JP2009268274A - Method of manufacturing coil for rotary electric machine and coil for rotary electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a coil for a rotary electric machine, which reduces the use amount of heating/pressurizing media in a heating/pressurizing process, shortens the manufacturing time, and manufactures the coil for the rotary electric machine with high reliability, and to provide the coil for the rotating electric machine manufactured by this manufacturing method. <P>SOLUTION: In the method of manufacturing the coil for the electric rotary machine, a conductor bundle 11 is electrically insulated and covered by winding a mica tape 12 impregnated with a thermosetting resin, a molding jig 14 is mounted on the insulated covered conductor bundle 11, the conductor bundle 11 mounted with the molding jig 14 is arranged in a vacuum-pressure tank 20 having an internal space 21 in a shape similar to the shape of the conductor bundle 11 mounted with the molding jig 14, and the inside of the vacuum-pressure tank 20 is vacuumed. Subsequently, the heating medium is press-injected into the vacuum-pressure tank 20, and the thermosetting resin impregnated with the mica tape 12 is cured. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a coil for a rotating electrical machine including a conductor and a mica tape wound around the outer periphery of the conductor to form an insulating layer, and in particular, after vacuum treatment, heating and pressurization treatment The manufacturing method of the coil for rotary electric machines which manufactures the coil for rotary electric machines by giving, and the coil for rotary electric machines manufactured by the manufacturing method of this coil for rotary electric machines.

  In general, an insulation coil used in a rotating electrical machine such as a high voltage electric motor is not subject to voltage, discharge due to voltage, heat due to Joule heat, eddy current loss, magnetic loss, etc., high temperature, electromagnetic vibration, etc. It is affected by various deterioration factors such as vibration and special environments. In order to ensure durability against these deteriorations and reliability in special environments, mica and thermosetting polymer organic resins typified by epoxy resins are widely used as the main constituent materials for insulation of rotating electrical machines. in use.

  The insulation method of the rotating electrical machine coil is roughly classified into an impregnation insulation method and a resin rich insulation method according to the manufacturing method. In the impregnation insulation method, a so-called dry mica tape in which laminated mica foil or flake mica foil and glass cloth or polymer film are bonded with an adhesive composed of a very small amount of organic resin is wound around a conductor bundle and impregnated. The resin is impregnated between the tape and in the mica foil layer and cured. Depending on the impregnation and curing timing, this impregnation insulation method is further divided into a single coil impregnation insulation method in which the coil is housed in the iron core after impregnation and curing, and an all impregnation method in which the coil is placed in the iron core before impregnation and then impregnated and cured. Further classified.

  On the other hand, in the resin-rich insulation method, the amount of adhesive is increased compared to the amount of adhesive of dry mica tape, and the mica tape itself is cured singly as a prepreg containing a curing agent, a curing catalyst, and a curing accelerator ( An uncured, semi-cured) so-called resin-rich mica tape is wound around a conductor bundle, and the uncured thermosetting resin in the mica tape is heated and pressurized to be cured. There are roughly two types of heating and pressing methods as the heating and pressing treatment. One heating and pressurizing method is a hot pressing method in which heating and pressurization are performed by a hot press apparatus, and the heated mold is pressurized with hydraulic pressure or the like. The other heating and pressurizing method is to place a coil in which a mica tape is wound around a bundle of conductors in a vacuum / pressure tank, and then evacuate it, and then transfer a heat medium such as molten asphalt into the tank. This is a hydraulic method in which the coil is heated and the inside of the tank is further pressurized to heat and pressurize the thermosetting resin in the mica tape (for example, Patent Document 1).

  In these heating and pressing methods, the same is true in that the thermosetting resin is heated and cured while the unreacted thermosetting resin in the mica tape is melted by heating and penetrating into the gap between the mica tapes. There is a difference in whether or not vacuum processing is performed. Further, in these heating and pressing methods, the time required for heating and pressing differs greatly, so that the thermosetting resin in the mica tape used in the hot press method is cured in a short time compared to the hydraulic method. Resin is often used.

  As described above, there are various types of manufacturing methods for coils for rotating electrical machines, and each rotating electrical machine manufacturer or coil specialized manufacturer defines a manufacturing method according to various circumstances. There is also an example in which a single manufacturer uses a plurality of manufacturing methods.

In recent years, demand for thermal power plants with a short construction period is increasing compared to nuclear and hydro power plants in China and India, where the economy has developed rapidly and power supply is tight. For this reason, it has become important to deliver products in a short period of time with high reliability at a low price. The generator coil, which is a coil for rotating electrical machines, is no exception, and a method of manufacturing with a small amount of material is required from the viewpoint of shortening the manufacturing period and depleting resources.
JP-A-10-58545

  In the conventional hydraulic system described above, coils are accumulated until a predetermined number of coils are manufactured, and the predetermined number of coils are collected and heated and pressurized at once using a large vacuum / pressure tank. So-called batch processing was performed. For this reason, the flow of the manufacturing process stagnates before the heat and pressure treatment process, and the manufacturing efficiency is lowered, which may hinder the shortening of the manufacturing time. Further, in the conventional hydraulic system, a large amount of heating / pressurizing medium represented by asphalt is used using a large tank, which is not desirable from the viewpoint of resource consumption.

  On the other hand, in the hot press method, since one or a plurality of coils are processed by one hot press apparatus, manufacturing by a flow process using a line or the like is possible. However, in the method of forming the entire coil with a mold, There was a problem that it took a long time to produce. In addition, when using multiple heat press devices, the manufacturing efficiency in the heating and pressurizing process is increased, but it is necessary to prepare a plurality of expensive dies, which increases the manufacturing cost and takes time to manufacture the dies. Have problems such as. In addition, when only the linear part of the coil is formed by a hot press device, the above-mentioned problems are greatly improved, but there is a difference in manufacturing performance between the linear part of the coil and the other parts. In some cases, it was not reliable.

  Therefore, the present invention has been made to solve such a problem, and can reduce the amount of heating / pressurizing medium used in the heating and pressurizing process, shorten the manufacturing time, and has high reliability. An object of the present invention is to provide a method for manufacturing a coil for a rotating electrical machine that can manufacture a coil for a rotating electrical machine, and a coil for a rotating electrical machine manufactured by the method for manufacturing a coil for a rotating electrical machine.

