阅读说明：本技术 电机的子导线的绝缘 (Insulation of sub-conductors of an electric machine ) 是由 罗宾·布伦纳 哈里·吕特克 诺伯特·舍恩鲍尔 于 2018-12-13 设计创作，主要内容包括：本发明公开了一种电导线(10),其具有两个或更多的子导线(9),其中,这些子导线(9)相互绝缘,其中,子导线(9)到该导线(10)中的相邻子导线(9)仅具有绝缘层(15),其中,每个子导线(9)或导线由聚酯纤维和玻璃纤维制成的绑带或仅由玻璃纤维包绕。(The invention relates to an electrical line (10) having two or more sub-lines (9), wherein the sub-lines (9) are insulated from one another, wherein the sub-lines (9) have only an insulating layer (15) to adjacent sub-lines (9) in the line (10), wherein each sub-line (9) or line is wrapped with a band made of polyester fibers and glass fibers or only with glass fibers.)

1. An electrical conductor (10) having two or more sub-conductors (9), wherein the sub-conductors (9) are insulated from each other, wherein the sub-conductors (9) have only an insulating layer (15) between adjacent sub-conductors (9) in the conductor (10), wherein the insulating layer (15) is a film or a lacquer insulation glued onto the sub-conductors (9), wherein each sub-conductor (9) or the conductor (10) is surrounded by a binder made of polyester fibres and glass fibres or by a binder made of glass fibres only.

2. The electrical lead (10) according to claim 1, characterized in that the sub-leads (9) have a substantially rectangular or square cross-section.

3. The electrical conductor (10) as claimed in claim 1 or 2, characterized in that the sub-conductors (9) are insulated, viewed in cross section, on an edge radius adjoining the side covered by the insulating layer (15).

4. The electrical lead (10) according to any one of the preceding claims, characterised in that the coverage of the sub-leads (9) by the insulating layer, viewed in cross-section, is between 30 and 70%.

5. Coil (21) of a winding system (3) of an electrical machine, having at least one wire (10) according to one of the preceding claims.

6. Stator (5) or stator segment of an electrical machine (1), having a winding system (3) which is arranged in slots (8) of the stator (5) or stator segment, each phase of the winding system having individual coils (21) which can be brought into electrical contact with one another, wherein the coils (21) have one or more conductors (10) which are each constructed from a plurality of partial conductors (9), wherein the partial conductors (9) are insulated from one another, wherein, at least in the respective slot (8), between a partial conductor (9) and an adjacent partial conductor (9) of its conductors (10) there is only an insulating layer (15), wherein each partial conductor (9) is surrounded by a polyester fiber-glass fiber band or by a glass fiber band only.

7. Stator (5) or stator segment according to claim 6, characterized in that the sub-wires (9) of one wire (10) are arranged radially and/or horizontally at least in the slots (8) of the stator (5).

8. An electrical machine (1), in particular a high-voltage electrical machine, having a stator (5) or a stator segment according to claim 6 or 7.

9. A method for manufacturing a wire (10), a stator (5) or a stator segment of an electrical machine (1), the method being realized by the steps of:

-providing bare sub-conductors (9),

-partially placing an insulating layer (15) on the sub-conductors (9), in particular by covering a predetermined amount of 30 to 70% of the sub-conductors (9) viewed in the circumferential direction,

-arranging the sub-conductors (9) of the conductor (10) such that only the insulating layer (15) is present between the sub-conductor (9) to an adjacent sub-conductor (9) in the conductor (10),

-wherein each of the subconductors (9) and/or the conductors (10) is/are wrapped, in particular in a single layer, by a band made of polyester fibres and glass fibres,

-wherein a fiber mixture consisting of polyester fibers and glass fibers is heated, such that the polyester melts and thereby the glass fibers stick together with the existing substrate, wherein the substrate is the surface of the insulation layer (15) or the bare sub-conductor (9).

10. Method for manufacturing a wire (10), a stator (5) or a stator segment of an electrical machine (1) according to claim 9, by:

-providing bare sub-conductors (9),

-partially placing an insulating layer (15) on the sub-conductors (9), in particular by covering a predetermined amount of 30 to 70% of the sub-conductors (9) viewed in the circumferential direction,

-arranging the sub-conductors (9) of the conductor (10) such that only the insulating layer (15) is present between the sub-conductor (9) to an adjacent sub-conductor (9) in the conductor (10),

-wherein the subconductors (9) are wrapped with a glass fibre band, subsequently impregnated with resin or lacquer and thereafter hardened.

