阅读说明：本技术 发电机定子组件及其绝缘处理方法、模具 (Generator stator assembly, insulation processing method thereof and mold ) 是由 刘勇 王欢 张凯琦 于 2019-09-27 设计创作，主要内容包括：本发明公开了一种发电机定子组件的绝缘处理方法,所述定子组件包括定子和嵌装于所述定子的铁芯槽内的单体线圈,所述绝缘处理方法包括：将成型的单体线圈放入预制的对应于单体线圈的模具中,再将装有单体线圈的模具采用绝缘材料进行浸渍处理,或者通过浇注的方式将绝缘材料灌入模具。该方法对单体线圈单独进行绝缘处理,使得单体线圈绝缘处理后再嵌入定子组件的定子铁芯槽,使得发电机定子组件的绝缘处理无需依赖大型设备,降低了对发电机定子组件的绝缘处理难度。本发明还公开了一种发电机定子组件及用于发电机定子组件绝缘处理的模具。(The invention discloses an insulation processing method of a generator stator assembly, wherein the stator assembly comprises a stator and a single coil embedded in an iron core groove of the stator, and the insulation processing method comprises the following steps: and placing the molded single coils into a prefabricated mold corresponding to the single coils, and then carrying out impregnation treatment on the mold provided with the single coils by adopting an insulating material, or pouring the insulating material into the mold in a pouring mode. According to the method, the single coils are separately subjected to insulation treatment, so that the single coils are embedded into the stator core slots of the stator assembly after the insulation treatment, the insulation treatment of the generator stator assembly does not need to depend on large equipment, and the insulation treatment difficulty of the generator stator assembly is reduced. The invention also discloses a generator stator assembly and a mould for the insulation treatment of the generator stator assembly.)

1. The insulation processing method of the generator stator assembly is characterized by comprising the following steps of:

and placing the molded single coils into a prefabricated mold corresponding to the single coils, and then carrying out impregnation treatment on the mold provided with the single coils by adopting an insulating material, or pouring the insulating material into the mold in a pouring mode.

2. The insulation treatment method according to claim 1, wherein after the mold provided with the single coils is subjected to the dipping or casting treatment, the mold is subjected to a drying treatment to cure the insulation material.

3. The insulation processing method according to claim 2, wherein after the baking process, the die and the single coil are separated, the single coil after the insulation process is subjected to an insulation test, and the single coil which is qualified in the test is fitted into the core groove of the stator.

4. An insulation treatment process according to any one of claims 1 to 3, characterized in that the inner surface of the mould is coated with a release agent or an oleophobic layer before the monomer coil is placed in the mould.

5. The insulation treatment method according to any one of claims 1 to 3, wherein the individual coils are not subjected to the insulation tape wrapping treatment before being placed in the mold.

6. Insulation treatment method according to any of claims 1-3, characterized in that the insulation material is in particular a water-based environmental paint.

7. The generator stator assembly comprises a stator core and a single coil embedded in an iron core groove of the stator core, and is characterized in that the single coil is formed and then impregnated with an insulating material, and the single coil is not bound with an insulating tape.

8. The mould is used for insulating the stator assembly of the generator, the stator assembly comprises a stator and a single coil embedded in an iron core groove of the stator, and the mould is characterized by comprising a first mould part with a first cavity and a second mould part with a second cavity, the first cavity and the second cavity are communicated to form a mould cavity under the butt joint state of the first mould part and the second mould part, and the shape of the mould cavity is matched with that of the single coil; the die is also provided with two through hole parts communicated with the die cavity.

9. The mold according to claim 8, wherein the single coil is a centralized winding coil, and comprises two parallel straight sections and two curved sections, the curved sections connect corresponding ends of the two straight sections, and the two straight sections and the two curved sections form a ring structure; the single coil also comprises two outgoing lines, and the two outgoing lines extend towards the same side along the length direction of the two straight sections respectively;

the first die part comprises a first annular body with an annular groove, the second die part comprises a second annular body with an annular groove, and the annular grooves of the first annular body and the second annular body are communicated and form the die cavity matched with the annular structure of the single coil in a butt joint state; the mould still include with the inserted sheet of the curve section shape looks adaptation of mould tip, first ring body with the periphery wall of the second ring body has and is used for supplying inserted sheet male slot, two confessions have been seted up on the inserted sheet the socket that the lead-out wire passed, the periphery wall of mould correspond the position of socket have with the breach of socket intercommunication.