  In order to achieve the above object, according to one aspect of the present invention, a winding step of winding a mica tape containing an uncured or semi-cured thermosetting resin around a conductor bundle composed of a plurality of coated wires; A molding jig attaching step for attaching a molding jig for molding to the conductor bundle around which the mica tape is wound, and a conductor bundle having the molding jig attached to the conductor bundle to which the molding jig is attached. Is placed in a vacuum / pressurization tank having an internal space similar in shape to a vacuum processing step of evacuating the vacuum / pressurization tank, and after the vacuum processing step, in the vacuum / pressurization tank A heating medium is press-fitted to cure the thermosetting resin contained in the mica tape, and after the thermosetting resin is cured, the heating medium is discharged from the vacuum / pressure tank. Heating medium discharge process Method of manufacturing a rotary electric machine coil, characterized by Bei is provided.

  Moreover, according to one aspect of the present invention, a winding step of winding a mica tape containing an uncured or semi-cured thermosetting resin around a conductor bundle composed of a plurality of coated wires, and molding for molding A forming jig attaching step for attaching the jig to the conductor bundle around which the mica tape is wound, and an accommodating step for accommodating the conductor bundle attached with the forming jig in a flexible bag-like vacuum bag And the conductor bundle accommodated in the vacuum bag is placed in a vacuum / pressure tank having an internal space similar to the shape of the conductor bundle to which the forming jig is attached. A vacuum processing step of evacuating, a thermosetting processing step of press-fitting a heating medium into the vacuum / pressure tank after the vacuum processing step, and curing the thermosetting resin contained in the mica tape, The thermosetting resin is cured The method of a rotating electric machine coil, characterized by comprising a heating medium discharge step of discharging the heating medium from said vacuum-pressure tank is provided.

  According to the method for manufacturing a coil for a rotating electrical machine of the present invention, the amount of heating / pressurizing medium used in the heating and pressurizing process can be reduced, the manufacturing time can be shortened, and the rotating electrical machine has high reliability. A coil can be manufactured. Moreover, the rotating electrical machine coil manufactured by the manufacturing method of the rotating electrical machine coil according to the present invention is homogeneous among the rotating electrical machine coils.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(First embodiment)
FIG. 1 is a view for explaining a method for manufacturing a rotating electrical machine coil according to a first embodiment of the present invention, and is a view showing a cross section of a conductor bundle 11 to which a forming jig 14 is attached. FIG. 2 is a view showing a cross section of the vacuum / pressure tank 20 in a state in which the conductor bundle 11 to which the forming jig 14 is attached is disposed in the vacuum / pressure tank 20. FIG. 3 is a flowchart for explaining a manufacturing process of a coil for a rotating electrical machine.

  As shown in FIG. 1, a conductor bundle 11 made of a plurality of copper wires 10 covered with an electrical insulating material is wound around a plurality of layers by a resin-rich insulating mica tape 12 to form a coil insulating layer. Yes. A Teflon (registered trademark) tape 13 is wound around the coil insulating layer of the mica tape 12. A molding jig 14 for molding is attached around the Teflon tape 13. The Teflon tape 13 prevents a heating medium described later from penetrating between the mica tapes 12 and also functions as a release agent for facilitating release from the forming jig 14. Here, the forming jig 14 is fixed around the Teflon tape 13 by winding a heat-shrinkable heat-shrinkable tape 15 around the forming jig 14 and heating it to shrink the heat-shrinkable tape 15. ing. In addition, after performing a heating and pressurizing process in the vacuum / pressurization tank 20, the heat shrink tape 15, the forming jig 14, and the Teflon tape 13 are removed.

  The mica tape 12 is an insulating member in which laminated mica paper or flake mica sheet and a reinforcing material are bonded together, and the laminated mica paper or flake mica sheet contains an uncured or semi-cured thermosetting resin. The material of the laminated mica may be either hard unfired laminated mica or hard fired laminated mica. In order to improve the mechanical strength, heat resistance, impregnation properties, etc. of these laminated mica, it is possible to mix aromatic polyamide fibrids (monofilaments) such as aramids into mixed mica and make paper, or use short glass fibers as laminated mica. You may use what mixed and made paper. Further, the flake mica material can be either mechanically bonded or manually bonded. The reinforcing material can reinforce the laminated mica paper or flake mica sheet, and can be applied without particular limitation as long as it is electrically insulating. For example, glass cloth, polymer film (polyester film or polyimide film) Etc.), an insulating sheet material such as a polyester nonwoven fabric can be used. Moreover, as a thermosetting resin, an epoxy resin, a phenol resin, an unsaturated polyester resin, a phenoxy resin, a thermosetting polyimide resin, etc. are applicable, for example. Moreover, you may use these thermosetting resins individually or in mixture of 2 or more types. Of these thermosetting resins, it is particularly preferable to use an epoxy resin from the viewpoints of insulation, mechanical properties, heat resistance, and the like.

  The forming jig 14 is a jig for forming a coil into a predetermined shape, and is formed of, for example, a plate member made of a metal such as iron or stainless steel, or a resin such as FRP (Fiber Reinforced Plastic). In addition, it is preferable that the forming jig 14 is formed of a material that can be used repeatedly from the viewpoint of economy and environmental load reduction. Further, the heat shrinkable tape 15 for fixing the forming jig 14 is made of a material having a heat resistance temperature equal to or higher than the temperature of the heating medium supplied into the vacuum / pressurized tank 20 because it contacts the heat medium. . Specifically, the heat shrink tape 15 is formed of, for example, polyethylene terephthalate (PET), fluororesin (FEP), or the like.

  Next, the configuration of the vacuum / pressurized tank 20 will be described with reference to FIG.

  As shown in FIG. 2, the vacuum / pressure tank 20 has an internal space 21 having a shape similar to the shape of the conductor bundle 11 to which the forming jig 14 is attached, and is divided into a plurality of divided components 20a, 20b, It is configured by fastening 20c with a flange portion. In the vacuum / pressurized tank 20, the conductor bundle 11 to which the forming jig 14 is attached is disposed in the internal space 21 and sealed. By constructing the vacuum / pressurized tank 20 in this way with a plurality of divided parts 20a, 20b, 20c, even when manufacturing coils of various shapes and dimensions, according to the shape and dimensions of the coil, The vacuum / pressurized tank 20 can be configured by combining the divided components. Therefore, since each component can be used repeatedly, resource consumption can be saved and the manufacturing cost can be reduced. Further, the vacuum / pressurization tank 20 may be configured to have a heat resistant temperature higher than the temperature of the heating medium and can withstand a pressure higher than the pressure when the inside of the vacuum / pressurization tank 20 is pressurized. Consists of.

