Brushless doubly-fed motor assembling process

Abstract

The invention relates to the technical field of production of brushless doubly-fed motors, and discloses a brushless doubly-fed motor assembly process, which comprises the following steps of: performing insulation treatment on the surface of a bent electromagnetic wire, and mounting the electromagnetic wire into a groove of a stator or a rotor; welding the end part, outside the groove, of the electromagnetic wire, winding an insulating tape on the welding part at a first set tension, and fixing the insulating tape to form a first insulating layer B; and forming a second insulating layer on the surface of the welding part with the first insulating layer B. When insulation treatment is carried out on a welding part, first set tension can be kept when an insulating tape is wound by utilizing an auxiliary tool, the situation that the insulating tape is loosened after being wound is prevented, and the situation that the winding quality cannot be guaranteed and the insulation effect is affected due to pure manual operation is avoided; moreover, a second insulating layer is also formed on the surface of the first insulating layer B, so that the insulation reliability is further ensured, the safety fault risk of the motor is reduced, and the maintenance cost is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the production technical field of brushless doubly-fed motor, more particularly, the present application relates to a brushless doubly-fed motor assembly process. BACKGROUND

[0002] In the production process of brushless doubly-fed motor, the processing and assembly of the electromagnetic wire are particularly important, especially for high-voltage and high-power motors, which usually use copper bar electromagnetic wire. However, due to the high hardness and poor flexibility of the copper bar, it cannot be directly wound, but needs to be bent into a specific shape, then insulated, and then installed into the slot of the stator or rotor. Finally, the end of the copper bar outside the slot is welded to form a complete loop.

[0003] The existing technology still has deficiencies in the insulation treatment of the electromagnetic wire, which makes the insulation layer of the electromagnetic wire easy to be damaged, and the maintenance cost is high.

[0004] Therefore, it is necessary to propose a brushless doubly-fed motor assembly process to at least partially solve the problems existing in the prior art. SUMMARY

[0005] A series of simplified concepts are introduced in the summary section, which will be further described in detail in the specific embodiment section. The summary section of the present application does not mean to attempt to limit the key features and necessary technical features of the claimed technical solution, nor to attempt to determine the protection scope of the claimed technical solution.

[0006] To at least partially solve the above problems, the present application provides a brushless doubly-fed motor assembly process, comprising: After insulating the surface of the bent electromagnetic wire, it is installed into the slot of the stator or rotor; The end of the electromagnetic wire outside the slot is welded, and the welding part is wound with an insulation tape at a first set tension and fixed to form a first insulation layer B; A second insulation layer is formed on the surface of the welding part with the first insulation layer B.

[0007] Preferably, the insulation treatment of the surface of the bent electromagnetic wire comprises: Determining the area of the electromagnetic wire that needs to be insulated; Winding the insulation tape at a first set tension and fixing it to form a first insulation layer A with a first set thickness.

[0008] Preferably, the fixing of the insulation tape comprises: winding a non-woven tape outside the wound insulation tape, and heating and curing the non-woven tape.

[0009] Preferably, the forming of the second insulation layer comprises: placing the stator or the rotor as a whole into a vacuum pressure impregnation device, and impregnating a resin material in a vacuum environment, so that the surface of the welding portion with the first insulation layer B and the surface of the bare electromagnetic wire with the first insulation layer A form the second insulation layer with the second set thickness.

[0010] Preferably, the insulation treatment of the surface of the bent electromagnetic wire is performed by an insulation treatment device which insulates the bent electromagnetic wire according to a set insulation treatment parameter. The set insulation treatment parameter comprises: a first set tension for winding the insulation tape, a second set tension for winding the weftless tape, and a first set thickness.

[0011] Preferably, the bending of the electromagnetic wire comprises: bending the electromagnetic wire according to a set bending parameter by a bending device. The set bending parameter comprises: a bending angle of the electromagnetic wire, a bending radius, and a bending position.