10. The mold according to claim 8, wherein the single coil is a distributed winding coil, the single coil is a closed ring structure, and one end of the single coil is provided with two outgoing lines extending outwards;

the first mold part comprises a first body with a first through groove and a first cover body, and the first cover body is used for blocking a notch of the first through groove to form a first through hole;

the second mold part comprises a second body with a second through groove and a second cover body, and the second cover body is used for blocking the notch of the second through groove to form a second through hole;

two ends of the first mold part are respectively used for being butted with two ends of the second mold part, and the first through hole and the second through hole are communicated to form the mold cavity under the state that the first mold part and the second mold part are butted;

the peripheral wall of the die is provided with a notch for the outgoing line to pass through.

Technical Field

The invention relates to the technical field of generator structures, in particular to a generator stator assembly and an insulation processing method thereof, and further relates to a mold for the insulation processing method of the generator stator assembly.

Background

Generator stator subassembly mainly includes stator core and inlays the monomer coil at the stator core inslot, and wherein, stator subassembly's insulating treatment mode is mostly: after the single coil is formed, a plurality of layers of insulating tapes (such as mica tapes) are integrally wound, then the insulating tapes are embedded into a stator core slot, vacuum pressure impregnation treatment is carried out, liquid insulating materials are adopted for impregnation in the treatment process, and a final insulating structure is formed after impregnation and solidification.

It can be known from the above insulation process that the size of the generator stator assembly is limited by the size of the subsequent dipping equipment, and if the size of the iron core is large, the dipping equipment with a corresponding large size is needed, so that the cost is increased, and the problem of difficulty in manufacturing is also existed. In addition, at present, manual operation is mostly adopted for winding the insulation tape on the single coil, the manual influence factor is large, the dispersion is influenced by the dispersion of the manual operation, and the dispersion also occurs to the insulation performance of the stator assembly of the generator.

In view of the above, it is desirable to improve an insulation treatment method for a stator assembly of an existing generator, so that the insulation treatment of the stator assembly is not limited by the size of the dipping equipment, and the difficulty of the insulation treatment is reduced.

Disclosure of Invention

In order to solve the technical problem, the invention provides an insulation processing method of a generator stator assembly, wherein the stator assembly comprises a stator and a single coil embedded in an iron core groove of the stator, and the insulation processing method comprises the following steps:

and (3) placing the formed single coils (without binding the insulating tape) into a prefabricated mould corresponding to the single coils, and then carrying out impregnation treatment on the mould provided with the single coils by adopting a liquid insulating material, or pouring the liquid insulating material into the mould in a pouring mode.

The insulation processing method provided by the invention is used for independently carrying out insulation processing on the single coils of the generator stator assembly, so that the single coils can be embedded into the slots of the stator core of the generator stator assembly after being subjected to insulation processing, the stator assembly does not need to be subjected to integral impregnation insulation processing, the use of large-size impregnation equipment matched with the size of the stator assembly is avoided, the size of the impregnation equipment or related pouring equipment used for carrying out insulation processing on the single coils is relatively small, the insulation processing of the generator stator assembly does not need to depend on large-size equipment, and the insulation processing difficulty of the generator stator assembly is reduced.

In the insulation treatment method, after the mold with the single coils is dipped or poured, the mold is dried to cure the insulation material.

According to the insulation processing method, after the drying processing, the die and the single coil are separated, the single coil after the insulation processing is subjected to insulation testing, and the single coil qualified in the testing is embedded in the iron core slot of the stator.

In the insulation treatment method, a release agent or an oil-repellent layer is coated on the inner surface of a mold before the monomer coil is placed in the mold.

According to the insulation treatment method, before the single coils are placed in the die, the single coils are not bound by the insulation tape.

According to the insulation treatment method, the coil is not wrapped with the insulation tape, so that the liquid insulation material can be water-based environment-friendly insulation paint.

The invention also provides a generator stator assembly which comprises a stator core and the single coils embedded in the stator core groove, wherein the single coils are impregnated by the liquid insulating material and are not bound by the insulating tape.

