Method for producing a winding overhang protection for a stator by means of a trickle coating process

Abstract

The invention relates to a method for producing a stator (2) of a dynamoelectric rotating machine (1), having the following steps: - providing a laminated core (3) of the stator (2), the laminated core being made of preferably stamped and stacked laminations and having a winding system (12) which is provided in substantially axially extending slots (13) and has a winding head (5) at each of the end faces (4) of the laminated core (3), the winding head being formed from the portions of the winding system (12) emerging axially from the slots (13), and the winding system (12) being made of wires having intermediate spaces (17), -impregnating the winding system (12) within the slots (13) and the winding head (5), an impregnating material being applied to the slots (13) and the winding head (5), and - carrying out a trickle coating process on one or both winding heads (5) (immediately) following the impregnation step, the trickle coating process being limited solely to the winding heads (5), and the stators (2) and / or trickle nozzles (19) being moved such that the winding heads (5) are provided with a specifiable coating thickness (20).

Description

[0001] 202410467

[0002] 1

[0003] Description

[0004] Method for manufacturing a winding head guard for a stator by trickle coating

[0005] The invention relates to a method for manufacturing a winding head guard of a stator of a dynamo-electric machine, a stator manufactured according to this method, a dynamo-electric machine with such a stator, as well as the use of such a dynamo-electric machine.

[0006] Dynamo-electric machines primarily feature a winding system arranged in slots within their stator. This winding system is constructed from a variety of wire types. For example, in the case of a round-wire stator winding in a low-voltage electric motor (typical industrial motors and e-mobility motors up to 1 kV), impregnation is usually achieved by immersion in a liquid reactive resin and curing at temperatures up to 160°C. In most cases, the impregnation technology employs a hot-dip or cold-dip process. State-of-the-art methods include, for example, electrical-heat impregnation processes or dip-and-bake processes (cold-dip processes with oven curing), which are used as continuous processes. Depending on the required impregnation quality, a vacuum pressure impregnation process, carried out as a batch process, is also conceivable. In this process, the stators are processed and impregnated individually, one after the other.

[0007] In all these processes, single-component resin systems based on unsaturated polyesters or polyesterimide copolymers are preferably used; common building blocks include maleic acid, phthalic acid, and glycol derivatives. Building blocks are synthetic chemicals used to produce further compounds or materials. To make them ready for processing, they are further modified with additives such as reactive diluents (styrene, acrylates, etc.), initiators, stabilizers, and so on. These resin systems are characterized by very good process stability as well as excellent electrical and thermal resistance. Most resin systems have a temperature index of 180–200°C; temperature indices above 200°C are also achievable, particularly for resin systems with polyesterimide copolymers as the backbone.

[0008] However, these materials also have technical weaknesses and offer only limited protection against increased external influences. This includes reduced resistance to water (condensation), oil (e.g., gear oil), dirt, and combinations thereof. 202410467

[0009] 2

[0010] In particular, dirt or dirt particles can especially impair the impregnation layer on the exposed winding head.

[0011] Due to the ester structures contained in the polymer backbone, the resins can be hydrolytically cleaved. Their resistance to water-oil mixtures under temperature influence is a weakness, especially if the oil contains sulfuric acid- or phosphoric acid-forming additives. These are common tribological additives. The acidic environment catalyzes the hydrolytic ester cleavage.

[0012] The additional winding head protection required on already impregnated stators is currently achieved through further immersion impregnation or dip coating. This requires the stator to first cool down from the actual impregnation process before being immersed in the protective coating or impregnation at room temperature. The stator then has to be dried or cured again for several hours at approximately 150°C. The energy consumption is enormous, as is the time required due to the cooling and oven drying times. Furthermore, a significant amount of energy is wasted because residual heat from previous processes cannot be utilized.