  The vacuum / pressure tank 20 includes a vacuuming pipe 22 for evacuating the vacuum / pressure tank 20 and a heating medium introduction pipe 23 for introducing a heating medium into the vacuum / pressure tank 20. And a heating medium discharge pipe 24 for discharging the heating medium from the vacuum / pressurized tank 20. Moreover, you may provide the piping 25 for a pressurization for pressurizing the inside of the vacuum and pressurization tank 20 as needed. In addition, when the pressure which should be set in the vacuum / pressurization tank 20 can be set with the supply pressure of the heating medium introduced from the heating medium introduction pipe 23, it is not necessary to provide the pressurization pipe 25. Each pipe is provided with shut-off valves 22a, 23a, 24a, 25a for shutting off the communication with the vacuum / pressurized tank 20. The vacuum / pressure tank 20 may be provided with heating means such as a heater for maintaining the temperature of the heating medium introduced into the vacuum / pressure tank 20.

  As described above, the internal space 21 in the vacuum / pressurized tank 20 is formed to have a shape similar to the shape of the conductor bundle 11 to which the forming jig 14 is attached. The distance between the heat shrink tape 15 formed on the outermost side of the conductor bundle 11 to which the forming jig 14 is attached is preferably 1 to 5 cm. This range is preferable because when the distance between the two is shorter than 1 cm, the heating time becomes longer due to the problem of heat capacity, and when it is longer than 5 cm, the amount of heating medium used increases. The conductor bundle 11 to which the forming jig 14 is attached is disposed in the above range of the internal space 21 by being supported by a support member (not shown).

  The heating medium supplied into the vacuum / pressurized tank 20 through the heating medium introduction pipe 23 is used to heat and cure the thermosetting resin impregnated in the mica tape 12. As this heating medium, for example, bitumen or a volatile substance having volatility at normal temperature and atmospheric pressure, which is heated to a curing temperature of 120 to 160 ° C. of a thermosetting resin, is used. Among bitumen, it is preferable to use natural asphalt, coal tar, petroleum asphalt, pitch, etc., particularly from the viewpoint of availability. As the volatile substance, for example, an inert liquid or the like is used, and among the inert liquids, a fluorine-based inert liquid (for example, Fluorinert; 3M) that is particularly thermally and chemically stable and excellent in electrical insulation. Is preferably used. Here, by using this volatile substance, for example, even if a heating medium adheres to the mica tape 12 or the like, it is volatile at normal temperature and atmospheric pressure, so it is necessary to use a solvent or the like to remove the heating medium. Absent. Furthermore, since the heating medium removal step can be omitted, the manufacturing process can be shortened.

Further, when a pressurizing pipe 25 for pressurizing the inside of the vacuum / pressurized tank 20 is provided, an inert gas such as N ₂ is used as a medium for pressurizing the inside of the vacuum / pressurized tank 20.

  In addition, in order to partition each component part 20a, 20b, 20c into the some divided | segmented each component part 20a, 20b, 20c which comprises the vacuum / pressurization tank 20, and to form the independent internal space 21, respectively. A partition member may be provided. In this case, each of the components 20a, 20b, and 20c is provided with a evacuation pipe 22, a heating medium introduction pipe 23, a heating medium discharge pipe 24, and, if necessary, a pressurization pipe 25. By configuring the vacuum / pressurized tank 20 in this way, the temperature of the heating medium, the pressure in each component 20a, 20b, 20c, etc., depending on each component 20a, 20b, 20c, that is, each part of the coil, etc. Can be adjusted.

  Next, the coil manufacturing process will be described with reference to FIGS.

  First, a resin-rich insulating mica tape 12 is wound a plurality of times around a conductor bundle 11 made of a plurality of copper wires 10 covered with an electrical insulating material to form a coil insulating layer (step S40 in FIG. 3).

  Subsequently, a Teflon tape 13 is wound around the coil insulating layer of the mica tape 12, a forming jig 14 is attached around the Teflon tape 13, and a heat-shrinkable heat-shrinkable tape is provided around the forming jig 14. 15 is wound to fix the forming jig 14, and the conductor bundle 11 having a cross-sectional shape shown in FIG. 1 is obtained (step S41 in FIG. 3).

  Subsequently, as shown in FIG. 2, the conductor bundle 11 to which the forming jig 14 is attached is placed in the internal space 21 of the vacuum / pressurized tank 20, the inner wall of the vacuum / pressurized tank 20, and the forming jig 14. It arrange | positions so that the distance between the heat shrink tapes 15 comprised on the outermost side of the attached conductor bundle 11 may become the above-mentioned predetermined range. After the arrangement, the vacuum / pressure tank 20 is evacuated through the evacuation pipe 22 to make the inside of the vacuum / pressurized tank 20 vacuum (for example, about 0.133 kPa in absolute pressure) (step S42 in FIG. 3). By evacuating the inside of the vacuum / pressurized tank 20, the volatile matter of the mica tape 12, moisture adhering to the mica tape 12 and the forming jig 14 is removed.

  Subsequently, after closing the shutoff valve 22a of the vacuuming pipe 22, the shutoff valve 23a of the heating medium introduction pipe 23 is opened, and the heating medium is introduced into the vacuum / pressure tank 20 in a vacuum state. The heating medium introduced into the vacuum / pressure tank 20 is filled in the internal space 21 in which the conductor bundle 11 to which the forming jig 14 is attached is disposed, and is further introduced under pressure, thereby forming the forming jig. A uniform pressure is applied to the entire conductor bundle 11 to which 14 is attached. The mica tape 12 wound around the conductor bundle 11 is heated by the heating medium, and the thermosetting resin contained in the mica tape 12 is cured (step S43 in FIG. 3). Here, the time for performing the thermosetting treatment with the heating medium is set based on the curing characteristics of the thermosetting resin. Note that the shut-off valve 23a of the heating medium introduction pipe 23 is closed when the inside of the vacuum / pressurized tank 20 reaches a predetermined pressure.