The single coil of the generator stator assembly is a single coil which is subjected to liquid insulation material dipping treatment, is consistent with the principle of the insulation treatment method of the generator stator assembly, and has the same technical effect.

The invention also provides a mould for the insulation treatment of the stator assembly of the generator, wherein the stator assembly comprises a stator and a single coil embedded in an iron core groove of the stator, the mould comprises a first mould part with a first cavity and a second mould part with a second cavity, the first cavity and the second cavity are communicated to form a mould cavity under the butt joint state of the first mould part and the second mould part, and the shape of the mould cavity is matched with that of the single coil; the die is also provided with two through hole parts communicated with the die cavity.

According to the die, the single coil is a centralized winding coil and comprises two parallel straight sections and two curve sections, the curve sections are connected with the corresponding end parts of the two straight sections, and the two straight sections and the two curve sections form an annular structure; the single coil also comprises two outgoing lines, and the two outgoing lines extend towards the same side along the length direction of the two straight sections respectively;

the first die part comprises a first annular body with an annular groove, the second die part comprises a second annular body with an annular groove, and the annular grooves of the first annular body and the second annular body are communicated and form the die cavity matched with the annular structure of the single coil in a butt joint state; the mould still include with the inserted sheet of the curve section shape looks adaptation of mould tip, first ring body with the periphery wall of the second ring body has and is used for supplying inserted sheet male slot, two confessions have been seted up on the inserted sheet the socket that the lead-out wire passed, the periphery wall of mould correspond the position of socket have with the breach of socket intercommunication.

According to the die, the single coil is a distributed winding coil, the single coil is of a closed annular structure, and one end of the single coil is provided with two outgoing lines extending outwards;

the first mold part comprises a first body with a first through groove and a first cover body, and the first cover body is used for blocking a notch of the first through groove to form a first through hole;

the second mold part comprises a second body with a second through groove and a second cover body, and the second cover body is used for blocking the notch of the second through groove to form a second through hole;

two ends of the first mold part are respectively used for being butted with two ends of the second mold part, and the first through hole and the second through hole are communicated to form the mold cavity under the state that the first mold part and the second mold part are butted;

the peripheral wall of the die is provided with a notch for the outgoing line to pass through.

Drawings

FIG. 1 is a flow diagram of a method for insulation treatment of a generator stator assembly in an exemplary embodiment;

FIG. 2 is a cross-sectional schematic view of a single coil of a generator stator assembly in an exemplary embodiment;

FIG. 3 is a schematic diagram of a centralized winding coil in an embodiment;

fig. 4 is a schematic structural view of a mold corresponding to the concentrated winding coil shown in fig. 3;

FIG. 5 is an exploded view of the mold shown in FIG. 4;

FIG. 6 is a schematic view of the first mold portion of the mold shown in FIG. 4;

FIG. 7 is a schematic view of the second mold portion of the mold shown in FIG. 4;

FIG. 8 is a schematic view of the insert of the mold shown in FIG. 4;

FIG. 9 is a top view of the insert shown in FIG. 8;

FIG. 10 is a schematic diagram of a distributed winding coil in an exemplary embodiment;

fig. 11 is a schematic structural view of a mold corresponding to the distributed winding coil shown in fig. 10;

FIG. 12 is a schematic view of a first mold body of the mold shown in FIG. 11;

FIG. 13 is a schematic structural view of a second mold body of the mold shown in FIG. 11;

fig. 14 is a schematic structural view of a cover plate of the mold shown in fig. 11.

Description of reference numerals:

a monolithic coil 100, a wire 110, inter-turn insulation 120, insulation material 130;

a concentrated winding coil 200, a straight section 210, a curved section 220, and outgoing lines 230;

the die comprises a first die 300, a first die part 310, a first annular groove 311, a second die part 320, a second annular groove 321, an inserting sheet 330, a socket 331, a notch 340 and a pipe fitting 350;

a distributed winding coil 400;

the die comprises a second die 500, a first die body 510, a first body 511, a first through hole 512, a second die body 520, a cover body 530, a cover body 531, a flanging 532 and a connecting pipe 550.