[0013] This process also requires its own very complex manufacturing equipment (immersion bath, handling system, oven and cooling section). Overall, the high costs associated with this process, due to the significant effort and time involved, are also considerable. Furthermore, the cleaning effort required on the inner and outer diameters of the stators is enormous. This is because the immersion process wets all areas – even those not intended to be coated – with the material. These areas include, for example, the stator's inner and outer diameters. Additionally, drips can form on the winding head, which must also be removed.

[0014] To counteract this, these areas must then be cleaned or extensively protected beforehand (e.g. by taping).

[0015] In the additional immersion process, the stator, heated by the curing of a standard impregnation, must first cool from approximately 150°C to room temperature, or even be cooled down. It can then be immersed again in a separate tank containing a special resin or lacquer that is resistant to, for example, moisture and oil, and then dried in an oven at high temperatures (150°C) for several hours. 202410467

[0016] 3

[0017] However, this process and the materials available for it have some disadvantages.

[0018] The repeated curing of the winding results in comparatively high energy consumption. Significant time is required due to cooling times and associated waiting periods, as well as the long oven cycles. The dipping process results in an undefined coating thickness on the winding head. Furthermore, automation of this dipping process is limited. Extensive cleaning is also necessary, for example, of the stator bore or parts thereof, which are inadvertently coated during the dipping process. The dipping process yields only comparatively thin and therefore insufficient coating thicknesses on the winding head. Moreover, these coating thicknesses cannot be adjusted or reproduced using this method.

[0019] These existing methods for creating winding head protection lead to increased emissions of VOCs (volatile organic compounds). This is the collective term for organic, i.e., carbon-containing, substances that evaporate into the gas phase at room temperature or higher temperatures, meaning they are volatile. These can also be harmful to health and / or the environment, thus necessitating the use of technical protective measures (e.g., exhaust systems, exhaust air purification, etc.).

[0020] Based on this, the invention aims to provide a simple and cost-effective method for manufacturing a winding head guard for a stator of a dynamoelectric machine, which can be easily adapted to a wide variety of stator designs.

[0021] The problem is solved by the features of the independent claims. Advantageous embodiments of the invention can be found in the dependent claims.

[0022] To meet all requirements for the additional coating of the windings, especially the winding head, trickling is used according to the invention. This technology allows the appropriate materials to be applied subsequently – i.e., after the stator has been impregnated – in a highly automated manner. 202410467

[0023] 4

[0024] The underlying electrical insulation system of the winding system, including the impregnation, is qualified and proven with regard to its service life and dielectric strength. According to the invention, this does not need to be modified for the increased requirements (oil, water, etc.), but is further improved by the simple method according to the invention with additional components.

[0025] This advantageously avoids a complex approval process for a completely new insulation system and utilizes the advantages of all individual components.

[0026] Since the aforementioned environmental influences particularly damage the exposed winding head of the stator due to its geometric properties, it is preferable to protect it with an additional layer. According to the invention, this layer is applied in a process-reliable, cost-effective, and highly automated manner.

[0027] The high variance of the stator windings is not a limitation, and a material selection can be made according to the environmental influences to be withstood before the coating process begins.

[0028] To provide additional protection for the already impregnated stators against the aforementioned environmental influences at the winding heads, coatings such as epoxy-based resins or lacquers with amine curing are particularly suitable. Amine compounds are common hardeners for epoxy resins. These compounds allow the epoxy resins to cure at room temperature or moderately elevated temperatures (below 80°C). They are therefore advantageous for the invention. The chemical reaction mechanism underlying amine curing is a polyaddition.

[0029] Epoxy-amine systems are characterized by very good resistance to moisture and oils, even in acidic environments. Particularly with gearboxes flanged to a motor, there is a risk of (gear) oil penetrating to the stator winding. Applications of such motors with flanged gearboxes include, for example, railway or bus drives.

[0030] However, roller drives with gearboxes are also conceivable.

