阅读说明：本技术 10kV级电机绝缘系统 (10 kV-level motor insulation system ) 是由 王雨萌 刘洋 于勇 徐娜 闫伟嘉 沈鸿儒 于 2021-09-15 设计创作，主要内容包括：本发明提供了一种10kV级电机绝缘系统,采用云母带绕包的铜扁线(1)绕制线圈,用厚为0.11mm,宽为25mm的添加芳纶纤维的环氧聚脂薄膜少胶粉云母带作为线圈的云母绝缘(2)在铜扁线(1)外面半叠绕6层,线圈云母绝缘(2)单面厚度1.32mm,用线性半导体低阻防晕带作为低阻防晕绝缘(3)在线圈云母绝缘(2)外直线部分1/3叠绕1层。本发明定子线圈单边主绝缘厚度由原来的1.80mm减薄到1.32mm,在电气绝缘性能满足原绝缘结构设计要求下,主绝缘厚度减薄了0.48mm,绝缘减薄率达到了20％以上。具有在相同体积下增大功率以及在相同功率下减小体积的目标,为节能降耗发展提供上升空间。(The invention provides a 10kV motor insulation system, a coil is wound by a mica tape-wrapped copper flat wire (1), 6 layers of mica insulation (2) which is 0.11mm thick and 25mm wide and is added with aramid fiber epoxy polyester film less glue powder mica tape and used as the coil are half-lap-wound outside the copper flat wire (1), the thickness of the single surface of the coil mica insulation (2) is 1.32mm, and a linear semiconductor low-resistance corona-proof tape is used as a low-resistance corona-proof insulation (3) and is lap-wound on 1 layer of 1/3 on the outer linear part of the coil mica insulation (2). The unilateral main insulation thickness of the stator coil is reduced to 1.32mm from the original 1.80mm, the main insulation thickness is reduced by 0.48mm under the condition that the electrical insulation performance meets the design requirement of the original insulation structure, and the insulation reduction rate reaches more than 20%. The method has the aims of increasing power under the same volume and reducing the volume under the same power, and provides a rising space for the development of energy conservation and consumption reduction.)

1. The utility model provides a 10kV level motor insulation system which characterized by: a coil is wound by a mica tape-wrapped copper flat wire (1), 6 layers of epoxy polyester film less glue powder mica tapes added with aramid fibers and having the thickness of 0.11mm and the width of 25mm are used as mica insulation (2) of the coil and are half-lapped outside the copper flat wire (1), the thickness of a single surface of the coil mica insulation (2) is 1.32mm, a linear semiconductor low-resistance corona-proof tape is used as a low-resistance corona-proof insulation (3) to be lap-wound on the 1/3 layer of the outer linear part of the coil mica insulation (2), then a nonlinear semiconductor high-resistance corona-proof tape configured by half-lapping 320-400-mesh silicon carbide at the corner and the end part of the coil mica insulation (2) is used as a middle-resistance corona-proof insulation (5) and a nonlinear semiconductor high-resistance corona-proof tape configured by 1600-1800-mesh silicon carbide is used as a high-resistance corona-proof insulation (6), wherein the lengths of the low-resistance corona-proof insulation (3), the middle-resistance corona-insulation (5) and the high-resistance insulation (6) are all 20mm in lap joint mode, then, a layer of epoxy polyester film low-glue powder mica tape added with aramid fiber is wound on the surfaces of the medium-resistance anti-corona insulation (5) and the high-resistance anti-corona insulation (6) in a half-lap mode to serve as additional insulation (7), 1 layer of single-face breathable protective tape is wound on the corner and the end of the coil in a half-lap mode to serve as coil protective insulation (8), the sum of the thicknesses of the single faces of the mica insulation (2) and the anti-corona insulation (3) on the straight line part of the coil reaches 1.44mm, high-purity solvent-free epoxy impregnating resin is used as impregnating resin (4), and the impregnating process is as follows:

1. preheating a workpiece at 80 +/-5 ℃, and preserving heat for 2 hours after reaching the temperature;

2. putting the workpiece into a soaking tank at the temperature of 35-40 ℃;

3. vacuumizing the leaching tank, wherein the vacuum degree is 20Pa, and the time is 4 h;

4. paint conveying and dipping: the temperature of the resin is 15-23 ℃, the height of the paint surface is 50-100 mm higher than that of the workpiece, the vacuum degree is 500-1000 Pa after the resin is stabilized, and the resin is kept for 10 minutes;