[0012] Preferably, the winding of the insulation tape on the welding portion with the first set tension comprises: temporarily fixing one end of the insulation tape to the welding portion after fixing the insulation tape on a winding mechanism; moving the winding mechanism to wind the insulation tape on the outside of the welding portion in a spiral shape, and the overlap rate of the spiral winding is greater than or equal to 50%; detecting the winding tension of the insulation tape in real time by the winding mechanism to make the winding tension meet the first set tension.

[0013] Preferably, the detecting of the winding tension of the insulation tape in real time by the winding mechanism comprises: extruding the support cylinder of the winding mechanism when the insulation tape is wound, so that the pressure sensing layer sleeved between the support cylinder and the support column detects the change of pressure; processing the pressure detected by the pressure sensing layer by a processor arranged in the support column to obtain the real-time winding tension.

[0014] Preferably, the pressure sensing layer comprises: an elastic layer arranged between the support cylinder and the support column, and a plurality of pressure sensors arranged between the elastic layer and the support column, and the plurality of pressure sensors are uniformly distributed along the circumference of the support column.

[0015] Preferably, the processing of the pressure detected by the pressure sensing layer by the processor comprises: obtaining pressure detection values of the plurality of pressure sensors and performing filtering processing on the pressure detection values to obtain a plurality of filtered pressure values; The maximum pressure value among multiple filtered pressure values ​​is selected, and the pressure sensor corresponding to the maximum pressure value and its circumferentially adjacent pressure sensors are indexed to obtain the high-pressure area. Calculate the average pressure value of the pressure sensor in the high-pressure area, and obtain the real-time winding tension based on the average pressure value.

[0016] Compared with the prior art, the present invention has at least the following beneficial effects: The brushless doubly fed motor assembly process of the present invention utilizes auxiliary tools to maintain a first set tension when insulating the welded parts, preventing the insulating tape from becoming loose after winding. This avoids the inability to guarantee winding quality due to purely manual operation, which would affect the insulation effect. Furthermore, a second insulating layer is formed on the surface of the first insulating layer B, further ensuring the reliability of the insulation, reducing the risk of motor safety failures, and reducing maintenance costs.

[0017] The brushless doubly fed motor assembly process described in this invention, along with other advantages, objectives, and features of this invention, will be partly apparent from the following description and partly understood by those skilled in the art through study and practice of this invention. Attached Figure Description

[0018] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a flowchart of the assembly process of the brushless doubly fed motor described in this invention; Figure 2 This is a flowchart of step S2 in the brushless doubly fed motor assembly process described in this invention; Figure 3 This is a schematic diagram of the internal structure of the winding mechanism in the brushless doubly fed motor assembly process described in this invention; Figure 4 This is a schematic diagram of the winding mechanism in the assembly process of the brushless doubly fed motor described in this invention; Figure 5 This is a flowchart of step S23 in the brushless doubly fed motor assembly process described in this invention. Detailed Implementation

[0019] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments, so that those skilled in the art can implement it based on the description.

[0020] It should be understood that terms such as “having,” “comprising,” and “including” as used herein do not exclude the presence or addition of one or more other elements or combinations thereof.

[0021] like Figure 1As shown, the present application provides a brushless doubly-fed motor assembly process, comprising: S1, after the surface of the bent magnet wire is insulated, it is installed into the slot of the stator or rotor; S2, the end of the magnet wire outside the slot is welded, the welding part is wound with an insulation tape at a first set tension and fixed to form a first insulation layer B; S3, a second insulation layer is formed on the surface of the welding part with the first insulation layer B.

[0022] Among them, the welding part refers to the part of the end of the magnet wire outside the slot which has not been insulated, and the part which has not been insulated needs to form the first insulation layer B and the second insulation layer.

