is clear; then the pressed motor winding is welded and insulated; then, the phase winding resistance test, phase insulation test, current carrying test, etc. are carried out; after passing the electrical performance test, the whole is packaged, and the outer surface of the winding is encapsulated with UV light-curing glue, thus completing a complete laser-cut, stacked and pressed motor winding preparation.

[0076] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and substitutions can be made without departing from the technical principles of the present invention. These improvements and substitutions should also be regarded as the scope of protection of the present invention.

Claims

1. A method for preparing a motor winding, characterized in that: The steps include: S1: For the prefabricated copper sheet blank, the conductor segments are cut and fixed with insulating glue. The conductor bodies on the copper sheet are segmented by laser cutting, and the cut seams are filled with insulating glue. The glue is cured and bonded to the conductor bodies on both sides of the cut seams, so that the relative positions of the segmented conductor bodies and the visual positioning holes are consistent. S2, conductor lead and short-circuit cutting, cutting the winding lead or short-circuit according to the needs of the circuit schematic; S3, the conductor leads and short-circuit wires are fixed with insulating glue. The cut seam is filled with insulating glue and the glue is cured to bond the conductor leads or short-circuit wires on both sides of the cut seam, so that the relative position of the separated conductor leads or short-circuit wires is consistent with the visual positioning hole; S4, curing the insulating glue on the workpiece to obtain the final filling and fixing effect; S5, cleaning the residual glue on the conductor copper plate, grinding and cleaning the residual glue on the surface of the cut copper plate, so that there is no conductive impurities intercalated between the conductors cut on the copper plate; S6, cutting the inner and outer pads of the conductor copper plate, and performing laser cutting and separation on the inner and outer pads of the conductor, i.e., the electrical connection points, to form independent electrical connection points; S7, hot pressing of the winding and connection of the electrical connection points, stacking the conductor copper plates and PP sheets in multiple layers and aligning the internal and external electrical connection points that are connected to each other, fixing the stacked conductor copper plates and PP sheets, and placing them in a vacuum hot press to bond and press the conductor copper plates and PP sheets and electrically connect the upper and lower electrical connection points at corresponding positions.

2. The method for preparing a motor winding according to claim 1, wherein: The prefabricated copper plate blank workpiece in S1 is obtained by the following steps: blanking the copper plate blank to obtain the copper plate workpiece, shaping the copper plate workpiece, completing the visual positioning hole and process hole cutting of the copper plate, and deburring the copper plate workpiece; Copper plate workpiece shaping, flatness shaping of uneven copper plate blanks to achieve the required flatness. Visual positioning holes and process holes are cut by laser cutting. Visual positioning holes are used for visual positioning recognition and discrimination. Deburring of copper plate workpieces, cleaning of surface bonding residual slag on the upper and lower surfaces of cutting; The insulating adhesive is a transparent and colorless UV light curing adhesive; The electrical connection method is a physical welding connection method such as reflow soldering and laser welding.

3. The method for preparing a motor winding according to claim 2, wherein: After the copper plate in S1 is shaped, the flatness tolerance does not exceed 0.1mm.

4. The method for preparing a motor winding according to claim 1, wherein: The secondary thermal curing parameters in S4 are: The insulating glue on the workpiece is heated and cured at 110°C within 6 minutes.

5. The method for preparing a motor winding according to claim 1, wherein: The method comprises step S7: Deburring, removing slag and conductive impurities from the electrical connection points, split seams, and upper and lower surfaces; Conductor pad pretreatment: polish and clean the connection surface of the conductor pad to remove oxide scale, oil stains and other unfavorable welding substances; Scrape and apply solder paste, and screen print solder paste on the pad position to make the solder paste full; Pad solder paste pretreatment, low temperature baking and dehydration treatment of the solder paste on the conductor copper plate.

6. The method for preparing a motor winding according to claim 5, wherein: Solder paste was scraped off in S7, and the thickness of the screen-printed steel mesh was 0.2 mm.

7. A method for preparing a motor winding according to claim 6, characterized in that: The method comprises step S8: The windings are hot pressed and the pads are electrically connected. The conductor copper plates and PP sheets are stacked and the internal and external electrical connection points that are connected to each other are aligned. The stacked conductor copper plates and PP sheets are fixed and placed in a vacuum hot press to bond and press the conductor copper plates and PP sheets and electrically connect the upper and lower electrical connection points at the corresponding positions.

8. The method for preparing a motor winding according to claim 7, wherein: The method comprises step S9: Visual inspection and quality control: Visual inspection of the semi-finished windings that have been pressed and bonded. The gaps between the pads are checked for solder overflow and adhesion or conductive impurities. Minor defects are cleaned with lasers for quality control.

9. A method for preparing a motor winding according to claim 8, characterized in that: The method comprises step S10: The pad connection part is sealed with glue, and the gap between the inner and outer pads is filled with insulating glue to ensure the pad position and the strength of the inner and outer circles and the insulation between the pad connection points; The inner and outer process edges are milled and removed by machining, and there is no sticky copper chips between the inner and outer pads and the gap is clear.

10. The method for preparing a motor winding according to claim 9, characterized in that: The method comprises step S11: Winding lead pretreatment: welding and insulation treatment of phase winding leads of pressed motor windings; Winding electrical performance testing, including phase winding resistance testing, phase-to-phase insulation testing, current carrying testing, etc. The whole is packaged and the outer surface of the winding is sealed with insulating glue. Thus, a complete laser-cut, stacked and pressed motor winding preparation is completed.

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