11. Method for manufacturing a coil (21) from a wire (10) manufactured according to the method of claim 9 or 10, wherein for the shaping of the coil (21) a body is applied which provides a contour on which the wire (10) is placed.

12. A method for producing a winding system (3) of a stator (5) or a stator segment, the method being implemented by the following steps:

-providing a magnetically conductive base body, in particular a lamination stack (22), having substantially axially extending slots (8),

-placing a pre-manufactured coil (21) according to claim 5 or a wire (10) according to any one of claims 1 to 4 into the slot (8) according to a predefinable winding scheme to obtain a winding system (3) of a stator (5) or stator segments,

-impregnating the winding system (3) in the slots (8).

Technical Field

The invention discloses an insulation of a sub-conductor of a conductor, a coil with a conductor, a stator of an electric machine with a coil, an electric machine with a stator and methods for manufacturing a conductor, a coil and a stator of an electric machine.

Background

In electrical machines, such as electric motors or generators, winding systems are constructed which are composed of individual coils. The coil has one or more mutually insulated wires. In particular, these individual partial conductors of the line have so-called wound insulators, which are usually only designed for relatively small voltages of up to 80V. Such a sub-conductor insulation is realized, for example, by means of an insulating varnish applied to the conductor.

As a rule of thumb, the partial conductors are made of copper or aluminum, wherein the partial conductors are insulated all around with a lacquer. Alternatively, the sub-conductors can also have tape insulation present all around.

The disadvantage here is that when the partial conductors of the conductor of the coil are arranged in the slots of the electric machine, the wound insulation bodies overlap one another in thickness and thus reduce the copper filling available in the slots.

Disclosure of Invention

Starting from this, the object of the invention is to provide a sufficient insulation of the partial conductors of the conductor, and also a winding system with coils of the conductor and a stator or stator segment of an electric machine, in order to achieve a relatively high machine efficiency while increasing the copper or aluminum filling degree in the slots of the stator of the electric machine by means of a simple production of the winding system.

The object is achieved by an electrical conductor having two or more sub-conductors, wherein the sub-conductors are insulated from each other, wherein only an insulating layer is provided between a sub-conductor and an adjacent sub-conductor in the conductor, wherein each sub-conductor or conductor is surrounded by a band made of polyester fibers and glass fibers or only by glass fibers.

The object is also achieved by a coil of a winding system of an electric machine, which has at least one conductor according to the invention.

The object is also achieved by a stator or a stator segment of an electrical machine having a winding system arranged in slots of the stator or stator segment, each phase of which has a single coil which can be electrically contacted with one another, wherein the coil has one or more conductors which each consist of a plurality of partial conductors, wherein the partial conductors are insulated from one another, wherein at least in the respective slot only an insulation layer is provided between a partial conductor to an adjacent partial conductor of the conductors of the partial conductor, wherein each partial conductor is surrounded by a polyester fiber-glass fiber band or only a glass fiber band.

The object is also achieved by an electric machine having a stator according to the invention or a stator segment according to the invention.

The object set is also achieved by a method for producing a conductor, which is achieved by the following steps:

-providing bare sub-conductors;

partially placing an insulating layer on the partial conductor, in particular by covering a predetermined amount of 30 to 70% of the partial conductor viewed in the circumferential direction;

-arranging the sub-conductors of a conductor such that there is only insulation between a sub-conductor to an adjacent sub-conductor in the conductor.

The object is also achieved by a method for manufacturing a coil from a wire according to the invention, wherein for shaping of the coil a body is applied which provides a contour, on which the wire is provided.

The object is also achieved by a method for producing a winding system for a stator or a stator segment, which is achieved by the following steps:

providing a magnetically conductive base body, in particular a lamination stack, having a substantially axially extending slot,

placing pre-manufactured coils or wires according to the invention into slots according to the invention according to a predeterminable winding scheme to obtain a winding system of the stator or stator segments,

-impregnating the winding system in the tank.

According to the invention, only the individual partial conductor sections of the conductor are now insulated, viewed in the circumferential direction. The insulating body therefore covers only predeterminable sections, as viewed in the circumferential direction of the cross section of the partial conductors. Thus, each sub-conductor has an uncovered (bare) and a covered (insulated) area.

According to the invention, therefore, only one insulation layer, i.e. a subconductor insulation layer, is present between the subconductors of the conductor when these subconductors are positioned. The exposed side of a partial line rests against the insulating side of the immediately adjacent partial line, so that a minimum of insulation is always provided between the individual partial lines.