[0031] These materials are used as two-component systems (2K systems), administered via trickle delivery. 202410467

[0032] 5

[0033] In this process, both material components (resin and hardener) are pumped and mixed in a static mixing tube and applied directly to at least one winding head of the rotating stator through at least one trickle nozzle. This process preferably takes place at room temperature or ambient temperature. The coating, in a predefinable layer thickness, is applied only and exclusively to the winding head(s) to be protected.

[0034] By adjusting the parameters of this process, such as the dosing quantity, conveying speed, rotational speed and direction of the stator, and the position and number of trickle nozzles, a desired layer thickness is precisely achieved on the surfaces of the winding head to be coated. Thus, a different layer thickness may be required on the end face of the winding head than on the side facing the air gap.

[0035] The winding head is the section of the winding system of a stator or rotor that protrudes from the end face of the respective laminated core and is exposed to the aforementioned environmental influences. Immediately after the winding system exits the slot at the end face, gaps approximately the width of the tooth shank are present, which can be closed by the process, provided the layer thickness is appropriately selected.

[0036] The curing of the additional coating of the winding heads also takes place at room temperature for approximately 24 hours without additional energy input through the use of room temperature curing 2K systems, which can only be used effectively with the trickle technology.

[0037] To further improve the coating result and accelerate the resin curing, it may be necessary to temperature-control the stator's laminated core to approximately 60-80°C.

[0038] To operate energy-efficiently, the residual heat from the laminated cores of the upstream hardening cycle is advantageously used for impregnating the stator. The total energy input is thus utilized twice.

[0039] Alternatively, but potentially more energy-intensive, subsequent hardening in an oven or inductive heating of the stators can accelerate the hardening process. 202410467

[0040] 6

[0041] By applying an additional winding head protection using the employed drip technology with 2-component epoxy resins, the winding head protection can now be applied retroactively, independent of the dimensional variations of the stator and / or rotor lamination stacks. Advantageously, the object to be coated can be processed at ambient temperature or, preferably, at residual heat up to 80 degrees Celsius.

[0042] A dedicated oven hardening process is therefore unnecessary. However, utilizing residual heat from upstream processes sufficiently accelerates the hardening process.

[0043] Furthermore, the inventive method for additionally coating the winding heads is fully automatable. The layer thicknesses are freely selectable and adjustable for each winding head. A second, complex dipping process is eliminated. Consequently, additional cleaning of the stator and the equipment involved is also unnecessary. The resin dosage is traceable. The inventive processing of materials without solvents / thinners makes it possible to avoid VOC emissions.

[0044] The coating of the winding head to a predefined layer thickness on the various surfaces of the winding head is only easily achievable through trickle coating. The stator bore and grooves are explicitly not coated. The technologically necessary movement of the trickle nozzle and / or stator (rotation or wobbling motion) for the trickle impregnation ensures a uniform, predefined flow of the applied material on the winding head, preventing drips.

[0045] In principle, it is also conceivable to coat the winding head with a one-component epoxy resin (1-K system). These 1-K systems are sufficiently stable even at room temperature and could be activated / cured by the residual heat of the stator. A subsequent oven curing process would also be advisable.

[0046] The invention and further embodiments of the invention are explained in more detail with reference to exemplary embodiments presented in principle; in this context:

[0047] FIG 1 shows a principal longitudinal section of a dynamoelectric machine,

[0048] FIG 2 shows a detailed view of a winding head,

[0049] FIG 3 Perspective detail view of a winding head. 202410467

[0050] 7

[0051] FIG 1 shows a schematic longitudinal section of a dynamo-electric rotary machine 1. The stator 2 has an axially stacked laminated core 3, which has a winding system 12 in slots 13 facing an air gap 14. The winding system 12 forms winding heads 5 on the end faces 4 of the laminated core 3 of the stator 2. The laminated core 3 is arranged in a housing 10, which supports a shaft 8 via bearing shields 15 and their bearings 11. The shaft 8 is non-rotatably connected to a rotor 7 and is rotatably mounted about an axis 9.