[0023] Among them, the magnet wire is a copper bar, and the copper bar is bent for subsequent assembly and end welding; since the stator and the rotor are both iron cores, the magnet wire needs to be insulated to prevent voltage breakdown risk and ensure safe use of the motor; In addition, the stator of the brushless doubly-fed motor adopts a deepened iron core slot, when the magnet wire is installed into the slot of the stator, the magnet wire installed in the inner layer of the slot forms a high-voltage winding, and the magnet wire installed in the outer layer forms a low-voltage winding, the inner layer and the outer layer are isolated by epoxy resin, and both layers of windings are treated according to high-voltage insulation standards to ensure insulation effect.

[0024] Since most of the surface of the magnet wire has been insulated, and the end outside the slot needs to be welded, it needs to be insulated after welding; in the prior art, since the shape of the welding part is irregular, manual operation is needed for insulation treatment, which makes the insulation treatment effect different, resulting in reduced insulation reliability; Therefore, when the welding part is insulated, the auxiliary tool can maintain the first set tension when winding the insulation tape, preventing the insulation tape from loosening after winding and affecting the insulation effect; and the second insulation layer is also formed on the surface of the first insulation layer B, further ensuring the reliability of the insulation, reducing the risk of safety failure, and reducing maintenance cost.

[0025] In one embodiment, the surface of the bent magnet wire is insulated, comprising: Determine the area of the magnet wire that needs to be insulated; Winding the insulation tape at a first set tension and fixing it to form a first insulation layer A with a first set thickness.

[0026] Among them, the insulation tape adopts mica tape, which is a fire-resistant insulation material with excellent high-temperature resistance and combustion resistance.

[0027] Wherein, except the end of the electromagnetic wire needs to be welded, it is the area that needs to be insulated, and the area is wound with insulation tape and non-woven tape.

[0028] Further, the fixing of the insulation tape includes: winding the non-woven tape outside the wound insulation tape, and heating and curing the non-woven tape.

[0029] Wherein, the non-woven tape is a semi-solid strip-shaped material made of thermosetting resin, which has high tensile strength, low elongation, high temperature resistance and excellent electrical insulation performance, and the parallel winding layer breakdown voltage can reach more than 20KV after curing at 155 degrees Celsius; the use of non-woven tape can fix the wound mica tape and the secondary insulation of the electromagnetic wire, ensuring the reliability of the copper bar insulation.

[0030] In one embodiment, the surface of the bent electromagnetic wire is insulated by using an insulation treatment device, which insulates the bent electromagnetic wire according to the set insulation treatment parameters. The set insulation treatment parameters include: the first set tension of winding the insulation tape, the second set tension of winding the non-woven tape and the first set thickness.

[0031] The insulation treatment device can use any device in the prior art that can wind insulation tape and non-woven tape, and can realize tension control and thickness detection; For example, a multi-station automatic device can be used, and the insulation tape winding station, the non-woven tape winding station and the heating and curing station are arranged in sequence. In the insulation tape winding station, a mechanical arm is used to carry a tension control device to automatically wind the insulation tape on the surface of the copper bar in a spiral shape. The first set thickness is 0.2mm, and the first set tension can be set according to experience within a tension range to avoid too tight or too loose to prevent the insulation tape from being damaged under a larger tension or causing the winding to loosen and affecting the insulation reliability. In the non-woven tape winding station, the same winding method as the insulation tape winding station can be used. Similarly, the second set tension can be set according to experience within a tension range to ensure the fixing effect and prevent loosening. The heating and curing station can use hot air or infrared heating to realize the heating and curing of the non-woven tape to ensure the fixing effect.

[0032] In one embodiment, the formation of the second insulation layer includes: putting the stator or rotor as a whole into a vacuum pressure impregnation device, and impregnating the resin material in a vacuum environment, so that the surface of the welded part with the first insulation layer B and the surface of the electromagnetic wire exposed outside with the first insulation layer A form a second insulation layer with a second set thickness.

[0033] The resin material is a resin configured by an epoxy modified heat-resistant unsaturated polyester resin, a special curing agent, an active diluent and the like. By impregnating the resin material in a vacuum environment, the resin can penetrate into the micropores of the first insulation layer B and the first insulation layer A (micropores of the mica tape and the weftless tape), so as to realize composite insulation. The second set thickness is 50-100 microns.

