A motor stator coil turn insulation structure

Abstract

The application provides a motor stator coil turn-to-turn insulation structure, comprising a coil conductor, a polyimide composite film and a polyimide film-powder mica tape; the coil conductor is wrapped with the polyimide composite film and sintered to form a single-strand conductor insulation layer with a thickness of more than 0.15 mm; after the multiple-strand coil conductor wrapped with the polyimide composite film is stacked, the whole is wrapped with the polyimide film-powder mica tape once. The application can reduce the amount of electromagnetic wire insulation material in the slot, improve the slot fill factor, increase the heat dissipation effect and reduce the electromagnetic cost. The application can be applied not only to the single-strand conductor turn-to-turn insulation structure of the motor stator coil but also to the single-strand conductor turn-to-turn insulation structure of the stator coil in other fields.

Description

Technical Field

[0001] This invention relates to the field of software, and more specifically to an inter-turn insulation structure for motor stator coils. Background Technology

[0002] In wind turbine design, the inter-turn insulation structure of the stator coil is a core component to ensure the long-term reliable operation of the motor. During generator operation, the stator coil is subjected to high voltage, high current, and frequent thermal cycling loads, and the inter-turn insulation layer must simultaneously possess excellent electrical insulation strength, heat aging resistance, and mechanical stability.

[0003] Currently, to ensure the electrical insulation performance of generators, the inter-turn insulation of single-strand conductors in wind turbine stator coils typically employs the following structure: First, a polyimide composite film is wrapped around and sintered around the single-strand conductor to form the bottom layer insulation; then, a polyimide film-mica tape is wrapped around the outside as reinforcing insulation. This scheme uses a double-layer composite insulation structure. To ensure sufficient electrical safety margin, the total insulation thickness of the single-strand conductor is generally designed to be above 0.40 mm. Figure 1 As shown.

[0004] However, this existing insulation structure has the following shortcomings: First, excessively thick insulation layers reduce the effective conductive area within the slot, resulting in a low slot fill factor and limiting further increases in generator power density.

[0005] Secondly, the amount of insulation material used is large. Both polyimide composite film and polyimide film-mica tape are high-performance insulation materials with high unit cost, which increases the manufacturing cost of generators.

[0006] Third, the heat from the conductor needs to pass through a thick insulation layer to be transferred to the core for heat dissipation. The heat conduction path is long and the thermal resistance is high, making it difficult for the coil to dissipate heat. This leads to an increase in temperature, which has an adverse effect on the lifespan of the insulation material and accelerates insulation aging during long-term operation.

[0007] Fourth, single-strand conductors are wrapped with double insulation separately. The wrapping process is complicated and increases production time. In addition, defects such as bubbles and wrinkles are easily generated during the wrapping of the two insulation materials, which affects the insulation forming quality and the inter-turn withstand voltage level.

[0008] In view of this, the existing stator coil insulation structure has obvious shortcomings in terms of material cost, heat dissipation performance and production efficiency. There is an urgent need for a new type of inter-turn insulation structure that can ensure the electrical performance of insulation, reduce material usage, improve heat dissipation and simplify the process. Summary of the Invention

[0009] This invention provides an inter-turn insulation structure for motor stator coils.

[0010] The specific plan is as follows: An inter-turn insulation structure for a motor stator coil includes a coil conductor, a polyimide composite film, and a polyimide film-mica tape. The coil conductor is wrapped with a polyimide composite film and sintered to form a single-strand conductor insulation layer with a thickness of 0.15 mm or more. After multiple strands of the coil conductor wrapped with the polyimide composite film are stacked, the entire coil is then wrapped once with a polyimide film-mica tape.

[0011] Furthermore, the coil conductor is wrapped with a polyimide composite film and sintered, without any other insulating material.

[0012] Furthermore, after the multiple strands of the coil conductors are stacked, they are wrapped once again with the polyimide film-mica tape, and the inter-turn insulation thickness remains unchanged.

[0013] Furthermore, the thickness of the polyimide composite film is 0.03–0.04 mm.

[0014] Furthermore, the polyimide composite film is a polyimide composite film coated with F-46 resin on one side, and its thickness is 0.038 mm.

[0015] Furthermore, the thickness of the polyimide film-mica tape is 0.07–0.1 mm.

[0016] Furthermore, the thickness of the polyimide film-mica tape is 0.09 mm.

[0017] Furthermore, the sintering temperature of the polyimide composite film after wrapping is 280℃~350℃.

[0018] Furthermore, the sintering time after the polyimide composite film is wrapped is 10 to 30 minutes.