  In the thermosetting process described above, the conductor bundle 11 may be heated by energizing the conductor bundle 11. Further, when the vacuum / pressurized tank 20 is made of a non-conductive nonmagnetic material such as FRP, for example, the vacuum / pressurized tank 20 is disposed in a coil connected to an AC power source, for example, The conductor bundle 11 may be heated by induction heating. Thus, the thermosetting resin contained in the mica tape 12 starts to be cured from the vicinity of the conductor bundle 11 by heating the conductor bundle 11 by energization heating or high frequency induction heating. Therefore, peeling between the conductor bundle 11 and the mica tape 12 due to curing shrinkage of the thermosetting resin can be suppressed, and the quality of the coil and the reliability in coil manufacture can be improved.

  After performing the above-mentioned thermosetting treatment for a predetermined time, the pressure in the vacuum / pressure tank 20 is released to the atmosphere, the shutoff valve 24a of the heating medium discharge pipe 24 is opened, and the heating medium is discharged from the vacuum / pressure tank 20 (Step S44 in FIG. 3). After the heating medium is discharged, the conductor bundle 11 to which the forming jig 14 is attached is taken out from the vacuum / pressure tank 20, and the heat shrink tape 15, the forming jig 14, the Teflon tape 13 and the attached heating medium are removed. A coil, that is, a coil for a rotating electrical machine is obtained.

  As described above, according to the method for manufacturing a rotating electrical machine coil of the first embodiment, a vacuum / pressurized tank having an internal space 21 having a shape similar to the shape of the conductor bundle 11 to which the forming jig 14 is attached. By using 20, the usage-amount of a heating medium can be reduced. The heating medium can also be set by setting a predetermined distance between the inner wall of the vacuum / pressurized tank 20 and the heat shrinkable tape 15 formed on the outermost side of the conductor bundle 11 to which the forming jig 14 is attached. The amount of use can be reduced. Further, when the conductor bundle 11 to which the forming jig 14 is attached is disposed in the vacuum / pressurized tank 20, the excessive internal space 21 is limited, so that the time required for evacuation in the vacuum processing step, thermosetting The time for introducing the heating medium in the treatment process can be reduced, and the manufacturing time can be shortened. Furthermore, since the thermosetting process can be performed on the entire coil at the same time, the quality of the coil can be homogenized as compared with, for example, a hot press method.

  Further, using the vacuum / pressurized tank 20 having an internal space 21 similar to the shape of the conductor bundle 11 to which the forming jig 14 is attached, each conductor bundle 11 to which the forming jig 14 is attached is Unlike the so-called batch process in which a large number of conductor bundles 11 to which the forming jig 14 is attached are processed together, for example, as in the conventional hydraulic method, manufacturing by a flow process using a line or the like is possible. Is possible.

  Further, according to the rotating electrical machine coil manufactured by the rotating electrical machine coil manufacturing method of the first embodiment, the conductor bundle 11 and the mica tape 12 are peeled off, and bubbles and defects are generated in the mica tape 12. Is suppressed, and the coil performance is good.

(Second Embodiment)
FIG. 4 is a diagram for explaining a method of manufacturing a rotating electrical machine coil according to a second embodiment of the present invention, and is a conductor bundle accommodated in a vacuum bag 50 and attached with a forming jig 14. 11 is a view showing a cross section of the vacuum / pressurized tank 20 in a state of being disposed in the vacuum / pressurized tank 20. FIG. 5 is a flowchart for explaining a manufacturing process of a coil for a rotating electrical machine. In addition, the same code | symbol is attached | subjected to the component same as 1st Embodiment, and the overlapping description is abbreviate | omitted or simplified. Moreover, in the manufacturing method of the coil for rotary electric machines of 2nd Embodiment, except for accommodating the conductor bundle 11 with which the jig 14 for shaping | molding was attached in the vacuum back | bag 50, and performing a process, it is 1st of this invention. Since it is the same as the manufacturing method of the coil for rotating electrical machines of the embodiment, the different configuration will be mainly described.

  As shown in FIG. 4, the vacuum / pressurized tank 20 has an internal space 21 having a shape similar to the shape of the conductor bundle 11 to which the forming jig 14 is attached, and is divided into a plurality of divided components 20a, 20b, It is configured by fastening 20c with a flange portion. In the vacuum / pressurized tank 20, the conductor bundle 11 to which the forming jig 14 attached and sealed in the vacuum bag 50 is disposed is sealed in the internal space 21. By constructing the vacuum / pressurized tank 20 in this way with a plurality of divided parts 20a, 20b, 20c, even when manufacturing coils of various shapes and dimensions, according to the shape and dimensions of the coil, The vacuum / pressurized tank 20 can be configured by combining the divided components. Therefore, since each component can be used repeatedly, resource consumption can be saved and the manufacturing cost can be reduced. Further, the vacuum / pressurized tank 20 may be configured to have a heat resistant temperature higher than the temperature of the heating medium and can withstand a pressure higher than the pressure when the inside of the vacuum / pressurized tank 20 is pressurized. Consists of.

  The vacuum / pressure tank 20 includes a vacuuming pipe 22 for evacuating the vacuum back 50, and a vacuum back 50 and a vacuum / pressure tank 20 in the vacuum / pressure tank 20. A heating medium introduction pipe 23 for introducing a heating medium therebetween, and a heating medium discharge pipe 24 for discharging the heating medium from between the vacuum bag 50 and the vacuum / pressurized tank 20 are provided. Moreover, you may provide the piping 25 for a pressurization for pressurizing the inside of the vacuum and pressurization tank 20 as needed. In addition, when the pressure which should be set in the vacuum / pressurization tank 20 can be set with the supply pressure of the heating medium introduced from the heating medium introduction pipe 23, it is not necessary to provide the pressurization pipe 25. Each pipe is provided with shut-off valves 22a, 23a, 24a, 25a for shutting off the communication with the vacuum / pressurized tank 20. The vacuum / pressure tank 20 may be provided with heating means such as a heater for maintaining the temperature of the heating medium introduced into the vacuum / pressure tank 20.

