Tensile, corrosion-resistant and high-voltage-resistant electromagnetic wire for large-scale wind turbine generator

Abstract

The utility model provides a tensile, corrosion-resistant and high-voltage-resistant electromagnetic wire for a large-scale wind turbine generator. The electromagnetic wire comprises a wire body, an insulating layer, a flame-retardant layer and an outer sheath, the wire body comprises a plurality of metal conductors and a wire core, the metal conductors are spirally wound on the wire core, the wire core is internally provided with at least three flexible tensile wires, and the flexible tensile wires are mutually wound and spirally arranged; the wire body is formed by twisting a plurality of metal conductors and has good flexibility and bending performance, the current-carrying capacity of the conductors can be improved, the wire core is arranged in the center of the metal conductors, the twisted flexible tensile wires are arranged in the wire core, and the tensile strength of the electromagnetic wire is improved; each insulating layer comprises an inner mica tape and an outer nano-modified epoxy resin, the mica tape is precisely wrapped on the wire body, the nano-modified epoxy resin covers the outer side of the mica tape, the double insulating layers have good high-voltage-resistant and corona-resistant effects, the flame-retardant layer plays a role in flame retardance, and the outer sheath plays roles in insulation, protection and wear resistance.

Description

Technical Field

[0001] This utility model belongs to the field of electromagnetic wire technology, and specifically relates to an electromagnetic wire for large wind turbine units that is tensile-resistant, corrosion-resistant, and high-voltage resistant. Background Technology

[0002] Magnet wire for wind turbines is a key material used in the manufacture of electromagnetic equipment such as generators and transformers in wind power generation equipment, significantly impacting the performance and reliability of wind turbines. Wind turbines generate high voltages during operation, requiring the magnet wire to withstand thousands of volts or even higher. Therefore, it needs excellent insulation properties to withstand high voltages without breakdown. The operation of wind turbines generates vibration and friction, necessitating good wear resistance in the magnet wire's insulation layer to prevent insulation failure due to abrasion. Wind turbines may operate in various environments, including humid and corrosive environments such as salt spray, requiring the magnet wire to possess certain corrosion resistance to extend its service life. As wind power technology develops towards larger scale and higher efficiency, higher demands are placed on the magnet wire used in wind turbines. Existing magnet wires' capabilities in high voltage resistance, wear resistance, and corrosion resistance are no longer sufficient to meet the development trend of larger wind turbines.

[0003] Therefore, the above-mentioned problems are technical issues that urgently need to be addressed. Utility Model Content

[0004] Purpose of the utility model: In view of the problems existing in the prior art, this utility model provides an electromagnetic wire that is tensile-resistant, corrosion-resistant, and high-voltage-resistant for large wind turbine units, aiming to solve the above-mentioned technical problems.

[0005] Technical solution: In order to achieve the above objectives, this utility model provides an electromagnetic wire for large wind turbines that is tensile-resistant, corrosion-resistant, and high-voltage resistant, including a conductor body, an insulation layer, a flame-retardant layer, and an outer sheath;

[0006] The conductor body includes a metal conductor and a core. The metal conductor comprises multiple strands spirally wound around the core. Each core contains at least three flexible tensile-resistant wires that are spirally intertwined. The conductor body is formed by stranding multiple metal conductors and then wrapped with an insulation layer. This structure offers good flexibility and bending performance, adapting to the complex wiring requirements of wind turbine units. Furthermore, the multi-strand stranding enhances the conductor's current-carrying capacity. The core, located at the center of the metal conductors and containing stranded flexible tensile-resistant wires, improves the tensile strength of the electromagnetic wire.

[0007] The insulation layer covers the outside of the conductor body and is integrally formed with the conductor body. The flame retardant layer covers the outside of the insulation layer. The outer sheath covers the outside of the flame retardant layer and is integrally formed with the flame retardant layer.