[0034] Of course, the second insulation layer can also be formed in other ways, such as uniformly spraying or coating epoxy insulating paint on the surfaces of the stator and rotor on which the electromagnetic wires are mounted.

[0035] In one embodiment, the bending of the electromagnetic wire includes: bending the electromagnetic wire according to the set bending parameters by using a bending device. The set bending parameters include: bending angle, bending radius and bending position of the electromagnetic wire.

[0036] Specifically, the copper bar is placed in the bending station, the bending position of the copper bar is positioned, and then the bending operation is performed according to the set bending angle and bending radius by using the bending device. The bending device is also provided with a visual detection device, such as a CCD camera, which can automatically scan the shape of the copper bar and compare it with the design model of the copper bar to determine whether the bent copper bar deviates, for example, if it deviates, it is automatically corrected, and if it does not deviate, it means that the copper bar bending is qualified. The deviation of the bending shape of the copper bar can be controlled within ±0.3mm, which can ensure the smooth assembly and welding of the copper bar.

[0037] As shown in FIG. Figure 2 In one embodiment, the welding portion is wound with an insulation tape at a first set tension, including: S21, fixing the insulation tape on the winding mechanism, and then temporarily fixing one end of the insulation tape with the welding portion; S22, moving the winding mechanism to wind the insulation tape spirally outside the welding portion, and the overlapping rate of the spiral winding is greater than or equal to 50%; S23, detecting the winding tension of the insulation tape in real time by using the winding mechanism, so that the winding tension meets the first set tension.

[0038] The insulation tape can be wound on the winding mechanism or wound on it. When winding the insulation tape at the welding portion, the operating space of the welding portion is small, so the winding mechanism is handheld. When operating, first, one end of the insulation tape is temporarily fixed with the welding portion by using a high-temperature-resistant adhesive tape, and then during the winding process, the winding mechanism does not rotate, but the insulation tape is unwound by manual operation. The winding mechanism is moved around the welding position, so that the insulating tape is wound in a spiral shape, and after each winding is completed, the wound part can be clamped by a clamp to prevent loosening during subsequent winding, and each winding of the insulating tape covers at least 50% of the previous winding, and an insulating tape with an identification line in the middle can be selected, and the identification line extends along the length direction of the insulating tape, so that the overlapping rate of each winding can be controlled conveniently during winding; The winding mechanism can detect the winding tension in real time, so that the operator can control the winding force, and the operator can control the winding effect of the insulating tape by using the winding mechanism, and the reliability of the insulating layer is ensured.

[0039] As Figures 3-5 shown, in one embodiment, the winding tension of the insulating tape is detected in real time by using the winding mechanism, which comprises the following steps: S231, when the insulating tape is wound, the support cylinder 1 of the winding mechanism is extruded, so that the pressure sensing layer 3 sleeved between the support cylinder 1 and the support column 2 detects the change of pressure; S232, the pressure detected by the pressure sensing layer 3 is processed by the processor 4 arranged in the support column 2, and the real-time winding tension is obtained.

[0040] The winding mechanism comprises a support column 2, a pressure sensing layer 3 and a support cylinder 1 which are fixedly sleeved in sequence from inside to outside, and the outside of the support cylinder 1 is wound with an insulating tape; the two ends of the support column 2 are also provided with handles 5 for hand holding, and a display screen and a loudspeaker are also arranged on the handles 5, when the real-time winding tension exceeds the set threshold value, the loudspeaker gives an alarm prompt, and the display screen is used to display the specific value of the obtained real-time winding tension.

[0041] Further, the pressure sensing layer 3 comprises: an elastic layer 31 arranged between the support cylinder 1 and the support column 2, and a plurality of pressure sensors 32 arranged between the elastic layer 31 and the support column 2, and the plurality of pressure sensors 32 are uniformly distributed along the circumferential direction of the support column 2.