By winding the individual partial conductors with a yarn mixture or yarn, in particular polyester glass fiber or glass fiber, a relatively high mechanical load capacity is achieved, for example when embedding the conductor or winding system in the slot, and relatively good partial discharge behavior of the winding system during operation of the electric machine is achieved. Here, an additional fastening of the insulation on the conductors by the sub-pairs can also be achieved by winding the sub-conductors with a binding tape made of a yarn mixture, in particular polyester glass fibers. Here, the strap, viewed in the circumferential direction, surrounds the entire partial conductor.

The cross section of the partial conductors thus has, viewed in the circumferential direction, sections with insulation and sections without insulation (bare side). The entire periphery of the sub-section is wrapped with a strap made of polyester-fiberglass or with fiberglass alone. The band is therefore on the insulator of the partial conductors on the one hand and on the exposed side of the partial conductors on the other hand.

For stability reasons, the entire wire, i.e. the entire two or more partial wires, can be wrapped in addition likewise with a band made of various band materials which subsequently form the main insulation of the wire.

It is also possible for the partial conductors to be laminated to one another only with partial insulation and/or for the entire conductor or the like to be wrapped for stability reasons only with a binding band made of one or different band materials, for example polyester-fiberglass.

In this case, the band can in principle have either parallel fibers or woven fibers.

Thus, in the sub-conductors arranged radially one above the other in the slots of the stator, the bare side of the second sub-conductor is correspondingly located on the insulator of the first sub-conductor, and so on, so that a minimum insulation is always provided between the individual sub-conductors.

Advantageously, in particular in the case of partial conductors which are arranged radially in slots of the stator or stator segment and which are rectangular in cross section, only the upper or lower side of the partial conductors is provided with an insulation.

The partial insulation of the partial conductors is in principle implemented as a tape insulation or a lacquer insulation.

The partial conductors are only partially covered by the partial conductor insulation in the slots, viewed in cross section, i.e. in the circumferential direction. The partial coverage is about 30 to 70% of the outer circumference of the sub-wire according to the cross-sectional shape of the sub-wire.

In this case, it is advantageous if such an insulation of the partial conductors also extends over the edge radius adjoining the covered side of the partial conductors. Thus, for example, when viewed in a rectangular cross section, the partial conductors are uncovered on one side, covered on one side and partially covered on both sides.

By means of the embodiment of the sub-conductor insulation according to the invention, the necessary volume of the insulation in the groove is reduced while the copper filling level or the aluminum filling level, i.e. the conductive cross section, is increased.

In principle, the partial conductors have a relatively good "stackable" cross section, wherein the substantially rectangular or square cross-sectional shape of the partial conductors is used first. This increases the degree of filling of the electrical conductors in the stator or stator segment.

The edges of the partial lines are preferably rounded in order not to damage the partial line insulation and/or to avoid local field strength maxima.

The wires are arranged radially or vertically and/or horizontally in the slots. Radial is to be understood here as meaning that the partial conductors are arranged from the groove bottom in the direction of the air gap of the electrical machine. At the same time, a horizontal arrangement of the subconductors is understood to be an arrangement which is substantially tangential with respect to the air gap.

In the case of a partial conductor having a rectangular cross-sectional shape and in particular being arranged radially in the slot, i.e. the narrow sides of the partial conductor adjoin one another, the partial coverage is smaller than in the embodiment in which they are placed overlapping on the long sides of the rectangular partial conductor.

The covering and/or the arrangement of the partial wires of the wires can be carried out as in the slots axially outside the slots, i.e. in the region of the winding heads of the stator or stator segment.

Based on the winding head design, which is carried out according to the machine type, it is also conceivable to adjust the coverage of the partial conductors and/or the thickness of the band, for example made of polyester glass fiber, i.e. the number of layers surrounding the partial conductors and/or the conductors, in the region of the winding head.

The insulation of the partial conductors forms a covering, preferably a film, in particular made of polyamide, which is provided with a (melt) adhesive, for example FEP (fluorinated ethylene propylene copolymer) and is positioned on the partial conductors, in particular glued on the partial conductors.

The covering, in particular the film, can be designed to be corona-resistant, for example by being appropriately filled with suitable particles. Subsequently, the particles, for example consisting of mica, have a thickness in the range of a few hundredths of a millimeter.

