Stator insulating layer processing technology, stator and motor

Abstract

The invention relates to the technical field of motor manufacturing, in particular to a stator insulating layer processing technology, a stator and a motor. The stator insulating layer processing technology provided by the invention comprises the following steps: heating a stator so that the temperatures of two to-be-coated ends of the stator reach a coating temperature; the two to-be-coated ends of the stator are sequentially coated with an insulating material for at least N times, the to-be-coated end is rotated by a preset angle in at least one insulating material coating process before the Nth insulating material coating of each to-be-coated end, and N is larger than or equal to 3; and vertically placing the coated stator in a drying oven, and curing the stator. As the stator is coated with the insulating layer for N times, and N is greater than or equal to 3, compared with one-time coating, the non-coated position or the thin position of the insulating layer can be subjected to supplementary coating during each time of coating, so that the thickness of the obtained insulating layer is uniform, the production quality of the insulating layer is improved, the thickness of the insulating layer is uniform, the reworking times of coating the insulating layer on the stator can be reduced, and the production cost is reduced. And the production efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of motor manufacturing, and in particular to a stator insulation layer processing technology, a stator and a motor. Background Art

[0002] In the electric drive system of new energy vehicles, the coating process of the drive motor stator is crucial. It not only provides insulation protection for the stator winding to prevent short circuits and leakage, but also significantly improves the NVH performance of the motor and enhances the motor's reliability and durability. The stator coating process may cause failures in product quality such as coating damage, unevenness, and insufficient thickness. From the perspective of production efficiency, the heating, cooling, and reheating process steps in the stator manufacturing process often significantly extend the production cycle and increase production time. In related technologies, the stator coating quality is poor during coating, resulting in the need to re-coat the stator if it fails the test after coating, which directly affects production quality and production efficiency.

[0003] Therefore, a stator insulation layer processing technology is urgently needed to solve the above technical problems. Summary of the Invention

[0004] The object of the present invention is to provide a stator insulation layer processing technology, a stator and a motor, which can improve the production quality of the insulation layer and increase production efficiency.

[0005] To achieve this object, the present invention adopts the following technical solutions:

[0006] A process for processing a stator insulation layer is provided. The stator has two ends to be coated, which are a welding end and a crown end. The process comprises:

[0007] heating the stator so that the temperature of the two ends of the stator to be coated reaches the coating temperature;

[0008] Applying insulation material to the two ends of the stator to be coated at least N times in sequence, and rotating the end to be coated by a preset angle during at least one insulation material coating process before the Nth insulation material coating, where N is greater than or equal to 3;

[0009] The coated stator is placed vertically in an oven to cure the stator.

[0010] As a preferred technical solution for the above-mentioned stator insulation layer processing technology, during the coating process of any end to be coated of the stator, in the process from the first insulation material coating to the N-1th insulation material coating process, the end to be coated of the stator is placed vertically in the coating tank and kept still for a first preset time, and then the stator is rotated by a preset angle, and then the welding terminal of the stator is taken out and hovered above the coating tank for a second preset time. During the Nth insulation material coating process, the end to be coated of the stator is placed vertically in the coating tank and kept still for a first preset time, and then the welding terminal of the stator is taken out and hovered above the coating tank for a second preset time.

[0011] As a preferred technical solution for the above-mentioned stator insulation layer processing technology, when adjacent secondary insulation materials are coated, the stators rotate in opposite directions.

[0012] As a preferred technical solution for the above-mentioned stator insulation layer processing technology, the preset angle has a value range of 13°-17°.

[0013] As a preferred technical solution for the above-mentioned stator insulation layer processing technology, when each end to be coated is subjected to the last coating, the fluidizing gas source in the coating pool stops working.

[0014] As a preferred technical solution of the above-mentioned stator insulation layer processing technology, the stator insulation layer processing technology further includes:

[0015] Paint the stator.