[0008] The insulation layer comprises an inner mica tape and an outer nano-modified epoxy resin. The mica tape is precisely wrapped around the conductor body, and the nano-modified epoxy resin covers the outer side of the mica tape. Mica tape, as an inorganic material, has excellent corona resistance and can withstand high voltages of 10-35kV, while the nano-modified epoxy resin exhibits superior corona resistance.

[0009] Furthermore, the gaps between the metal conductors are filled with rubber powder, which is located between the insulation layer and the wire core.

[0010] Furthermore, a semi-conductive resistive water layer is provided on the outer side of the insulating layer, and the inner side of the semi-conductive resistive water layer is closely attached to the outer side of the insulating layer.

[0011] Furthermore, the outer layer of the semiconducting resistive water layer is covered with a metal braided layer, which is located between the semiconducting resistive water layer and the flame retardant layer.

[0012] Furthermore, the flame-retardant layer comprises an inner flame-retardant mica tape, a middle flame-retardant coating, and an outer ceramicized silicone rubber.

[0013] Furthermore, the flame-retardant mica tape is wrapped around the outside of the semiconducting resistive water layer, and the flame-retardant coating is an intumescent flame-retardant coating.

[0014] Furthermore, the outer sheath is a PTFE outer sheath, and a wear-resistant layer is provided on the outer side of the outer sheath.

[0015] Furthermore, the metal conductor is a copper alloy with nickel plated on its outer surface.

[0016] Furthermore, the intumescent flame-retardant coating is an epoxy resin-based intumescent flame-retardant coating, and the semiconducting resistive water layer is a metal oxide-filled semiconducting resistive water layer.

[0017] As can be seen from the above technical solution, this utility model has the following beneficial effects:

[0018] 1) This utility model features an insulation layer, with an inner layer of mica tape and an outer layer of nano-modified epoxy resin, resulting in a high withstand voltage. Simultaneously, the rubber powder inside the conductor body, the flame-retardant mica tape in the flame-retardant layer, and the PTFE outer sheath, together with the insulation layer, form a multi-layered insulation system with extremely high withstand voltage. 2) This utility model provides an electromagnetic wire for large wind turbine units that is tensile-resistant, corrosion-resistant, and high-voltage resistant. The overall mechanical strength of the conductor is increased through rubber powder, flexible tensile filaments in the core, and a metal braided layer, making it more resistant to tensile, bending, and compressive forces, reducing the possibility of conductor damage due to external forces, and improving the conductor's durability and reliability. Attached Figure Description

[0019] Figure 1This is a schematic diagram of the structure of an electromagnetic wire for large wind turbine units that is tensile-resistant, corrosion-resistant, and high-voltage resistant, as described in this utility model.

[0020] Figure 2 This is a schematic diagram of the insulating layer described in this utility model;

[0021] Figure 3 This is a schematic diagram of the flame-retardant layer described in this utility model.

[0022] In the diagram: 1-Conductor body, 11-Metal conductor, 12-Wire core, 13-Flexible tensile-resistant wire, 2-Insulation layer, 21-Mica tape, 22-Nano-modified epoxy resin, 3-Flame retardant layer, 31-Flame retardant mica tape, 32-Flame retardant coating, 33-Ceramicized silicone rubber, 4-Outer sheath, 5-Rubber powder, 6-Semi-conductive water-resistant layer, 7-Metal braided layer. Detailed Implementation

[0023] It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention.

[0024] like Figure 1-2 As shown: An electromagnetic wire for large wind turbines that is tensile-resistant, corrosion-resistant, and high-voltage resistant includes a conductor body 1, an insulation layer 2, a flame-retardant layer 3, and an outer sheath 4;

[0025] The conductor body 1 includes a metal conductor 11 and a core 12. The metal conductor 11 comprises multiple strands spirally wound around the core 12. The core 12 contains at least three flexible tensile-resistant wires 13, which are spirally intertwined. The conductor body 1 is formed by stranding multiple metal conductors 11 and then wrapped with an insulation layer 2. This structure has good flexibility and bending performance, adapting to the complex wiring requirements of wind turbine units. Simultaneously, the multi-strand stranding improves the current-carrying capacity of the conductor. The stranded flexible tensile-resistant wires 13 within the core 12 enhance the tensile strength of the electromagnetic wire.