By winding the individual partial conductors with a yarn mixture or yarn, in particular polyester glass fiber or glass fiber, for example, a relatively high mechanical load capacity and relatively good partial discharge behavior of the winding system during operation of the electric machine are achieved when the conductor or winding system is inserted into the slot. Furthermore, an additional fixing of the insulation on the partial conductors can also be achieved by winding the partial conductors with a binding tape made of a yarn mixture, in particular polyester glass fibers. Here, the band surrounds the entire partial conductor, as viewed in the circumferential direction.

This embodiment of the partial lines is not limited to the region in the slots of the stator or stator segment, but can also be switched into the winding heads of the stator or stator segment.

The polyester glass fibers have different fiber thicknesses and different fiber numbers according to the specifications for the insulation strength. The portion of polyester fibers should not exceed 50% by weight of the overall weight of the strap.

The winding should be as smooth and uninterrupted as possible due to the machining and/or partial discharge behavior. The winding can be carried out as a single layer or as multiple layers depending on the mechanical requirements.

Preferably, the polyester fibers are made of polyethylene terephthalate, since they have the required temperature stability during operation of the electrical machine and/or the required melting properties during the production process of the electrical conductors and/or coils.

The coils of the winding system of the stator or stator segment are formed from one or more such wires. Here, the shaping of the coil is predetermined by the body providing the contour, on which the conductor is provided. The embodiment according to the invention of the conductor leads results in a relatively increased copper filling in the slots of the stator or stator segment. The winding system in the slots of the stator or stator segment, however, also has in principle slots and main insulation for the magnetically conductive base, i.e. for example the lamination stack, and for the coils of the other phases in the region of the slots or winding heads.

Drawings

The invention and advantageous embodiments of the invention are explained in detail with reference to examples. Shown here are:

FIG. 1 is a schematic electric machine;

FIG. 2 is a cross-section of a high voltage isolated slot;

FIG. 3 is a coil with individual sub-conductors;

FIG. 4 is a detail view of a sub-conductor;

FIG. 5 is an additional coil with sub-conductors;

fig. 6 is a flow chart of coil production.

Detailed Description

Fig. 1 shows a schematic longitudinal section of an electric machine 1 having a stator 5 spaced apart by an air gap 20 of a rotor 6, the rotor 6 being connected to a shaft 4 in a rotationally fixed manner and being mounted rotatably about an axis. The stator 5 can also be composed of individual stator segments, which are joined to one another, as viewed in the circumferential direction.

In the stator 5, facing the air gap 20, there is a winding system 3 arranged in the slots 8, not shown in detail, of a magnetically conductive lamination stack 22, which form a winding head on the end face of the stator 5.

The winding system known to date and shown by way of example according to fig. 2 has two conductors 10 with their partial conductors 9 in the slot 8, wherein in this case there are two layers of windings. Each layer thus has a conductor 10 with a subconductor 9. The slot filling substance 14 not only insulates the wires 10 with respect to the slot bottom, but also between two wires 10, as well as between the uppermost wire 10 and the slot taper.

Here, each partial conductor 9 has a partial conductor insulator 15 surrounding it, which accommodates the existing coil insulator and can be designed for a range of approximately 80 to 100V in a high-voltage electrical machine. Each wire 10 is surrounded by a main insulation 11, wherein the entire winding system in the slot 8 is likewise insulated by the slot insulation 11 with respect to the lamination stack of the stator 5.

With the described structure, each sub-conductor insulator 15 has a layer thickness which accumulates in the slot 8 over the radial height of the conductor 10 and thus leads to a reduction in the copper filling of the winding system 3 in the slot 8. This reduces the efficiency of the electric motor 1.

According to the invention, in the case of a coil 21 having at least one conductor 10 and a radially overlapping arrangement of the partial conductors 9 of the conductor, only the partial conductor insulation 15 on one side is correspondingly provided according to fig. 3, so that only one minimum required insulation is present between the respectively adjacent partial conductors 9.

Fig. 4 shows a detail of the sub-conductor 9 of substantially rectangular shape, which is seen in cross section with the covering 16 of the part covered by the sub-conductor insulator 15. The partial coverage is about 30 to 70% of the outer circumference of the sub-wire 9 according to the cross-sectional shape of the sub-wire 9.

In other words: in the case of a rectangular cross-sectional shape of the sub-conductors 9 and in particular a radial arrangement in the slots 8, i.e. the narrow sides of the sub-conductors 9 adjoin one another, the partial coverage in the circumferential direction is smaller than in the embodiment according to fig. 3, in which the long sides of the sub-conductors 9 adjoin one another.

Preferably, the insulation on the sub-conductor 9 is a film, in particular made of polyamide, which is provided with a (melt) glue, for example FEP (fluorinated ethylene propylene copolymer) and positioned on the sub-conductor, in particular glued on the conductor.