5. after the paint conveying impregnation is finished, the pressure is increased by stages

(1) The pressure of the first stage is 0.04MPa, and the time is 10 minutes;

(2) the pressure of the second stage is 0.1MPa, and the time is 5 minutes;

(3) the pressure of the third stage is 0.3Mpa, and the time is 20 minutes;

(4) the pressure of the fourth stage is 0.5MPa, and the time is 6 hours;

6. after the stage pressure rise is finished, the impregnating resin (4) is conveyed back to the paint storage tank again, and the pressure is not more than 0.2 Mpa;

7. suspending the dipped workpiece in the air, and carrying out dripping treatment on the dipping resin on the surface of the workpiece for 20-30 minutes;

8. placing the workpiece in an oven for baking and curing: baking temperature: the temperature is kept at 140 +/-5 ℃ for 6 hours, and at 160 +/-5 ℃ for 16 hours, thus completing the whole process.

The technical field is as follows:

the invention relates to a 10kV motor insulation system.

Background art:

the manufacturing development of the motor has been continued for hundreds of years, people master relatively mature motor production technology, and the service life of insulation is well known to determine the service life of the motor. The development of future motors is moving towards the smallest possible size, the largest possible power and the highest possible efficiency. The end of the root is that the slot utilization rate of the motor can be improved to the greatest extent, and the thinning insulation thickness can improve the slot utilization rate but the service life of the well-known insulation life determining motor, so who can thin the insulation thickness on the basis of ensuring the service life of the motor and who occupies the absolute market of the motor industry.

At present, an insulation structure of an F-class 10kV high-voltage motor is relatively mature, but with the progress of the process and the development of materials, a large reduction space exists in the main insulation thickness. In the domestic patent search, a document with the patent number of 201744660528, namely 'a manufacturing method of a 10kV compact high-voltage motor ultrathin insulation structure', is found, and the document refers to the fact that a single glass fiber-covered film-wrapped sintered copper flat wire or a film-wrapped mica-wrapped copper flat wire is wound to form a coil; the main insulation thickness is reduced to 1.8mm by mixing and wrapping a 0.11 multiplied by 25mm thin epoxy polyester film reinforced low-gelatine powder mica tape and an epoxy glass cloth reinforced low-gelatine powder mica tape on the straight line and the end part of the coil, and the required insulation structure is obtained by carrying out anti-corona treatment, integral dipping 1149-2 epoxy unsaturated polyester impregnating varnish on the wound stator after connecting the coil, drying and other treatment measures. However, the insulating single glass fiber-covered film-wrapped sintered copper flat wire or the film-wrapped mica-wrapped copper flat wire used for insulation is a conventional winding copper flat wire, and the insulation thickness of the wire of the conventional winding copper flat wire is obviously thicker. The thickness of the double-sided insulation is 1.8mm, the thickness of the double-sided insulation does not include the thickness of the anti-corona insulation, and the thickness of the main insulation is thicker. The epoxy unsaturated polyester impregnating varnish used in the structure is a non-environment-friendly type varnish.

The invention content is as follows:

the invention provides a 10kV motor insulation system, which is used for thinning and optimizing the main insulation thickness of a 10kV motor stator, can increase the motor power under the same volume and also reduce the motor volume under the same power, and provides a rising space for the development of energy conservation and consumption reduction.

The technical scheme of the invention is as follows:

a10 kV-level motor insulation system is characterized in that a coil is wound by a mica tape-wrapped copper flat wire (1), 6 layers of mica insulation (2) which is 0.11mm thick and 25mm wide and is added with aramid fiber epoxy polyester film less glue powder mica tape is used as the coil outside the copper flat wire (1) in a half-lap winding mode, the thickness of the single surface of the coil mica insulation (2) is 1.32mm, a linear semiconductor low-resistance corona-proof tape is used as a low-resistance corona-proof insulation (3) and is wound on 1/3 layers of the outer straight line part of the coil mica insulation (2), then a nonlinear semiconductor high-resistance corona-proof tape which is configured by 320-400-mesh silicon carbide is sequentially wound on the corner and the end part of the coil mica insulation (2) in a half-lap winding mode and is used as a medium-resistance corona-proof insulation (5) and a nonlinear semiconductor high-resistance corona-proof tape which is configured by 1600-mesh silicon carbide in a high-mesh silicon carbide and is used as a corona-resistance insulation (6), wherein the lap-joint lengths of the low-resistance corona-proof insulation (3), the medium-resistance corona-proof insulation (5) and the high-resistance corona-insulation (6) are 20mm, then, a layer of epoxy polyester film low-glue powder mica tape added with aramid fiber is wound on the surfaces of the medium-resistance anti-corona insulation (5) and the high-resistance anti-corona insulation (6) in a half-lap mode to serve as additional insulation (7), 1 layer of single-face breathable protective tape is wound on the corner and the end of the coil in a half-lap mode to serve as coil protective insulation (8), the sum of the thicknesses of the single faces of the mica insulation (2) and the anti-corona insulation (3) on the straight line part of the coil reaches 1.44mm, high-purity solvent-free epoxy impregnating resin is used as impregnating resin (4), and the impregnating process is as follows:

1. preheating a workpiece at 80 +/-5 ℃, and preserving heat for 2 hours after reaching the temperature;

2. putting the workpiece into a soaking tank at the temperature of 35-40 ℃;

3. vacuumizing the leaching tank, wherein the vacuum degree is 20Pa, and the time is 4 h;

4. paint conveying and dipping: the temperature of the resin is 15-23 ℃, the height of the paint surface is 50-100 mm higher than that of the workpiece, the vacuum degree is 500-1000 Pa after the resin is stabilized, and the resin is kept for 10 minutes;

5. after the paint conveying impregnation is finished, the pressure is increased by stages

(1) The pressure of the first stage is 0.04MPa, and the time is 10 minutes;

(2) the pressure of the second stage is 0.1MPa, and the time is 5 minutes;

(3) the pressure of the third stage is 0.3Mpa, and the time is 20 minutes;

(4) the pressure of the fourth stage is 0.5MPa, and the time is 6 hours;

6. after the stage pressure rise is finished, the impregnating resin (4) is conveyed back to the paint storage tank again, and the pressure is not more than 0.2 Mpa;

7. suspending the dipped workpiece in the air, and carrying out dripping treatment on the dipping resin on the surface of the workpiece for 20-30 minutes;

8. placing the workpiece in an oven for baking and curing: baking temperature: the temperature is kept at 140 +/-5 ℃ for 6 hours, and at 160 +/-5 ℃ for 16 hours, thus completing the whole process.

The invention has the technical effects that:

in the insulating structure, the insulating strength is greatly improved, and the insulating thickness is obviously reduced. In the application of the invention, the mica tape wrapped copper flat wire adopted for winding the coil is a copper flat wire which is wrapped by a single-side thin film reinforced less-glue mica tape, the double-side insulation thickness of the copper flat wire is only 0.36-0.40 mm, the insulation thickness of the copper flat wire is reduced by 0.2-0.3 mm compared with the insulation thickness (0.6-0.70 mm) of the traditional stator winding wire with the same voltage level, and the breakdown voltage of an insulation layer is improved while the insulation is reduced. The permeability is good after vacuum pressure impregnation, the corona resistance and the dielectric property of the winding are greatly improved, and the service life is longer;

in the application of the invention, the 0.11mm epoxy polyester film dry mica tape is used as the insulating material of the coil, and the material has the advantages that: 1) the single-side reinforcement reduces the content of the reinforcing material in the mica tape and improves the content of mica; 2) the high-quantitative scale powder mica paper is adopted, so that the cut-through resistance of the mica tape is improved; 3) the flake mica paper containing aramid fiber is used as a base material, the electrical performance and the mechanical performance are improved, 4) the content of glue is low, the permeability of a mica tape is improved, and the integrity of a motor winding is enhanced; 5) the coil has enough tensile strength, does not delaminate and fly powder, is beneficial to the wrapping of the main insulation of the coil, and does not pollute the environment; 6) the mica tape contains an accelerant, so that winding impregnation and solidification are facilitated; 7) the mica tape is thin, so that the insulation thickness of the winding can be reduced;

in the application of the invention, the solvent-free high-purity epoxy impregnating resin and the matched vacuum pressure impregnating process are used, so that the winding insulation can achieve the effect of no air gap or less air gaps, the continuity and the thermal conductivity of each part of the insulation are good, the slot filling rate is high, the winding is firmly fixed, and the moisture resistance and the electrical performance are excellent, thereby improving the technical and economic indexes, the operation reliability and the service life of the motor.