[0042] The processor 4 arranged in the support column 2 is connected with the plurality of pressure sensors 32 respectively.

[0043] When the winding mechanism is used, one end of the insulating tape is fixed on the welding position, and then the winding mechanism is moved to wind the insulating tape on the welding position in a spiral shape, when winding, the insulating tape extrudes the support cylinder 1 of the winding mechanism, so that the pressure sensing layer 3 sleeved between the support cylinder 1 and the support column 2 detects the change of pressure (the pressures detected by the plurality of pressure sensors 32 are different, and when the insulating tape extrudes one side of the support cylinder 1, the pressures detected by the corresponding number of pressure sensors on that side will become larger); the pressure detected by the pressure sensing layer 3 is processed by the processor 4 arranged in the support column 2, and the real-time winding tension is obtained.

[0044] In one embodiment, the processor 4 processes the pressure detected by the pressure sensing layer 3, including: Obtaining pressure detection values of the plurality of pressure sensors 32 and performing filtering processing to obtain a plurality of filtered pressure values; Selecting the maximum pressure value from the plurality of filtered pressure values, and indexing the pressure sensor 32 corresponding to the maximum pressure value and its circumferentially adjacent pressure sensors 32 to obtain a high pressure area; Calculating the average pressure value of the pressure sensors 32 in the high pressure area, and obtaining the real-time winding tension according to the average pressure value.

[0045] The processor 4 obtains the pressure detection values of the plurality of pressure sensors 32 at a set sampling frequency, and uses a filter to smooth the data to reduce noise; Then, the maximum pressure value in the plurality of filtered pressure values is obtained, which indicates that the position of the pressure sensor 32 corresponding to the maximum pressure value is the position of the maximum extrusion force of the insulating tape on the support cylinder 1. Then, the circumferentially adjacent pressure sensors 32 to the pressure sensor 32 are indexed to obtain a high pressure area of the insulating tape acting on the support cylinder 1; Then, the average pressure value of the pressure sensors 32 in the high pressure area is calculated. The number of pressure sensors 32 in the high pressure area is at least 3, and the specific number depends on the number of pressure sensors 32 corresponding to the maximum pressure value; Finally, the real-time winding tension is obtained according to the relationship between the average pressure value and the winding tension; For example, the conversion relationship between the positive pressure and the tension in the prior art can be used for calculation; Or, the product of the average pressure value and a set constant can be used to obtain the real-time winding tension. The set constant can be obtained according to experiments. The experiments can be winding experiments under known tensions, keeping the type of insulating tape used in the experiments and the surface of the winding object consistent, recording the data of the plurality of pressure sensors 32, especially the average pressure value in the high pressure area during winding; by repeating the experiments under different known tensions multiple times, the relationship between the average pressure value in the high pressure area and the real-time winding tension is obtained, and the set constant is obtained.

[0046] Through the above method, the real-time winding tension can be accurately detected. The structure of the winding mechanism and the detection method of the winding tension are relatively simple, and have real-time and accuracy, which is convenient for operators to use, improves the winding effect of the insulating tape, and ensures the insulation reliability of the insulating layer.

[0047] In the description of the application, it is to be understood that the orientations or positional relationships indicated by the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like are based on the orientations or positional relationships shown in the drawings, and are only for the convenience of describing the application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the application.

[0048] In the present application, unless otherwise clearly specified and limited, the terms "mounting", "connecting", "connecting", "fixing" and the like should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or it can be integrated; it can be mechanically connected, or it can be electrically connected or communicate with each other; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the internal communication of two elements or the interaction relationship between two elements, unless otherwise clearly limited. For those skilled in the art, the specific meanings of the above terms in the present application can be understood according to the specific circumstances.