[0052] When the dynamo-electric rotary electric machine 1 is operated, the rotor 7 is set into rotation by electromagnetic interaction of the energized winding system 12 with the rotor 7.

[0053] The winding head 5 is particularly exposed to environmental influences in an open machine. However, even in a closed machine, a fan accelerates 16 particles onto the winding head 5, which can lead to abrasion and thus impair the insulation system.

[0054] The winding system 12 can form a multi-phase, for example a three-phase stator winding system. The windings of the individual phases are usually inserted sequentially into the slots 13.

[0055] The windings of winding system 12 can be configured as so-called random windings or so-called laid windings, depending on requirements. The windings are made, for example, of round wires or enamelled wires, and can be formed, for instance, as copper strands consisting of a multitude of copper wires.

[0056] The winding head 5 is formed by the sections of the winding system 12 that emerge from or re-enter the end face 4 of the lamination stack. These sections are typically bundled or tied together. This tying can be done, for example, with adhesive tape or similar material.

[0057] The winding head 5 is thus the section of the winding system 12 of the stator 2 or rotor 7 that protrudes from the end face 4 of the respective laminated core and is exposed to the aforementioned environmental influences. Immediately after the end face slot exit of the winding system 12, gaps 17 approximately the width of the tooth shank 18 are present, which can be closed by the process, provided the coating 6 has a corresponding thickness. 202410467

[0058] 8

[0059] To provide additional protection for the already impregnated stators 2 against the aforementioned environmental influences at the winding heads 5, a coating 6 is applied using epoxy-based resins or lacquers with amine curing. Epoxy-amine systems are characterized by very good resistance to moisture and oils, which can be crucial for the application areas of the dynamoelectric machines 1.

[0060] These materials are used as 2-component variants (2 K system), with the administration of these materials being carried out using drip technology.

[0061] In this process, both material components (resin and hardener) are conveyed by pumps and mixed in a static mixing tube. The mixture is then applied directly to at least one winding head 5 of the rotating stator 2 through at least one trickle nozzle 19 at a predefinable distance. This process preferably takes place at room temperature or ambient temperature. The coating 6, in a predefinable layer thickness 20, is applied only and exclusively to the winding head 5 of the stator 2 and / or rotor 7 that is to be protected.

[0062] By adjusting the parameters of this trickle application process, such as the dosing quantity, conveying speed, rotational speed and direction of rotation of the stator 2, the position and number of the trickle nozzles 19, and the distance to the winding head 5, a desired layer thickness 20 is precisely achieved on the surfaces of the winding head 5 to be coated. The winding system 12, and in particular the winding head 5, can be processed at ambient temperature or even when warm (<100°C). Trickle application with warm stators 2 (<100°C) is advantageous for resin distribution, especially on the winding head 5, and thus enables faster resin application.

[0063] Additional oven curing of the applied coating 6 is also unnecessary. However, utilizing residual heat from upstream (impregnation) processes can advantageously accelerate the curing process.

[0064] When applying this additional coating 6 to the winding head 5, in order to be protected against external influences, significantly shorter cycle times are required than with the previous methods.

[0065] Less process energy is required, and even the residual heat from the upstream furnace processes of the stator 2 impregnation process can be utilized. Furthermore, the possibility of automating this trickle impregnation process offers additional savings.

[0066] 9

[0067] Costs are reduced. In addition, this winding head protection can be retrofitted to almost any stator 2 - i.e., regardless of the variance of the winding system 12, the axial projection 21 of the winding head 5, the length and diameter of the laminated core 2.

[0068] FIG. 2 shows a detailed view of a winding head 5 protruding from the end face 4 of the stator's laminated core 3. The coating 6 thus adheres seamlessly to the laminated core 3. The coating thickness 20 can also vary on a winding head 5. A trickle nozzle 19 is shown, by means of which the two-component material is applied to the winding head 5.