The insulation structure mentioned in the application of the invention is used in a certain important project in China (the motor normally operates for more than 5 years), and the performance indexes of the test simulation coil manufactured by utilizing the thinned structure are as follows: 1) and (3) testing the power frequency voltage resistance of the ground insulation: the resistance to the passing of 34kV alternating voltage for 1min is realized; 2) the instantaneous power frequency breakdown voltage is more than or equal to 70 kV; 3) the instantaneous power frequency electric intensity is more than or equal to 50 MV/m; 4) corona initial voltage is more than or equal to 2U_N(ii) a 5) Normal dielectric loss tangent tan delta_0.2UN1 or less, and the dielectric loss tangent tan delta at hot state (155 ℃) is 8 or less; the indexes meet (are partially superior to) the specifications of JB/T12685-2016 technical conditions for stator coils of high-voltage motors. 5. By adopting the invention, on the premise of ensuring that the winding performance conforms to JB/T12685-. The motor designed by the invention can increase the motor power under the same volume and reduce the motor volume under the same power, thereby providing a rising space for the development of energy conservation and consumption reduction.

Description of the drawings:

FIG. 1 is a schematic view of a linear insulation structure according to the present invention

FIG. 2 is a schematic view of the corner and end insulation structure of the present invention

Detailed Description

The invention will be further illustrated with reference to specific embodiments.

A 10kV motor insulation system as shown in fig. 1: a coil is wound by a mica tape-wrapped copper flat wire 1, a mica insulation layer 2 which is 0.11mm thick and 25mm wide and is added with aramid fiber epoxy polyester film less glue powder mica tape is used as a mica insulation layer of the coil and is wrapped in a half-lap mode for 6 layers outside the copper flat wire 1, the single side thickness of the mica insulation layer 2 of the coil is 1.32mm, as shown in figure 2, a linear semiconductor low-resistance corona-proof tape is used as a low-resistance corona-proof insulation layer 3 and is wrapped in a stack mode for 1 layer on the outer straight line part 1/3 of the mica insulation layer 2 of the coil, then a nonlinear semiconductor high-resistance corona-proof tape which is configured by half-lap winding 320-400 meshes silicon carbide on the corner and the end part of the mica insulation layer 2 of the coil is used as a middle-resistance corona-proof insulation layer 5 and a nonlinear semiconductor high-resistance corona-proof tape which is configured by 1600-1800 meshes silicon carbide in sequence and is used as a high-resistance corona-resistance insulation layer 6, wherein the lap-joint lengths of the low-resistance corona-resistance insulation layer 3, the middle-resistance corona-resistance insulation layer, the middle-resistance corona-resistance insulation layer 5 and the high-resistance layer are all 20mm, and the epoxy polyester film added with aramid fiber is wrapped on the surface of the middle-resistance layer 5 and the high-resistance layer of the high-corona-resistance layer 6 of the high-corona-resistance insulation layer The mica tape with less gelatine powder is used as an additional insulation 7, a single-face ventilation protective tape with 1 layer is wound at the corner and the end of the coil in a half-lap mode and is used as a coil protection insulation 8, the sum of the single-face thicknesses of the mica insulation 2 and the corona-proof insulation 3 at the straight part of the coil reaches 1.44mm, high-purity solvent-free epoxy impregnating resin is used as the impregnating resin 4, and the impregnating process is as follows:

1. preheating a workpiece at 80 +/-5 ℃, and preserving heat for 2 hours after reaching the temperature;

2. putting the workpiece into a soaking tank at the temperature of 35-40 ℃;

3. vacuumizing the leaching tank, wherein the vacuum degree is 20Pa, and the time is 4 h;

4. paint conveying and dipping: the temperature of the resin is 15-23 ℃, the height of the paint surface is 50-100 mm higher than that of the workpiece, the vacuum degree is 500-1000 Pa after the resin is stabilized, and the resin is kept for 10 minutes;

5. after the paint conveying impregnation is finished, the pressure is increased by stages

(1) The pressure of the first stage is 0.04MPa, and the time is 10 minutes;

(2) the pressure of the second stage is 0.1MPa, and the time is 5 minutes;

(3) the pressure of the third stage is 0.3Mpa, and the time is 20 minutes;

(4) the pressure of the fourth stage is 0.5MPa, and the time is 6 hours;

6. after the stage pressure rise is finished, the impregnating resin (4) is conveyed back to the paint storage tank again, and the pressure is not more than 0.2 Mpa;

7. suspending the dipped workpiece in the air, and carrying out dripping treatment on the dipping resin on the surface of the workpiece for 20-30 minutes;

8. placing the workpiece in an oven for baking and curing: baking temperature: keeping the temperature at 140 +/-5 ℃ for 6 hours and keeping the temperature at 160 +/-5 ℃ for 16 hours.