[0016] As a preferred technical solution for the above-mentioned stator insulation layer processing technology, after the two ends of the stator to be coated are coated with insulation material N times, multiple inspection points are selected for thickness inspection on the welding end of the stator, and multiple inspection points are selected for thickness inspection on the busbar at the crown end of the stator.

[0017] As a preferred technical solution for the above-mentioned stator insulation layer processing technology, after the thickness detection is completed, the stator is subjected to a motor performance test.

[0018] A stator is provided, which is manufactured using the stator insulation layer processing technology described in any of the above solutions.

[0019] A motor is provided, comprising a rotor and the above-mentioned stator, wherein the rotor is located in an area surrounded by the stator.

[0020] The present invention provides the following beneficial effects:

[0021] The stator insulation layer processing process provided by the present invention includes: S101, heating the stator to bring the temperature of the two ends to be coated of the stator to the coating temperature; S102, sequentially applying insulation material to the two ends to be coated at least N times, and rotating each end to be coated by a preset angle during at least one insulating material coating process before the Nth insulating material coating, where N ≥ 3; S103, vertically placing the coated stator in an oven to cure the stator. Because the stator insulation layer is coated N times, where N ≥ 3, each coating can be used to supplement uncoated or thinner areas, compared to a single coating. This ensures a uniform insulation layer thickness, improves the production quality of the insulation layer, and reduces the number of reworks required for stator insulation coating, thereby improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in describing the embodiments of the present invention. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the contents of the embodiments of the present invention and these drawings without any creative work.

[0023] Figure 1 A schematic diagram of the main steps of a stator insulation layer processing process provided by an embodiment of the present invention;

[0024] Figure 2 A schematic diagram of the steps of coating a stator with insulating material according to an embodiment of the present invention;

[0025] Figure 3 A front view of a stator provided in an embodiment of the present invention;

[0026] Figure 4 A schematic diagram of detection points for detecting temperature at the welding end during stator preheating according to an embodiment of the present invention;

[0027] Figure 5 A schematic diagram of detection points for detecting temperature at the crown end during stator preheating according to an embodiment of the present invention;

[0028] Figure 6 Schematic diagram of eight detection points for detecting the thickness of the weld end of the stator after coating is completed according to an embodiment of the present invention;

[0029] Figure 7 A schematic diagram of three detection points for detecting the thickness of the crown end of a stator after coating is completed according to an embodiment of the present invention;

[0030] Figure 8 A temperature variation curve diagram of each step of the stator during paint dripping provided by an embodiment of the present invention;

[0031] Figure 9 A temperature variation curve diagram of each step during coating of a stator provided by an embodiment of the present invention;

[0032] Figure 10 This is a temperature change curve diagram of each process after the stator is sprayed with paint and coated according to an embodiment of the present invention.

[0033] In the picture:

[0034] 1. Stator; 11. Welding end; 12. Crown end. DETAILED DESCRIPTION

[0035] The present invention will be further described in detail below with reference to the accompanying drawings and examples. It will be understood that the specific embodiments described herein are intended only to illustrate the present invention and are not intended to limit the present invention. It should also be noted that, for ease of description, the accompanying drawings only illustrate portions relevant to the present invention, not all structures.

[0036] In the description of the present invention, unless otherwise expressly specified or limited, the terms "connected," "connected," and "fixed" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integration; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention in specific circumstances.

[0037] In the present invention, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Furthermore, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0038] In the description of this embodiment, the terms "upper," "lower," "right," and other orientations or positional relationships are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely for ease of description and simplified operation. They do not indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second" are used solely for descriptive purposes and have no special meanings.

[0039] The motor has a stator and a rotor, wherein the stator includes a stator core, a stator winding and insulating paper, the stator core has a plurality of winding slots, the stator winding includes a plurality of wires passing through the winding slots, and the plurality of wires form a crown end on one side of the stator core and a welding end on the other side of the stator core.