  As described above, the internal space 21 in the vacuum / pressurized tank 20 is formed to have a shape similar to the shape of the conductor bundle 11 to which the forming jig 14 is attached. The distance between the heat shrink tape 15 formed on the outermost side of the conductor bundle 11 to which the forming jig 14 is attached is preferably 1 to 5 cm. This range is preferable because when the distance between the two is shorter than 1 cm, the heating time becomes longer due to the problem of heat capacity, and when it is longer than 5 cm, the amount of heating medium used increases. The conductor bundle 11 to which the forming jig 14 is attached is disposed in the above range of the internal space 21 by being supported by a support member (not shown).

  The vacuum bag 50 is a flexible bag-like hermetic bag and is made of silicone rubber or the like. Specifically, for example, a rubber material reinforced with glass cloth is used. Moreover, since the vacuum bag 50 is in contact with the heating medium, the vacuum bag 50 has heat resistance equal to or higher than the temperature of the heating medium. The thickness of the vacuum bag 50 is about 1 to 2 mm.

  Next, the coil manufacturing process will be described with reference to FIGS.

  First, a resin-rich insulating mica tape 12 is wound a plurality of times around a conductor bundle 11 made of a plurality of copper wires 10 covered with an electrical insulating material to form a coil insulating layer (step S60 in FIG. 5).

  Subsequently, a Teflon tape 13 is wound around the coil insulating layer of the mica tape 12, a forming jig 14 is attached around the Teflon tape 13, and a heat-shrinkable heat-shrinkable tape is provided around the forming jig 14. 15 is wound to fix the forming jig 14, and the conductor bundle 11 having a cross-sectional shape shown in FIG. 1 is obtained (step S61 in FIG. 5).

  Subsequently, the conductor bundle 11 to which the forming jig 14 is attached is accommodated in the vacuum bag 50 and sealed (step S62 in FIG. 5).

  Subsequently, as shown in FIG. 4, the conductor bundle 11 accommodated in the vacuum bag 50 and to which the forming jig 14 is attached is placed in the internal space 21 of the vacuum / pressure tank 20 in the vacuum / pressure tank. It arrange | positions so that the distance between the inner wall of 20 and the heat shrink tape 15 comprised on the outermost side of the conductor bundle 11 to which the shaping | molding jig 14 was attached may become the above-mentioned predetermined range. After the placement, vacuuming is performed through the vacuuming pipe 22, and the vacuum back 50 is evacuated (for example, about 0.133 kPa in absolute pressure) (step S63 in FIG. 5). By making the inside of the vacuum bag 50 into a vacuum, the flexible vacuum bag 50 is in close contact with the heat-shrinkable tape 15 configured on the outermost side of the conductor bundle 11. Further, by evacuating the vacuum bag 50, the volatile matter of the mica tape 12, moisture adhering to the mica tape 12 and the forming jig 14 is removed.

  Subsequently, after shutting off the shutoff valve 22 a of the vacuuming pipe 22, the shutoff valve 23 a of the heating medium introduction pipe 23 is opened to heat the internal space 21 between the vacuum bag 50 and the vacuum / pressurized tank 20. Introduce media. The heating medium introduced between the vacuum bag 50 and the vacuum / pressurization tank 20 is filled in the internal space 21 and further introduced under pressure, whereby the conductor bundle 11 to which the forming jig 14 is attached. In addition, a uniform pressure is applied throughout the vacuum bag 50. The mica tape 12 wound around the conductor bundle 11 is heated by the heating medium, and the thermosetting resin contained in the mica tape 12 is cured (step S64 in FIG. 5). Here, the time for performing the thermosetting treatment with the heating medium is set based on the curing characteristics of the thermosetting resin. Note that the shut-off valve 23a of the heating medium introduction pipe 23 is closed when the inside of the vacuum / pressurized tank 20 reaches a predetermined pressure.

  In the thermosetting process described above, the conductor bundle 11 may be heated by energizing the conductor bundle 11. Further, when the vacuum / pressurized tank 20 is made of a non-conductive nonmagnetic material such as FRP, for example, the vacuum / pressurized tank 20 is disposed in a coil connected to an AC power source, for example, The conductor bundle 11 may be heated by induction heating. Thus, the thermosetting resin contained in the mica tape 12 starts to be cured from the vicinity of the conductor bundle 11 by heating the conductor bundle 11 by energization heating or high frequency induction heating. Therefore, peeling between the conductor bundle 11 and the mica tape 12 due to curing shrinkage of the thermosetting resin can be suppressed, and the quality of the coil and the reliability in coil manufacture can be improved.

  After performing the above-described thermosetting treatment for a predetermined time, the pressure in the vacuum / pressure tank 20 is released to the atmosphere, the shutoff valve 24a of the heating medium discharge pipe 24 is opened, and the vacuum back 50 and the vacuum / pressure tank 20 are opened. The heating medium is discharged from between (step S65 in FIG. 5). After the heating medium is discharged, the conductor bundle 11 with the forming jig 14 accommodated in the vacuum bag 50 is taken out from the vacuum / pressure tank 20, and the vacuum bag 50, the heat shrink tape 15, The forming jig 14 and the Teflon tape 13 are removed to obtain a coil, that is, a rotating electrical machine coil.

  As described above, according to the method for manufacturing a coil for a rotating electrical machine of the second embodiment, a vacuum / pressurized tank having an internal space 21 similar to the shape of the conductor bundle 11 to which the forming jig 14 is attached. By using 20, the usage-amount of a heating medium can be reduced. The heating medium can also be set by setting a predetermined distance between the inner wall of the vacuum / pressurized tank 20 and the heat shrinkable tape 15 formed on the outermost side of the conductor bundle 11 to which the forming jig 14 is attached. The amount of use can be reduced. In the vacuum processing step, the space in the vacuum bag 50 is a space smaller than the excess internal space 21 when the conductor bundle 11 to which the forming jig 14 is attached is disposed in the vacuum / pressure tank 20. Therefore, the time for evacuation can be further reduced, and the manufacturing time can be shortened. Furthermore, since the thermosetting process can be performed on the entire coil at the same time, the quality of the coil can be homogenized as compared with, for example, a hot press method.

  Further, since the heating medium contacts the conductor bundle 11 to which the forming jig 14 is attached via the vacuum bag 50, the conductor bundle 11 to which the forming jig 14 is attached does not directly contact the heating medium. The heating medium removal step can be omitted. As a result, the manufacturing process can be shortened.