By winding the individual partial conductors with a yarn mixture or yarn, in particular polyester glass fiber or glass fiber, for example, when embedding the conductor or winding system in the slot 8, a relatively improved partial discharge behavior of the winding system 3 in operation of the electric machine 1 is achieved.

Here, an additional fixing of the insulation on the subconductor 9 can also be achieved by wrapping the subconductor 9 with a band 30 made of a yarn mixture, in particular polyester glass fibers. The band 30 surrounds the entire partial conductor 9, as viewed in the circumferential direction. An additional fixing of the insulation on the sub-conductor 9 is thereby also achieved according to fig. 3 and 4.

The band 30 made of polyester fibers and/or glass fibers surrounds the entire sub-conductor 9 as viewed in the circumferential direction. Advantageously, the strap 30 is implemented as a single layer only, so as not to affect the degree of filling in the groove 8.

This embodiment of the partial lines 9 is not limited to the region in the slots 8 of the stator 5 or stator segment, but can also be switched into the winding heads 3 of the stator 5 or stator segment.

Advantageously, the sub-conductors 9 have a substantially rectangular or square cross-sectional shape. Here, the edges of the subconductor 9 are rounded so as not to damage the subconductor insulation 15. The subconductors 9 are arranged radially or vertically and/or horizontally in the slots 8 of the stator 5 of the electrical machine 1.

Fig. 5 shows a second embodiment of a conductor 10 with horizontally and vertically arranged sub-conductors 9. Here, the two sides of the rectangular sub-conductor 9, viewed in cross section, are provided approximately completely or completely with sub-conductor insulators 15. The partial conductors 9 adjoining the partial conductor insulation 15 do not have a partial conductor insulation 15 on these sides according to the invention. However, as shown in fig. 3 or 4, for example, adjacent edges of the respective sub-conductors 9 can be realized.

The polyester glass fibers of the band 30 have different fiber thicknesses and different fiber numbers as specified for the insulation strength. The portion of polyester fibers should not exceed 50% by weight of the overall weight of the strap 30.

The wrapping of the subconductor 9 and/or of the wires 10 by the strap 30 should be as smooth as possible and uninterrupted. The winding can be carried out as a single layer or as multiple layers depending on the mechanical requirements.

Preferably, the polyester fibers are made of polyethylene terephthalate, since the fibers have the required temperature stability during operation of the electrical machine 1 and/or the required melting properties during the production process of the electrical conductor 10 and/or the coil 21. The glass fibers are preferably made of E-glass (E-Glas) because of the low alkalinity.

The idea according to the invention for increasing the degree of filling of the electrical conductors 10 in the slots 8 by partial sub-conductor insulation is applicable to one, two or more layers of windings in the stator 5 or stator segment of the electrical machine 1.

The method for producing the coil 21 now has the following steps, as shown in principle in fig. 6:

bare sub-conductors 9 are provided 40. The sub-conductors 9 are insulated according to step 41 by partial insulation with a predeterminable covering 16. By subsequently additionally winding the insulation 15 on the partial conductor 9 by means of the winding 42 of the band 30. The fiber mixture of polyester fibers and glass fibers is heated in step 43 to melt the polyester and thus to bond the glass fibers to the existing substrate, i.e. the surface of the insulation layer 15 and/or the bare subconductor 9. In step 44, the conductor 10 is shaped into a coil 21, wherein a body providing a contour is used for shaping the coil 21, on which the conductor 10 is arranged. Subsequently, these sub-wires 9 are impregnated together with the main insulator 11.

Alternatively, the coil 21 can also be produced as follows according to fig. 6:

the method comprises the steps of providing 40 a bare sub-conductor 9, insulating the sub-conductor 9 by partial insulation according to step 41 with a predeterminable covering 16, winding the sub-conductor 9 with a glass fiber tape according to step 45, subsequently impregnating the wound sub-conductor 9 with resin and lacquer according to step 46 and hardening, which effects the adhesion. Finally, the conductor 10 produced according to step 46 is now also shaped according to step 44 into a coil 21, wherein a profiled body is used for shaping the coil 21, on which the conductor 10 is arranged.

Such a coil 21 is used in the winding arrangement 3 by the electric machine 1, in particular a high-voltage electric machine, for example in the context of a wind turbine. The efficiency of such an electric machine 1 is increased by the relatively increased copper or aluminum filling of the wires 10 in the slots 8 of the stator 5 or stator segment.