[0040] The stator coating process is extremely important. It not only provides insulation protection for the stator winding to prevent short circuits and leakage, but also significantly improves the NVH performance of the motor and enhances the reliability and durability of the motor. The stator coating process may cause failures in product quality such as coating damage, unevenness, and insufficient thickness. From the perspective of production efficiency, the heating, cooling, and reheating process steps in the stator manufacturing process often significantly extend the production cycle and increase production time. Therefore, it is crucial to formulate a reasonable coating process. The present invention provides a stator insulation layer processing technology to improve production quality and efficiency.

[0041] For ease of description, Figure 3 As shown, the stator 1 is limited to have two ends to be coated, and the two ends to be coated are the welding end 11 and the crown end 12 described above.

[0042] like Figure 1 As shown, the stator insulation layer processing technology includes:

[0043] S101, heating the stator 1 so that the temperature of the two ends to be coated of the stator 1 reaches the coating temperature;

[0044] S102, coating the two ends of the stator 1 with insulating material at least N times in sequence, and rotating each end by a preset angle during at least one insulating material coating process before the Nth insulating material coating, where N is greater than or equal to 3;

[0045] S103 , placing the coated stator 1 vertically in an oven to cure the stator 1 .

[0046] Since the stator 1 is coated with the insulating layer N times, and N ≥ 3, compared with one coating, the uncoated or thinner insulating layer positions can be supplementally coated each time, so that the thickness of the obtained insulating layer can be uniform, thereby improving the production quality of the insulating layer. The uniform thickness of the insulating layer can reduce the number of rework times for coating the stator 1 with the insulating layer, thereby improving production efficiency.

[0047] During the coating process of any end to be coated of the stator 1, from the first insulating material coating process to the N-1 insulating material coating process, the end to be coated of the stator 1 is placed vertically in the coating tank and allowed to rest for a first preset time, then the stator 1 is rotated by a preset angle, and then the welding end 11 of the stator 1 is taken out and allowed to hover and remain still above the coating tank for a second preset time. During the Nth insulating material coating process, the end to be coated of the stator 1 is placed vertically in the coating tank and allowed to rest for a first preset time, then the welding end 11 of the stator 1 is taken out and allowed to hover and remain still above the coating tank for a second preset time. Placing the end to be coated of the stator 1 vertically in the coating tank and allowing it to rest for a first preset time allows the end to be coated of the stator 1 to repeatedly contact the insulating material in the coating tank, providing time for the insulating material to adhere to the end to be coated. In addition, rotating the stator 1 by a preset angle allows the insulating material around the end to be coated to loosen and flow toward the end to be coated so as to contact the end to be coated, thereby increasing the amount of insulating material adhered to the end to be coated, thereby avoiding a small amount of insulating material coated on the end to be coated. During the Nth coating process, the end to be coated of the stator 1 is placed vertically into the coating pool and allowed to remain stationary for a first preset time. Then, the welding end 11 of the stator 1 is taken out and allowed to remain stationary above the coating pool for a second preset time. This can prevent the insulating material attached to the end to be coated from falling off during the rotation of the end to be coated, thereby improving the coating efficiency.

[0048] In some embodiments, the stator 1 rotates in opposite directions during adjacent insulation material coatings. For example, during the first insulation material coating, the stator 1 rotates in a first direction, and during the second insulation material coating, the stator 1 rotates in a second direction, the first direction being opposite to the second direction. For example, one of the first direction and the second direction is clockwise, and the other is counterclockwise.

[0049] For example, the preset angle ranges from 13° to 17°. Optionally, the preset angle ranges from 13°, 14°, 15°, 16°, or 17°, which is not specifically limited in this embodiment. Compared with existing preset angles, this preset angle reduces the rotation angle during the coating process, reduces the time required, and improves production efficiency.

[0050] When each end to be coated is coated for the last time, the fluidizing gas source in the coating pool stops working. After the fluidizing gas source is turned off, the insulating material in the coating pool is less loose than when the fluidizing gas source is working, which can save energy.