[0049] Although the embodiments of the present application have been disclosed as above, it is not limited only to the applications listed in the specification and embodiments, and it can be fully applied to various fields suitable for the present application, and additional modifications can be easily realized by those skilled in the art, and therefore the present application is not limited to specific details and the figures shown and described herein, without departing from the general concept defined by the present application.

Claims

1. A brushless doubly-fed motor assembly process, characterized in that, include: After insulating the surface of the bent electromagnetic wire, it is installed into the slot of the stator or rotor. The end of the electromagnetic wire outside the slot is welded, and the welded part is wrapped with insulating tape with a first set tension and fixed to form a first insulating layer B; A second insulating layer is formed on the surface of the welded part that has the first insulating layer B.

2. The assembly process of the brushless doubly-fed motor according to claim 1, characterized in that, Insulation treatment of the bent electromagnetic wire surface includes: Determine the areas where the electromagnetic wires need to be insulated; An insulating tape is wound around this area with a first set tension and fixed to form a first insulating layer A with a first set thickness.

3. The brushless doubly-fed motor assembly process according to claim 2, characterized in that, Fixing the insulating tape includes: wrapping a non-woven tape around the outside of the wound insulating tape and heating and curing the non-woven tape.

4. The brushless doubly-fed motor assembly process according to claim 2, characterized in that, The formation of the second insulating layer includes: placing the stator or rotor as a whole into a vacuum pressure impregnation device, impregnating it with resin material in a vacuum environment, thereby forming a second insulating layer with a second predetermined thickness on the surface of the welded part with the first insulating layer B and the surface of the exposed electromagnetic wire with the first insulating layer A.

5. The brushless doubly-fed motor assembly process according to claim 3, characterized in that, The surface of the bent electromagnetic wire is insulated using an insulation treatment device, which performs the insulation treatment on the bent electromagnetic wire according to the set insulation treatment parameters. The insulation treatment parameters include: the first set tension for winding the insulating tape, the second set tension for winding the non-woven tape, and the first set thickness.

6. The assembly process of the brushless doubly-fed motor according to claim 1, characterized in that, Bending the electromagnetic wire includes: using a bending device to bend the electromagnetic wire according to set bending parameters; The bending parameters include the bending angle, bending radius, and bending position of the electromagnetic wire.

7. The brushless doubly-fed motor assembly process according to claim 1, characterized in that, The insulating tape is wound around the welded area at a first set tension, including: Fix the insulating tape to the winding mechanism, and then temporarily fix one end of the insulating tape to the welding part; The moving winding mechanism is used to make the insulating tape spirally wound around the outside of the welded part, and the overlap rate of the spiral winding is greater than or equal to 50%; The winding tension of the insulating tape is detected in real time using a winding mechanism to ensure that the winding tension meets the first set tension.

8. The assembly process of the brushless doubly-fed motor according to claim 7, characterized in that, The winding tension of the insulating tape is monitored in real time using a winding mechanism, including: When the insulating tape is wound, it squeezes the support cylinder of the winding mechanism, causing the pressure sensing layer sleeved between the support cylinder and the support column to detect the pressure change; By processing the pressure detected by the pressure sensing layer through a processor installed inside the support column, the real-time winding tension can be obtained.

9. The assembly process of the brushless doubly-fed motor according to claim 8, characterized in that, The pressure sensing layer includes: an elastic layer disposed between the support cylinder and the support column, and multiple pressure sensors disposed between the elastic layer and the support column, the multiple pressure sensors being evenly distributed along the circumference of the support column.

10. The brushless doubly-fed motor assembly process according to claim 9, characterized in that, The processor processes the pressure detected by the pressure sensing layer, including: The pressure detection values ​​from multiple pressure sensors are acquired and filtered to obtain multiple filtered pressure values. The maximum pressure value among multiple filtered pressure values ​​is selected, and the pressure sensor corresponding to the maximum pressure value and its circumferentially adjacent pressure sensors are indexed to obtain the high-pressure area. Calculate the average pressure value of the pressure sensor in the high-pressure area, and obtain the real-time winding tension based on the average pressure value.

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