Detailed Description

In order that those skilled in the art will better understand the disclosure, the invention will be described in further detail with reference to the accompanying drawings and specific embodiments.

For the sake of simplicity of understanding and description, the following description is made in conjunction with the generator stator assembly and the insulation processing method thereof, and the mold for insulation processing, and the advantageous effects will not be repeated.

Referring to fig. 1 and 2, fig. 1 is a flow chart illustrating a method for insulation treatment of a stator assembly of a generator in an embodiment; FIG. 2 is a schematic cross-sectional view of a single coil of a generator stator assembly in an example embodiment.

The generator stator assembly mainly comprises a stator and a single coil 100 embedded in an iron core groove of the stator, and the insulation treatment of the generator stator assembly mainly ensures the insulation of the single coil 100.

In this embodiment, the insulation processing method for the stator assembly of the generator includes the steps of:

s1, manufacturing a single coil, and prefabricating a die corresponding to the single coil;

the manufacturing method of the single coil 100 is substantially the same as that of the prior art, the single coil 100 is formed by winding the conducting wire 110 with the turn-to-turn insulation 120, the winding method is determined according to the requirement of the stator assembly of the generator, and the turn-to-turn insulation 120 between the conducting wires 110 of the single coil 100 can be selected according to the requirement.

The "single coil" herein does not imply a winding method of the coil, and only indicates the minimum unit of the coil wound in the core slot.

The mold corresponds to the shape and structure of the unit coil 100.

S2, placing the formed single coils into corresponding moulds, and then impregnating the moulds with the single coils with liquid insulating materials, or pouring the liquid insulating materials into the moulds in a pouring mode to perform insulating impregnation on the single coils.

As described above, the insulation processing method of the generator stator assembly is to perform insulation processing on the single coils 100 separately after the single coils 100 are manufactured, so that each single coil 100 can be embedded into the stator core slot of the generator stator assembly after insulation processing, and then the stator assembly does not need to be subjected to overall impregnation insulation processing, thereby avoiding the use of impregnation equipment with a larger size matched with the size of the stator assembly, wherein the size of the impregnation equipment or related pouring equipment used for performing insulation processing on the single coils 100 is relatively small, so that the insulation processing of the generator stator assembly does not need to depend on large equipment, and the insulation processing difficulty of the generator stator assembly is reduced.

After the insulation treatment, the sectional structure of the unit coil 100 fitted into the core slot of the stator is shown in fig. 2, and the outer circumference of the unit coil 100 is covered with the insulating material 130.

In the specific scheme, because the surface of the coil is not wrapped with the insulating tape, the insulating material adopted in the dipping treatment or the pouring treatment can be more oily impregnating resin or aqueous environment-friendly impregnating resin (paint) used by the existing large-scale motor, so that the manufacturing process of the stator component is more environment-friendly.

In step S1, after the single coil 100 is wound and formed, a subsequent separate insulation processing step is performed, so that it is not necessary to perform an insulation tape wrapping process on the single coil 100 as in the prior art, that is, in this embodiment, after the single coil 100 is manufactured in step S1, the insulation tape wrapping process is not performed on the single coil 100. Therefore, manual wrapping treatment is omitted, the influence of the dispersibility caused by the manual wrapping treatment is avoided, and the insulating property of the follow-up generator stator assembly is more consistent.

In a specific embodiment, after step S2, the method further includes:

and step S3, drying the mould filled with the single coils 100 after the insulation treatment to solidify the insulation material.

Specifically, a drying device, such as a baking oven, may be used to perform the drying process, and the drying temperature may be set according to actual requirements, which is not limited herein.

And step S4, separating the die and the single coil 100, performing an insulation test on the single coil 100, and embedding the single coil 100 qualified in the test into an iron core slot of the stator.

The insulation test of the single-body coil 100 may be performed by a conventional detection method, and will not be described in detail.

In a specific embodiment, to facilitate the separation of the unit coil 100 from the mold, between the foregoing step S1 and step S2, that is, before the unit coil 100 is placed in the mold, the method further includes step S11: and coating a release agent or an oleophobic layer on the inner surface of the mould.

The release agent or the oil-repellent layer can be made of existing mature materials as long as the monomer coil 100 and the die can be conveniently separated in the follow-up process.