  Further, using the vacuum / pressure tank 20 having an internal space 21 similar in shape to the conductor bundle 11 to which the forming jig 14 is attached, the forming jig 14 accommodated in the vacuum bag 50 is attached. Since each process can be performed on the conductor bundle 11 thus obtained, so-called batch processing, in which a large number of conductor bundles 11 to which the forming jig 14 is attached is processed together, for example, as in the conventional hydraulic method, In contrast, manufacturing by a flow process using a line or the like is possible.

  In addition, according to the rotating electrical machine coil manufactured by the rotating electrical machine coil manufacturing method of the second embodiment, the conductor bundle 11 and the mica tape 12 are peeled off, and bubbles and defects are generated in the mica tape 12. Is suppressed, and the coil performance is good.

  FIG. 6 is a view showing a cross section of the vacuum bag 50 when the vacuum bag 50 is composed of component parts divided into a plurality of parts. As shown in FIG. 6, the bag-like bag having flexibility described above is divided into a plurality of parts, each of the divided parts (50 a to 50 e) is provided with a connecting flange 60, and the vacuum is obtained by connecting via the flange 60. The back 50 may be configured. With this configuration, the vacuum back 50 can be configured in accordance with the shape and size of the conductor bundle 11 accommodated in the vacuum back 50.

  Next, Examples 1 to 3 show that the rotating electrical machine coil manufactured by the manufacturing method of the rotating electrical machine coil according to the present invention has the same coil performance as the rotating electrical machine coil manufactured by the conventional hydraulic method. This will be described based on Example 3 and Comparative Example 1. In addition, in the manufacturing process of the coil for rotary electric machines used in Examples 1 to 3 and Comparative Example 1, the above-described insulating coating process and the forming jig attaching process are the same, so these processes will be described only in Example 1. To do.

Example 1
The coil for rotating electrical machines used in Example 1 was manufactured as follows. Here, the manufactured rotating electrical machine coil is the same as the manufacturing method of the rotating electrical machine coil in the first embodiment, and therefore will be described with reference to FIGS. 1 and 2.

  First, around a conductor bundle 11 made of a plurality of copper wires 10 wound with glass-tetron fiber and coated by heating and welding, a mica tape 12 made of hard fired laminated mica tape containing a phenol novolac epoxy resin is used. A coil insulating layer was formed by winding 10 turns in a / 2 stack.

  Subsequently, the Teflon tape 13 was wound once by 3 mm on the periphery of the coil insulating layer made of the mica tape 12. Then, a plate-shaped forming jig 14 having a thickness of 2.3 mm made of SS steel was attached around the Teflon tape 13. Further, a heat-shrinkable heat-shrinkable tape 15 made of a PET material was wound around the forming jig 14 four times in a 1/2 layer to fix the forming jig 14.

  Subsequently, as shown in FIG. 2, the conductor bundle 11 to which the forming jig 14 is attached is placed in the internal space 21 of the vacuum / pressurized tank 20, the inner wall of the vacuum / pressurized tank 20, and the forming jig 14. It arrange | positioned so that the distance between the heat shrink tapes 15 comprised in the outermost part of the attached conductor bundle 11 might be set to 50 mm. After the placement, the vacuum was drawn through the vacuuming pipe 22, and the inside of the vacuum / pressurized tank 20 was set to 0.133 kPa in absolute pressure.

  Subsequently, after closing the shutoff valve 22a of the evacuation pipe 22, the shutoff valve 23a of the heating medium introduction pipe 23 is opened, and the temperature of asphalt is 160 ° C. in the vacuum / pressure tank 20 in a vacuum state. The heating medium was introduced. After introducing the heating medium, nitrogen gas was supplied as the pressure medium from the pressure pipe 25, and the inside of the vacuum / pressure tank 20 was pressurized to 500 kPa (G) to cure the thermosetting resin included in the mica tape 12. .

  After performing the above-described thermosetting treatment for 20 hours, the pressure in the vacuum / pressure tank 20 is released to the atmosphere, the shut-off valve 24a of the heating medium discharge pipe 24 is opened, and the heating medium is discharged from the vacuum / pressure tank 20 did. After the heating medium is discharged, the conductor bundle 11 to which the forming jig 14 is attached is taken out from the vacuum / pressure tank 20, and the heat shrink tape 15, the forming jig 14, the Teflon tape 13 and the attached heating medium are removed. A coil for a rotating electrical machine was obtained.

  The voltage characteristic of dielectric loss tangent was measured by attaching a guard electrode using a high voltage automatic tan δ measurement system (DAC-5005, manufactured by Soken Denki Co., Ltd.) using the coil for a rotating electrical machine manufactured in the above-described process. And the difference of the dielectric loss tangent showing the bubble and defect in the mica tape 12 which is an insulating layer in the coil for rotary electric machines was calculated. Here, the difference is a value obtained by subtracting the dielectric loss tangent at 0.2 times the rated voltage from the dielectric loss tangent at the actual coil operating voltage (E / √3) when the rated voltage is E. is there. As a result of the measurement, the difference in dielectric loss tangent was 0.1%.

(Example 2)
The coil for rotating electrical machines used in Example 2 was manufactured as follows. Here, the manufactured rotating electrical machine coil is the same as the manufacturing method of the rotating electrical machine coil according to the second embodiment, and will be described with reference to FIG.

  The conductor bundle 11 to which the forming jig 14 was attached was accommodated in a vacuum bag 50 made of fiber-reinforced silicone rubber and sealed.

  As shown in FIG. 4, the conductor bundle 11, which is accommodated in the vacuum bag 50 and to which the forming jig 14 is attached, is placed in the internal space 21 of the vacuum / pressurized tank 20 and the inner wall of the vacuum / pressurized tank 20. And the heat-shrinkable tape 15 that is configured on the outermost side of the conductor bundle 11 to which the forming jig 14 is attached. After the placement, vacuuming was performed through the vacuuming pipe 22, and the inside of the vacuum back 50 was set to 0.133 kPa in absolute pressure.