[0026] The insulation layer 2 covers the outside of the conductor body 1, and the insulation layer and the conductor body 1 are integrally formed. The flame retardant layer 3 covers the outside of the insulation layer 2. The outer sheath 4 covers the outside of the flame retardant layer 3, and the outer sheath 4 and the flame retardant layer 3 are integrally formed.

[0027] The insulating layer 2 comprises an inner mica tape 21 and an outer nano-modified epoxy resin 22. The mica tape 21 is precisely wrapped around the conductor body 1, and the nano-modified epoxy resin 22 covers the outer side of the mica tape 21. The combination of the mica tape 21 and the nano-modified epoxy resin 22 provides excellent high-voltage resistance and corona resistance. Furthermore, the addition of nano-Al2O3 / SiO2 to the nano-modified epoxy resin enhances its dielectric strength and corona resistance, making it suitable for high-voltage frequency conversion environments.

[0028] Specifically, the gaps between the metal conductors 11 are filled with rubber powder 5, which is located between the insulation layer 2 and the wire core 12. Rubber powder 5 possesses good elasticity, flexibility, and insulation properties. Adding rubber powder 5 improves the conductor's flexibility and bending resistance, making it less prone to breakage during use. Furthermore, rubber powder 5 enhances the conductor's insulation and waterproof properties.

[0029] Specifically, a semiconducting resistive water layer 6 is provided on the outer side of the insulating layer 2, and the inner side of the semiconducting resistive water layer 6 is closely attached to the outer side of the insulating layer 2.

[0030] In a preferred embodiment, the outer layer of the semiconducting resistive water layer 6 is covered with a metal braided layer 7, which is located between the semiconducting resistive water layer 6 and the flame-retardant layer 3. The metal braided layer 7, woven from metal wires, possesses high strength and toughness, increasing the overall mechanical strength of the conductor and making it more resistant to tensile, bending, and compressive forces. This reduces the possibility of conductor damage due to external forces, improving the conductor's durability and reliability. The metal braided layer 7 also acts as a shield for electromagnetic waves, forming a closed metal mesh that confines the electromagnetic field inside the conductor to a certain range, reducing electromagnetic signal leakage and preventing interference from external electromagnetic waves. Furthermore, as an equipotential body, the metal braided layer 7 can make the electric field distribution more uniform, reducing electric field concentration. This helps reduce the electric field strength on the conductor surface, avoiding problems such as corona discharge and insulation breakdown caused by excessively high electric field strength, thus improving the safety and stability of the conductor's operation.

[0031] like Figure 3 As shown, the flame-retardant layer 3 includes an inner flame-retardant mica tape 31, a middle flame-retardant coating 32, and an outer ceramicized silicone rubber 33.

[0032] The flame-retardant mica tape 31 is wrapped around the outside of the semi-conductive resistive water layer 6, and the flame-retardant coating 32 is an intumescent flame-retardant coating. The flame-retardant mica tape 31 does not melt or drip at a high temperature of 800℃. The middle intumescent flame-retardant coating 32 foams when heated to isolate oxygen, and the outer ceramicized silicone rubber 33 forms a hard protective layer after ablation. The three-layer firewall structure achieves an effective flame-retardant effect.

[0033] Specifically, the outer sheath 4 is a PTFE outer sheath, and a wear-resistant layer is provided on the outer side of the outer sheath 4.

[0034] Specifically, the metal conductor 11 is a copper alloy with a nickel-plated outer surface. The nickel-plated copper alloy can prevent the conductor from oxidizing and has excellent corrosion resistance.