In the embodiment, the mold for the insulation treatment of the stator assembly of the generator comprises a first mold part with a first cavity and a second mold part with a second cavity, wherein in a butt joint state, the first cavity and the second cavity can be communicated to form a mold cavity, and the shape of the mold cavity is matched with that of the manufactured single coil; the mold is divided into two parts to facilitate the assembly of the single coil and the mold. Specifically, the die is further provided with two through hole parts communicated with the die cavity, so that the insulating material can enter the die during dipping or pouring, and the air pressure balance is kept in the insulating treatment.

For the generator stator assembly, the single coils 100 have two types of concentrated windings and distributed windings, and the following description will be directed to the corresponding molds of the two types of coils.

Referring to fig. 3 to 9, fig. 3 is a schematic structural diagram of a concentrated winding coil in an embodiment; fig. 4 is a schematic structural view of a mold corresponding to the concentrated winding coil shown in fig. 3; FIG. 5 is an exploded view of the mold shown in FIG. 4; FIG. 6 is a schematic view of the first mold portion of the mold shown in FIG. 4; FIG. 7 is a schematic view of the second mold portion of the mold shown in FIG. 4; FIG. 8 is a schematic view of the insert of the mold shown in FIG. 4; figure 9 is a top view of the insert shown in figure 8.

Fig. 3 shows a structure of a concentrated winding coil 200 in an example, where the concentrated winding coil 200 is a racetrack structure and mainly includes two parallel straight sections 210 and two curved sections 220, the curved sections 220 are used to connect corresponding ends of the two straight sections 210, the concentrated winding coil 200 further includes two outgoing lines 230, the two outgoing lines 230 respectively extend toward the same side along a length direction of the two straight sections 210, and for the concentrated winding coil 200, the two outgoing lines 230 are respectively located at upper and lower sides of a winding, where the upper and lower sides are based on a plane perpendicular to an annular surface of the winding.

The concentrated winding coil 200 has a certain thickness in the vertical direction, the first mold 300 corresponding to the concentrated winding coil 200 includes a first mold part 310 and a second mold part 320, the first mold part 310 includes a first annular body having a first annular groove 311, the second mold part 320 includes a second annular body having a second annular groove 321, when the first mold part 310 and the second mold part 320 are butted, the notch directions of the first annular groove 311 and the second annular groove 321 are opposite, and in the butted state, the first annular groove 311 and the second annular groove 321 are communicated to form a mold cavity, and the shape of the mold cavity is matched with that of the concentrated winding coil 200.

Obviously, the first annular groove 311 is the first cavity, and the second annular groove 321 is the second cavity.

In particular, the first mold part 310 and the second mold part 320 may be disposed in the thickness direction.

It is understood that, in order to form the first annular groove 311 and the second annular groove 321, the first annular body and the second annular body each have an annular inner circumferential wall and an annular outer circumferential wall.

The first mold 300 further comprises an insertion sheet 330, the insertion sheet 330 is matched with the shape of the curved section of the end of the first mold, the peripheral wall of the same end of the first annular body and the second annular body is provided with a slot for inserting the insertion sheet 330, the insertion sheet 330 is provided with two insertion holes 331 for leading out wires 230 of the concentrated winding coil 200 to pass through, and the peripheral walls of the first annular body and the second annular body are provided with notches 340 corresponding to the positions of the insertion holes 331, so that the leading out wires 230 passing through the insertion sheet 330 can extend out of the first mold 300 during assembly. It is apparent that the gap 340 matches the shape of the pinout 230.

When assembling the concentrated winding coil 200 and the first mold 300, the concentrated winding coil 200 may be first placed in the first annular groove 311 of the first mold part 310, and then the insertion piece 330 may be inserted into and engaged with the outer circumferential wall of the first mold part 310 after passing through the two lead wires 230 of the concentrated winding coil 200, and then the second mold part 320 may be engaged with the first mold part 310.

In the illustrated embodiment, two pipe members 350 are connected to the peripheral wall of the first mold part 310, and communicate with the mold cavity, in use, one pipe member 350 can be used as an inlet for the insulating material to enter the mold, and the other pipe member 350 can balance the air pressure. It is understood that the two tubes 350 are the two through-hole portions.