[0019] The beneficial effects of this invention are as follows: the inter-turn insulation structure of the single-strand conductor of the motor stator coil can reduce the amount of insulation material used in the slot, improve the slot fill factor, increase heat dissipation, and reduce electromagnetic costs. This invention can not only be used for inter-turn insulation structures of single-strand conductors in motor stator coils, but also for inter-turn insulation structures of single-strand conductors in stator coils in other fields. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of an existing solution in the background art.

[0021] Figure 2 This is a schematic diagram of the structure of the present invention.

[0022] List of reference numerals in the attached diagram: 1-Coil conductor, 2-Polyimide composite film, 3-Polyimide film-mica tape. Detailed Implementation

[0023] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are for illustrative purposes only and are not intended to limit the scope of the invention.

[0024] like Figure 2 As shown, the present invention provides an inter-turn insulation structure for a motor stator coil, comprising a coil conductor 1, a polyimide composite film 2, and a polyimide film-mica tape 3; the coil conductor 1 is wrapped with the polyimide composite film 2 and sintered to form a single-strand conductor insulation layer with a thickness of more than 0.15 mm; after multiple strands of the coil conductor 1 wrapped with the polyimide composite film 2 are stacked, the entire coil conductor 1 is then wrapped once with the polyimide film-mica tape 3.

[0025] In this embodiment, the coil conductor 1 is wrapped with a polyimide composite film 2 and sintered, without any other insulating material. After the multi-strand coil conductor 1 is stacked, it is wrapped once again with a polyimide film-mica tape 3, and the inter-turn insulation thickness remains unchanged.

[0026] In this embodiment, the polyimide composite film 2 is a polyimide composite film coated with F-46 resin on one side, and its thickness is 0.038 mm. The thickness of the polyimide film-mica tape 3 is 0.09 mm. Example 1

[0027] In this embodiment, the thickness of the polyimide composite film 2 is 0.03 mm. The thickness of the polyimide film-mica tape 3 is 0.1 mm. The sintering temperature after wrapping the polyimide composite film 2 is 300°C. The sintering time after wrapping the polyimide composite film 2 is 6 min. Example 2

[0028] In this embodiment, the thickness of the polyimide composite film 2 is 0.04 mm. The thickness of the polyimide film-mica tape 3 is 0.07 mm. The sintering temperature of the polyimide composite film 2 after wrapping is 400°C. The sintering time of the polyimide composite film 2 after wrapping is 3 min. Example 3

[0029] In this embodiment, the thickness of the polyimide composite film 2 is 0.035 mm. The thickness of the polyimide film-mica tape 3 is 0.08 mm. The sintering temperature of the polyimide composite film 2 after wrapping is 350°C. The sintering time of the polyimide composite film 2 after wrapping is 4 min.

[0030] The technical means disclosed in this invention are not limited to those disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of this invention, and these improvements and modifications are also considered within the scope of protection of this invention.

Claims

1. An electrical machine stator coil turn insulation structure, characterized by, It includes a coil conductor (1), a polyimide composite film (2), and a polyimide film-mica tape (3); the coil conductor (1) is wrapped with a polyimide composite film (2) and sintered to form a single-strand conductor insulation layer with a thickness of more than 0.15 mm; after multiple strands of the coil conductor (1) wrapped with the polyimide composite film (2) are stacked, the whole is wrapped once with a polyimide film-mica tape (3).

2. The inter-turn insulation structure of a motor stator coil according to claim 1, characterized in that, The coil conductor (1) is wrapped with a polyimide composite film (2) and sintered, without any other insulating material.

3. The inter-turn insulation structure of a motor stator coil according to claim 1, characterized in that, After the multiple coil conductors (1) are stacked, they are wrapped once with the polyimide film-mica tape (3), and the inter-turn insulation thickness remains unchanged.

4. The inter-turn insulation structure of a motor stator coil according to claim 1, characterized in that, The thickness of the polyimide composite film (2) is 0.03 to 0.04 mm.

5. The inter-turn insulation structure of a motor stator coil according to claim 1, characterized in that, The polyimide composite film (2) is a polyimide composite film coated with F-46 resin on one side, and its thickness is 0.038 mm.

6. The inter-turn insulation structure of a motor stator coil according to claim 1, characterized in that, The thickness of the polyimide film-mica tape (3) is 0.07-0.1 mm.

7. The inter-turn insulation structure of a motor stator coil according to claim 1, characterized in that, The thickness of the polyimide film-mica tape (3) is 0.09 mm.

8. The inter-turn insulation structure of a motor stator coil according to claim 1, characterized in that, The sintering temperature of the polyimide composite film (2) after wrapping is 280℃~350℃.

9. The inter-turn insulation structure of a motor stator coil according to claim 1, characterized in that, The sintering time of the polyimide composite film (2) after wrapping is 10 to 30 minutes.

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