[0035] In addition, the intumescent flame-retardant coating is an epoxy resin-based intumescent flame-retardant coating, and the semiconducting resistive water layer 6 is a metal oxide-filled semiconducting resistive water layer. The metal oxides therein have good chemical stability and high temperature resistance, which enables the semiconducting resistive water layer to maintain good performance in high temperature environments.

[0036] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements can be made without departing from the principle of the present utility model, and these improvements should also be considered within the protection scope of the present utility model.

Claims

1. An electromagnetic wire for large wind turbine generators that is tensile-resistant, corrosion-resistant, and high-voltage-resistant, characterized in that: It includes the conductor body (1), insulation layer (2), flame retardant layer (3) and outer sheath (4); The conductor body (1) includes a metal conductor (11) and a wire core (12). The metal conductor (11) includes multiple wires that are spirally wound around the wire core (12). The wire core (12) is provided with flexible tensile filaments (13). The flexible tensile filaments (13) are at least 3 and are spirally wound together. The insulation layer (2) covers the outside of the conductor body (1), and the insulation layer and the conductor body (1) are integrally formed. The flame retardant layer (3) covers the outside of the insulation layer (2), and the outer sheath (4) covers the outside of the flame retardant layer (3), and the outer sheath (4) and the flame retardant layer (3) are integrally formed. The insulating layer (2) includes an inner mica tape (21) and an outer nano-modified epoxy resin (22). The mica tape (21) is precisely wrapped around the conductor body (1), and the nano-modified epoxy resin (22) covers the outside of the mica tape (21).

2. The electromagnetic wire for large wind turbine units with tensile strength, corrosion resistance, and high voltage resistance according to claim 1, characterized in that, The gaps between the metal conductors (11) are filled with rubber powder (5), which is located between the insulation layer (2) and the wire core (12).

3. The electromagnetic wire for large wind turbine units with tensile strength, corrosion resistance, and high voltage resistance according to claim 1, characterized in that, The outer side of the insulating layer (2) is also provided with a semi-conductive resistive water layer (6), and the inner side of the semi-conductive resistive water layer (6) is closely attached to the outer side of the insulating layer (2).

4. The electromagnetic wire for large wind turbine units with tensile strength, corrosion resistance, and high voltage resistance according to claim 3, characterized in that, The outer layer of the semiconducting resistive water layer (6) is covered with a metal braided layer (7), which is located between the semiconducting resistive water layer (6) and the flame retardant layer (3).

5. The electromagnetic wire for large wind turbine units with tensile strength, corrosion resistance, and high voltage resistance according to claim 4, characterized in that, The flame-retardant layer (3) includes an inner flame-retardant mica tape (31), a middle flame-retardant coating (32), and an outer ceramicized silicone rubber (33).

6. The electromagnetic wire for large wind turbine units with tensile strength, corrosion resistance, and high voltage resistance according to claim 5, characterized in that, The flame-retardant mica tape (31) is wrapped around the outside of the semiconducting resistive water layer (6), and the flame-retardant coating (32) is an intumescent flame-retardant coating.

7. The electromagnetic wire for large wind turbine units with tensile strength, corrosion resistance, and high voltage resistance according to claim 6, characterized in that, The outer sheath (4) is a PTFE outer sheath, and a wear-resistant layer is provided on the outer side of the outer sheath (4).

8. The electromagnetic wire for large wind turbine units with tensile strength, corrosion resistance, and high voltage resistance according to claim 1, characterized in that, The metal conductor (11) is a copper alloy with nickel plating on its outer surface.

9. The electromagnetic wire for large wind turbine units with tensile strength, corrosion resistance, and high voltage resistance according to claim 6, characterized in that, The intumescent flame-retardant coating is an epoxy resin-based intumescent flame-retardant coating, and the semiconducting resistive water layer (6) is a metal oxide-filled semiconducting resistive water layer.

Images