[0051] Taking the coating of the two coated ends of stator 1 three times as an example, the coating process is as follows:

[0052] During the first insulating material coating, the first end of the stator 1 to be coated is placed vertically into the coating tank and allowed to rest for a first preset time. The stator 1 is then rotated in a first direction for a preset angle. The first end of the stator 1 to be coated is then taken out and allowed to hover above the coating tank for a second preset time.

[0053] The first end of the stator 1 to be coated is placed vertically into the coating tank and allowed to rest for a first preset time. The stator 1 is then rotated in a second direction by a preset angle. The first end of the stator 1 to be coated is then taken out and allowed to hover above the coating tank and remain stationary for a second preset time.

[0054] The first end of the stator 1 to be coated is placed vertically into the coating tank and remains stationary for a first preset coating time. Then, the first end of the stator 1 to be coated is taken out and remains stationary above the coating tank for a first preset time to achieve the third coating of the stator 1.

[0055] The second end of the stator 1 to be coated is placed vertically into the coating tank and allowed to rest for a first preset time. The stator 1 is then rotated in a first direction by a preset angle. The first end of the stator 1 to be coated is then taken out and allowed to hover above the coating tank and remain stationary for a second preset time.

[0056] The second end of the stator 1 to be coated is placed vertically into the coating tank and allowed to rest for a first preset time. The stator 1 is then rotated in a second direction by a preset angle. The first end of the stator 1 to be coated is then taken out and allowed to hover above the coating tank and remain stationary for a second preset time.

[0057] The second end of the stator 1 to be coated is placed vertically into the coating tank and remains stationary for a first preset coating time. Then, the first end of the stator 1 to be coated is taken out and remains stationary above the coating tank for a first preset time to achieve the third coating of the stator 1.

[0058] It should be noted that the preheating temperature, curing temperature and process duration of each coating step of the stator 1 should be set according to the characteristics of the coating material and the drawing requirements of the motor product.

[0059] The purpose of heating the stator 1 is to preheat the stator 1 to the moving temperature to provide conditions for coating and ensure that the insulating material can adhere to the stator surface. The stator 1 is preheated to the preset temperature. During the preheating process, the temperature of the stator 1 needs to be collected regularly. Specifically, the temperature is collected using an infrared temperature measuring gun to test the temperature of the crown end 12 of the stator 1 and the welding end 11 of the stator 1. The test method is to test 6 positions evenly distributed around the circumference of both ends. The 6 positions of the welding end 11 are H1, H2, H3, H4, H5 and H6, respectively. See the details. Figure 4; The six positions of the crown end 12 are H7, H8, H9, H10, H11 and H12, the specific parts Figure 5 After the stator 1 is preheated and reaches the process requirements, coating can be carried out. The insulating material used in the coating is in powder form.

[0060] Specifically, for example, the welding end 11 is coated first and the crown end 12 is coated later. Figure 2 As shown, the coating of the stator 1 includes the following steps:

[0061] 201. Stator 1 is preheated to a preset temperature;

[0062] 202. Place the welding end 11 of the stator 1 vertically into the coating tank and allow it to remain stationary for a first preset time. Then, rotate the stator 1 in a first direction by a preset angle. Then, remove the welding end 11 of the stator 1 and allow it to remain stationary above the coating tank for a second preset time.

[0063] 203. Place the welding end 11 of the stator 1 vertically into the coating tank and allow it to remain stationary for a first preset time. Then, rotate the stator 1 in a second direction by a preset angle. Then, remove the welding end 11 of the stator 1 and allow it to remain stationary above the coating tank for a second preset time.

[0064] 204. Place the welding end 11 of the stator 1 vertically into the coating tank and allow it to remain stationary for a first preset coating time. Then, take the welding end 11 of the stator 1 out and allow it to remain stationary above the coating tank for a second preset coating time.