  Subsequently, after closing the shutoff valve 22a of the evacuation pipe 22, the shutoff valve 23a of the heating medium introduction pipe 23 is opened, and the internal space 21 between the vacuum back 50 and the vacuum / pressurization tank 20 is opened. A heating medium having an asphalt temperature of 160 ° C. was introduced. After introducing the heating medium, nitrogen gas was supplied as the pressure medium from the pressure pipe 25, and the inside of the vacuum / pressure tank 20 was pressurized to 500 kPa (G) to cure the thermosetting resin included in the mica tape 12. .

  After performing the above-described thermosetting treatment for 20 hours, the pressure in the vacuum / pressure tank 20 is released to the atmosphere, the shutoff valve 24a of the heating medium discharge pipe 24 is opened, and the vacuum back 50 and the vacuum / pressure tank 20 are opened. The heating medium was discharged from between. After the heating medium is discharged, the conductor bundle 11 to which the forming jig 14 is attached is taken out from the vacuum / pressure tank 20, and the vacuum bag 50, the heat shrink tape 15, the forming jig 14, and the Teflon tape 13 are removed. A coil for a rotating electrical machine was obtained.

  The voltage characteristics of dielectric loss tangent were measured by the same method as in Example 1 by using the rotating electrical machine coil produced in the above process. And the difference of the dielectric loss tangent showing the bubble and defect in the mica tape 12 which is an insulating layer in the coil for rotary electric machines was calculated. As a result of the measurement, the difference in dielectric loss tangent was 0.08%.

(Example 3)
The rotating electrical machine coil used in Example 3 was manufactured as follows. Here, the manufactured rotating electrical machine coil is the same as the manufacturing method of the rotating electrical machine coil according to the second embodiment, and will be described with reference to FIG.

  The conductor bundle 11 to which the forming jig 14 was attached was accommodated in a vacuum bag 50 made of fiber-reinforced silicone rubber and sealed.

  As shown in FIG. 4, the conductor bundle 11, which is accommodated in the vacuum bag 50 and to which the forming jig 14 is attached, is placed in the internal space 21 of the vacuum / pressurized tank 20 and the inner wall of the vacuum / pressurized tank 20. And the heat-shrinkable tape 15 that is configured on the outermost side of the conductor bundle 11 to which the forming jig 14 is attached. After the placement, vacuuming was performed through the vacuuming pipe 22, and the inside of the vacuum back 50 was set to 0.133 kPa in absolute pressure.

  Subsequently, after closing the shutoff valve 22a of the evacuation pipe 22, the shutoff valve 23a of the heating medium introduction pipe 23 is opened, and the internal space 21 between the vacuum back 50 and the vacuum / pressurization tank 20 is opened. A heating medium having an asphalt temperature of 160 ° C. was introduced. After introducing the heating medium, nitrogen gas is supplied from the pressurizing pipe 25 as a pressurizing medium, the inside of the vacuum / pressurizing tank 20 is pressurized to 500 kPa (G), and a voltage of 30 to 50 V is applied to energize the conductor. The bundle 11 was heated to cure the thermosetting resin included in the mica tape 12.

  After performing the above-described thermosetting treatment for 20 hours, the pressure in the vacuum / pressure tank 20 is released to the atmosphere, the shutoff valve 24a of the heating medium discharge pipe 24 is opened, and the vacuum back 50 and the vacuum / pressure tank 20 are opened. The heating medium was discharged from between. After the heating medium is discharged, the conductor bundle 11 to which the forming jig 14 is attached is taken out from the vacuum / pressure tank 20, and the vacuum bag 50, the heat shrink tape 15, the forming jig 14, and the Teflon tape 13 are removed. A coil for a rotating electrical machine was obtained.

  The voltage characteristics of dielectric loss tangent were measured by the same method as in Example 1 using the rotating electrical machine coil produced in the above-described process. And the difference of the dielectric loss tangent showing the bubble and defect in the mica tape 12 which is an insulating layer in the coil for rotary electric machines was calculated. As a result of the measurement, the difference in dielectric loss tangent was 0.11%.

(Comparative Example 1)
The coil for a rotating electrical machine used in Comparative Example 1 was manufactured as follows by a conventional hydraulic method using a large vacuum / pressurized tank. FIG. 7 is a view for explaining a conventional method for manufacturing a coil for a rotating electrical machine by a hydraulic method, in a state where a conductor bundle 11 to which a forming jig 14 is attached is disposed in a vacuum / pressure tank 70. 3 is a view showing a cross section of a vacuum / pressurized tank 70. FIG.

  As shown in FIG. 7, the vacuum / pressure tank 70 includes a receiving tank 71 for containing a heating medium therein, and the receiving tank 71 includes a heating medium introduction pipe for introducing the heating medium into the receiving tank 71. 72 and a heating medium discharge pipe 73 for discharging the heating medium from the receiving tank 71 are provided through the vacuum / pressure tank 70, respectively. Further, the vacuum / pressure tank 70 is provided with a evacuation pipe 74 for evacuating the inside of the vacuum / pressure tank 70 and a pressurization pipe 75 for pressurizing the inside of the vacuum / pressure tank 70. ing. Each pipe is provided with shut-off valves 72a, 73a, 74a, 75a for shutting off the communication with the receiving tank 71 or the vacuum / pressurized tank 70.

  In the first comparative example, 40 conductor bundles 11 having the forming jig 14 attached thereto were accommodated in the receiving tank 71 and sealed in the vacuum / pressurized tank 70.

  Subsequently, evacuation was performed via the evacuation pipe 74, and the inside of the vacuum / pressurized tank 70 was set to 0.133 kPa in absolute pressure.

  Subsequently, after closing the shutoff valve 74a of the evacuation pipe 74, the shutoff valve 72a of the heating medium introduction pipe 72 is opened, and a heating medium having a temperature of 160 ° C. made of polyethylene is placed in the vacuum receiving tank 71. Was introduced. After introducing the heating medium, nitrogen gas is supplied as a pressure medium from the pressure pipe 75, the inside of the vacuum / pressure tank 70 is pressurized to 500 kPa (G), and the thermosetting resin impregnated with the mica tape 12 is cured. It was.

  After performing the above-described thermosetting treatment for 20 hours, the pressure in the vacuum / pressure tank 70 was released to the atmosphere, the shutoff valve 73a of the heating medium discharge pipe 73 was opened, and the heating medium was discharged from the receiving tank 71. After the heating medium is discharged, the conductor bundle 11 to which the forming jig 14 is attached is taken out from the vacuum / pressure tank 70, and the heat shrink tape 15, the forming jig 14, the Teflon tape 13, and the attached heating medium are removed. Thus, a rotating electrical machine coil was obtained.