[0069] FIG. 3 shows a perspective detail view of the winding head 5, which is formed by the sections of the winding system 12 that project from the end face 4 of the laminated core 3. The coating 6 even allows the gaps 17 between the slot exits of the winding system 12 to be closed using the trickle coating method according to the invention. These gaps 17 are each at most as wide as a tooth located between two adjacent slots 13.

[0070] The dynamoelectric machine 1 with such a stator 2 is used particularly in industrial environments, in transport technology, the food industry, as well as in process engineering as a drive for a compressor, fan, pump or compressor.

[0071] 202410467

[0072] Reference symbol list

[0073] 1 dynamoelectric machine

[0074] 2 Stator

[0075] 3 stator lamination stack

[0076] 4 End face of stator lamination stack

[0077] 5 winding head

[0078] 6 Coating Winding head

[0079] 7 Rotor

[0080] 8 wave

[0081] 9-axis

[0082] 10 cases

[0083] 11 warehouses

[0084] 12 winding system

[0085] 13 Nut

[0086] 14 air gap

[0087] 15 Storage sign

[0088] 16 fans

[0089] 17 spaces

[0090] 18 tooth shaft

[0091] 19 Drip nozzle

[0092] 20 layer thickness

[0093] 21 axial projection

Claims

202410467 11 Patent claims 1. Method for manufacturing a stator (2) of a dynamoelectric rotary machine (1) by the following steps: Providing a laminated core (3) of the stator (2), preferably made of stamped laminated sheets, which has a winding system (12) arranged in substantially axially extending slots (13), which has a winding head (5) on each of the end faces (4) of the laminated core (3), which is formed from the sections of the winding system (12) that extend axially from the slots (13), wherein the winding system (12) is formed from wires that have gaps (17), Impregnation of the winding system (12) within the slots (13) and the winding head (5), wherein the slots (13) and the winding head (5) are supplied with an impregnating material, the impregnation is followed (immediately) by a trickle coating of one or both winding heads (5) limited exclusively to the winding heads (5), wherein the stators (2) and / or trickle nozzles (19) are moved in such a way that the winding heads (5) are provided with a predetermined layer thickness (20).

2. Method according to claim 1, characterized in that a 2-component epoxy resin is preferably used as the dripping material, wherein both components are conveyed by means of pumps and mixed in a static mixing tube (resin and hardener) and applied directly to the winding heads (5) of the rotating stator (2) through a drip nozzle (19).

3. Method according to claim 1 or 2, characterized in that the trickling process takes place at below 80 degrees, preferably at room temperature.

4. Method according to one of the preceding claims, characterized in that the drip coating is carried out using epoxy-based resins or lacquers with amine curing.

5. Method according to one of the preceding claims, characterized in that during the production of the coating material the drip nozzle (19) and / or the stator (2) are moved in such a way that the coating material is applied layer by layer and over the entire surface to the winding head (5) in a predefinable manner by a rolling movement of the stator (2) and / or a traversing movement of the drip nozzle (19). 202410467 12 6. Method according to one of the preceding claims, characterized in that all gaps (17) are closed with the coating (6).

7. Method according to one of the preceding claims, characterized in that the coating (6) encloses the entire winding heads (5), wherein the layer thickness (20) is applied more in the areas of the respective winding head (5) which are subject to particular stress from these external influences, in particular where abrasion of the winding head (5) is to be expected during operation of the dynamoelectric machine (1).

8. Method according to one of the preceding claims, characterized in that the application of the coating (6) of the winding head (5) is carried out fully automatically, in particular with a robot having at least one drip nozzle (19).

9. Stator (2) with a winding system (12) which forms winding heads (5) on end faces (4) of its laminated core (3) having a coating (6) applied according to a method according to claims 1 to 8.

10. Dynamoelectric machine (1) with a stator (2) according to claim 9.

11. Use of a dynamoelectric machine (1) in an industrial environment, in transport engineering, the food industry, as well as in process engineering, as a drive for a compressor, fan, pump or compressor.

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