[0065] 205, inverted stator 1;

[0066] 202. Place the crown end 12 of the stator 1 vertically into the coating tank and allow it to remain stationary for a first preset time. Then, rotate the stator 1 in a first direction by a preset angle. Then, remove the crown end 12 of the stator 1 and allow it to remain stationary above the coating tank for a second preset time.

[0067] 203. Place the crown end 12 of the stator 1 vertically into the coating tank and allow it to remain stationary for a first preset time. Then, rotate the stator 1 in a second direction by a preset angle. Then, remove the crown end 12 of the stator 1 and allow it to remain stationary above the coating tank for a second preset time.

[0068] 204. Place the crown end 12 of the stator 1 vertically into the coating tank and allow it to remain stationary for a first preset coating time. Then, take the crown end 12 of the stator 1 out and allow it to remain stationary above the coating tank for a second preset coating time.

[0069] 209. Heat and solidify the stator 1.

[0070] When curing the stator 1 , it is necessary to heat the stator 1 to a set curing temperature and cure it for a third preset time.

[0071] In addition, the process for processing the insulation layer of the stator 1 further includes: dripping paint on the stator 1 .

[0072] It should be noted that when the stator 1 is being painted and coated, the paint can be dripped first and then coated, or coated first and then painted. The order of paint dripping and coating needs to be determined according to the insulating material to be coated and the paint dripping material.

[0073] In terms of the connection between coating and dripping, the present invention provides a connection selection scheme between coating and dripping, and the specific implementation method is as follows:

[0074] Formulate coating and dripping paint separately according to the coating material characteristics, dripping paint material characteristics and product drawing requirements;

[0075] According to the selected coating and dripping requirements, the temperature change curve of the parts required during coating and dripping is drawn. For example, taking the selection of an insulating material, such as epoxy insulating powder, the corresponding process and temperature of the material during dripping and coating are shown in Table 1. The temperature connection change curve of the coating process and dripping process is drawn. Figure 8 、 Figure 9 and Figure 10 .

[0076] Table 1

[0077]

[0078] According to the above analysis based on the temperature change, the temperature of the paint dripping and curing just meets the preheating temperature of the coating. Therefore, for this kind of insulation material, the process connection solution of first dripping the paint and then coating can be selected;

[0079] Then, according to the process connection method, the overall temperature curve of the insulation process is improved to achieve the connection between the coating preheating process and the paint dripping curing process.

[0080] Furthermore, after both ends of stator 1 to be coated have been coated with insulation material N times, thickness testing is performed at multiple inspection points on the weld end 11 of stator 1, and at multiple inspection points on the busbar at the crown end 12 of stator 1. The purpose of this testing is to determine whether the insulation layer thickness of stator 1 meets the requirements after coating. If it does not, rework and re-coating are required to reduce the defective rate of stator 1 after coating, thereby reducing production costs.

[0081] Specifically, a detection point is selected for stator 1, specifically, as Figure 6 As shown, eight detection points B1, B2, B3, B4, B5, B6, B7 and B8 are selected from the welding end 11 of the stator 1 at evenly distributed positions around the circumference; Figure 7As shown, three positions of the crown end 12 of the stator 1 are selected as detection points A1, A2 and A3.

[0082] Before and after coating the insulating material, the insulation layer thickness is tested at each test point of the stator 1. The thickness of the end to be coated before coating is a, the thickness of the end to be coated after coating is b, and the coating thickness is h. The difference between the two test results is used to calculate whether the coating thickness is qualified. The calculation formula is h = (b a) / 2.

[0083] After the thickness test is completed, the motor performance test is performed on the stator 1. The motor performance test is performed using a comprehensive tester. The specific test method is as follows:

[0084] Place stator 1 on an insulating platform with the busbar facing upwards;

[0085] Connect the three-phase lines and neutral point of the busbar of stator 1 to the comprehensive tester through wires;

[0086] In accordance with the test process requirements, insulation, resistance and other aspects are tested respectively. Table 2 shows the electrical performance test parameters of a stator obtained by the above-mentioned stator insulation layer processing technology.