  The voltage characteristics of dielectric loss tangent were measured by the same method as in Example 1 using the rotating electrical machine coil produced in the above-described process. And the difference of the dielectric loss tangent showing the bubble and defect in the mica tape 12 which is an insulating layer in the coil for rotary electric machines was calculated. As a result of the measurement, the difference in dielectric loss tangent was 0.08%.

(Summary of Examples 1 to 3 and Comparative Example 1)
Table 1 shows the difference in dielectric loss tangent between Examples 1 to 3 and Comparative Example 1.

  As shown in Table 1, it was found that the difference in dielectric loss tangent in Examples 1 to 3 and Comparative Example 1 showed substantially the same value. Thereby, even when the coil for a rotating electrical machine is manufactured by the method for manufacturing a coil for a rotating electrical machine according to the present invention, the amount of heating medium used can be reduced and the manufacturing time can be shortened. It was found that the coil performance was equivalent to a coil for rotating electrical machines.

  In the implementation stage, the constituent elements can be modified and embodied without departing from the technical idea of the present invention. Furthermore, various modifications are possible, such as appropriately combining a plurality of components shown in the above embodiment, or deleting some components from all the components shown in the embodiment. Embodiments of the present invention can be expanded or modified within the scope of the technical idea of the present invention, and these expanded and modified embodiments are also included in the technical scope of the present invention.

It is a figure for demonstrating the manufacturing method of the coil for rotary electric machines of the 1st Embodiment of this invention, and is a figure which shows the cross section of the conductor bundle to which the jig for shaping | molding was attached. The figure which shows the cross section of the vacuum and a pressurization tank in the state in which the conductor bundle with which the jig for shaping | molding was attached has been arrange | positioned in a vacuum and a pressurization tank. The flowchart for demonstrating the manufacturing process of the coil for rotary electric machines of the 1st Embodiment of this invention. It is a figure for demonstrating the manufacturing method of the coil for rotary electric machines of the 2nd Embodiment of this invention, and the conductor bundle with which the jig for shaping | molding accommodated in the vacuum back | bag is attached is a vacuum and pressurization. The figure which shows the cross section of the vacuum and pressurization tank in the state arrange | positioned in a tank. The flowchart for demonstrating the manufacturing process of the coil for rotary electric machines of the 2nd Embodiment of this invention. The figure which shows the cross section of the vacuum bag when comprising the vacuum bag from the component divided | segmented into plurality. It is a figure for demonstrating the manufacturing method of the coil for rotary electric machines by the conventional hydraulic method, and the cross section of the vacuum * pressurization tank in the state where the conductor bundle with which the forming jig was attached was arrange | positioned in a vacuum / pressurization tank FIG.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Copper wire, 11 ... Conductor bundle, 12 ... Mica tape, 13 ... Teflon tape, 14 ... Molding jig, 15 ... Heat shrink tape, 20 ... Vacuum / pressurization tank, 20a, 22a, 23a, 24a, 25a ... Constituent part, 21 ... internal space, 22 ... evacuation piping, 23 ... heating medium introduction piping, 24 ... heating medium discharge piping, 25 ... pressurization piping.

Claims (10)

A winding step of winding a mica tape containing an uncured or semi-cured thermosetting resin around a conductor bundle composed of a plurality of coated wires;
A molding jig mounting step for mounting a molding jig for molding on the conductor bundle wound with the mica tape;
The conductor bundle to which the forming jig is attached is disposed in a vacuum / pressure tank having an internal space similar to the shape of the conductor bundle to which the forming jig is attached, and the inside of the vacuum / pressure tank is A vacuum processing step for creating a vacuum;
After the vacuum treatment step, a heating medium is press-fitted into the vacuum / pressurization tank, and a thermosetting treatment step for curing the thermosetting resin contained in the mica tape,
A heating medium discharging step of discharging the heating medium from the vacuum / pressurized tank after the thermosetting resin is cured. A winding step of winding a mica tape containing an uncured or semi-cured thermosetting resin around a conductor bundle composed of a plurality of coated wires;
A molding jig mounting step for mounting a molding jig for molding on the conductor bundle wound with the mica tape;
An accommodating step of accommodating the conductor bundle to which the forming jig is attached in a flexible bag-like vacuum bag;
The conductor bundle housed in the vacuum bag is placed in a vacuum / pressure tank having an internal space similar to the shape of the conductor bundle to which the forming jig is attached, and the vacuum bag is evacuated. Vacuum processing step to
After the vacuum treatment step, a heating medium is press-fitted into the vacuum / pressurization tank, and a thermosetting treatment step for curing the thermosetting resin contained in the mica tape,
A heating medium discharging step of discharging the heating medium from the vacuum / pressurized tank after the thermosetting resin is cured.   The said thermosetting process WHEREIN: The pressurization process which pressurizes the inside of the said vacuum and a pressurization tank after press-fitting a heating medium in the said vacuum and a pressurization tank was further comprised. A method of manufacturing a coil for a rotating electrical machine.   The method for manufacturing a coil for a rotating electrical machine according to any one of claims 1 to 3, wherein, in the thermosetting treatment step, the conductor bundle is heated by energizing the conductor bundle.   The vacuum / pressurized tank is made of a non-conductive non-magnetic material, and the conductor bundle is heated with a high frequency in the thermosetting process. A method of manufacturing a coil for a rotating electrical machine.   The method for manufacturing a coil for a rotating electrical machine according to any one of claims 1 to 5, wherein the vacuum / pressure tank is configured by fastening a plurality of divided components.   The method for manufacturing a coil for a rotating electrical machine according to claim 6, wherein an internal space formed by each of the divided components is partitioned for each component.   The method for manufacturing a coil for a rotating electrical machine according to any one of claims 1 to 7, wherein the heating medium is made of bitumen.   The method for manufacturing a coil for a rotating electrical machine according to any one of claims 1 to 7, wherein the heating medium is made of a material having volatility in an environment of normal temperature and atmospheric pressure.   A coil for rotating electrical machines manufactured by the method for manufacturing a coil for rotating electrical machines according to any one of claims 1 to 9.

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