In practice, the specific arrangement positions of the two pipes 350 can be set at other positions of the first mold 300 according to specific situations.

Referring to fig. 10 to 14, fig. 10 is a schematic structural diagram of a distributed winding coil according to an embodiment; fig. 11 is a schematic structural view of a mold corresponding to the distributed winding coil shown in fig. 10; FIG. 12 is a schematic view of a first mold body of the mold shown in FIG. 11; FIG. 13 is a schematic structural view of a second mold body of the mold shown in FIG. 11; fig. 14 is a schematic structural view of a cover plate of the mold shown in fig. 11 and 12.

Fig. 10 shows a specific shape structure of the distributed winding coil 400 in an example, the distributed winding coil 400 is a closed ring structure, and the specific form of the ring is not limited to that shown in the figure, and the distributed winding coil 400 is arranged according to the requirement in practical application. In practice, one end of the distributed winding coil 400 also has two outgoing lines (not shown).

In general, the thickness of the distributed winding coil 400 in the direction perpendicular to the annular face thereof is small, so that its corresponding mold is not easily divided into two parts in the thickness direction.

In this embodiment, the second mold 500 corresponding to the distributed winding coil 400 includes a first mold body 510 and a second mold body 520, which are butted to form a ring structure corresponding to the distributed winding coil 400, that is, the first mold body 510 and the second mold body 520 are respectively a part of the formed ring structure.

The first mold body 510 includes a first body 511 having a through slot and a cover 530, wherein the cover 530 is used for sealing the through slot of the through slot, so that the first mold body 510 formed by assembling the cover 530 and the first body 511 has a first through hole 512.

The second mold body 520 is similar to the first mold body 510 in composition, and includes a second body 521 having a through groove and a cover 530, and the cover 530 closes an opening of the through groove to form a second through hole.

Obviously, the first through hole is the first cavity, and the second through hole 512 is the second cavity.

After the two ends of the first mold body 510 are respectively butted with the two ends of the second mold body 520, the first through hole of the first mold body 510 is communicated with the second through hole of the second mold body 520 to form a mold cavity of the second mold 500, and the shape of the mold cavity is matched with that of the distributed winding coil 400.

During assembly, a portion of the distributed winding coil 400 may be first embedded into the through groove of the first body 511, then the cover 530 is fitted with the first body 511, then the rest of the distributed winding coil 400 is embedded into the second body of the second mold body 520, and then the other cover 530 is fitted with the second body, so that the distributed winding coil 400 is loaded into the second mold 500; the distributed winding coil 400 may be embedded in the first body 511 and the second body, and then the corresponding covers 530 may be assembled on the first body 511 and the second body, respectively.

In the illustrated embodiment, the first mold body 510 and the second mold body 520 are generally symmetrically disposed along a longitudinal centerline of the first mold 500 for ease of manufacture.

In a specific embodiment, the cover 530 includes a cover body 531 and a folded edge 532 bent toward the same side along two side edges of the cover body 531, and the peripheral walls of the first body 511 and the second body have slots corresponding to the folded edge 532, so as to facilitate the installation of the cover 530.

Specifically, as shown in fig. 14, the turned-over edges 532 are not provided near both end portions of the cover body 531, so that notches for the lead-out wires of the distributed winding coil 400 to protrude can be formed between the end portions of the cover body 531 and the body of the mold body.

In the illustrated embodiment, two connecting pipes 550 are inserted into the peripheral wall of the first mold body 510 and communicate with the through grooves, and it can be understood that the two connecting pipes 550 are the two through hole portions.

The mould structure that this embodiment provided both can be used for the dipping to handle, also can be used for the pouring to handle, selects dipping mode or pouring mode to carry out insulation treatment to the monomer coil according to the demand in the practical application.

The generator stator assembly, the insulation processing method thereof and the mold provided by the invention are described in detail above. The principles and embodiments of the present invention are explained herein using specific examples, which are presented only to assist in understanding the method and its core concepts. It should be noted that, for those skilled in the art, it is possible to make various improvements and modifications to the present invention without departing from the principle of the present invention, and those improvements and modifications also fall within the scope of the claims of the present invention.