[0087] Table 2

[0088]

[0089]

[0090] The present invention also provides a stator manufactured using the stator insulation layer processing process provided herein. Because the stator insulation layer is coated N times, where N is ≥ 3, each coating can be used to recoat uncoated or thinner areas, compared to a single coating. This ensures a uniform insulation layer thickness, improving the production quality of the insulation layer. A uniform insulation layer thickness reduces the number of reworks required for the stator insulation layer, thereby improving production efficiency.

[0091] The present invention also provides a motor comprising a rotor and a stator provided by the present invention, wherein the rotor is located within the area enclosed by the stator. The stator is manufactured using the stator insulation layer processing process provided by the present invention. Because the stator insulation layer is coated N times, where N ≥ 3, each coating can be performed to additionally coat uncoated or thinner areas, compared to a single coating. This ensures a uniform insulation layer thickness, improving the production quality of the insulation layer. A uniform insulation layer thickness can reduce the number of reworks required for the stator insulation layer, thereby improving production efficiency.

[0092] Furthermore, the above are only preferred embodiments of the present invention and the technical principles employed. Those skilled in the art will appreciate that the present invention is not limited to the specific embodiments described herein, and that various obvious changes, readjustments, and substitutions are possible for those skilled in the art without departing from the scope of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments and may include many other equivalent embodiments without departing from the scope of the present invention. The scope of the present invention is determined by the scope of the appended claims.

Claims

1. A stator insulation layer processing process, characterized in that: The stator has two ends to be coated, namely a welding end and a crown end. The process includes: heating the stator so that the temperature of the two ends of the stator to be coated reaches the coating temperature; Applying insulation material to the two ends of the stator to be coated at least N times in sequence, and rotating the end to be coated by a preset angle during at least one insulation material coating process before the Nth insulation material coating, where N is greater than or equal to 3; The coated stator is placed vertically in an oven to cure the stator.

2. The stator insulation layer processing process according to claim 1, characterized in that: During the coating process of any end to be coated of the stator, from the first insulating material coating to the N-1 insulating material coating process, the end to be coated of the stator is placed vertically in the coating tank and remains stationary for a first preset time, then the stator is rotated by a preset angle, and then the welding terminal of the stator is taken out and hovered above the coating tank for a second preset time. During the Nth insulating material coating process, the end to be coated of the stator is placed vertically in the coating tank and remains stationary for a first preset time, then the welding terminal of the stator is taken out and hovered above the coating tank for a second preset time.

3. The stator insulation layer processing process according to claim 2, characterized in that: When adjacent secondary insulation materials are applied, the stator rotation direction is opposite.

4. The stator insulation layer processing process according to any one of claims 1 to 3, characterized in that: The preset angle ranges from 13° to 17°.

5. The stator insulation layer processing process according to any one of claims 1 to 3, characterized in that: When each end to be coated is coated for the last time, the fluidizing gas source in the coating pool stops working.

6. The stator insulation layer processing process according to any one of claims 1 to 3, characterized in that: The stator insulation layer processing process also includes: Paint the stator.

7. The stator insulation layer processing process according to any one of claims 1 to 3, characterized in that: After N times of insulation material coating is completed on both ends of the stator to be coated, multiple inspection points are selected for thickness inspection on the welding end of the stator, and multiple inspection points are selected for thickness inspection on the busbar at the crown end of the stator.

8. The stator insulation layer processing process according to any one of claims 1 to 3, characterized in that: After the thickness test is completed, the stator is tested for motor performance.

9. A stator, characterized in that The stator insulation layer is manufactured using the stator insulation layer processing process described in any one of claims 1 to 8.

10. The motor is characterized in that The invention comprises a rotor and the stator according to claim 9, wherein the rotor is located in an area enclosed by the stator.

Images