CN114301205A - Novel composite material conductor coil for motor - Google Patents

Abstract

The invention provides a novel composite material conductor coil for a motor, which is composed of a lead head, a copper-aluminum composite material conductor, and coil insulation. The copper-aluminum composite material conductor is sequentially provided with a copper ring layer, a copper-aluminum diffusion layer, and an aluminum core layer from the outside to the inside; the thickness of the copper-aluminum diffusion layer is 0.5-30 microns. Beneficial effects of the present invention: on the premise of ensuring the same current carrying capacity, the coil described in the present invention is lower in cost and lighter in weight than copper coils. Using the coil described in the invention can reduce the cost and weight of the motor.

Description

A new type of composite material conductor coil for motor

technical field

The invention relates to a new type of composite material conductor coil for electric motors, more particularly, to a copper-aluminum composite material conductor coil for electric motors.

Background technique

At present, the coil conductors used in most motors are pure copper; the cost of pure copper is high and the weight is heavy; resulting in high production costs, and at the same time, when the ends of the coils are connected during the preparation process, the welding operation is not mature, and the coil ends The connection failure rate of the part increases.

SUMMARY OF THE INVENTION

In order to solve the above problems, the present invention discloses a new type of composite material conductor coil for motor, which can not only reduce the cost of the motor, but also reduce the weight of the motor; under the same current carrying capacity, the copper-aluminum composite material conductor is stronger than the pure copper conductor. The price is reduced by 30% and the weight is reduced by 50%.

The technical scheme adopted by the present invention to solve the technical problem is: a new type of composite material conductor coil for motor, which is composed of a lead head, a copper-aluminum composite material conductor, and coil insulation.

The copper-aluminum composite material conductor is sequentially provided with a copper ring layer, a copper-aluminum diffusion layer, and an aluminum core layer from the outside to the inside; the thickness of the copper-aluminum diffusion layer is 0.5-30 microns.

The lead joint is made of pure copper or pure aluminum, and the lead joint and the copper-aluminum composite conductor are metallurgically bonded.

The lead joint is pure copper or pure aluminum in order to facilitate the welding between the coils. Since the welding of copper-aluminum composite conductors is difficult to operate and not hard welding, the addition of pure copper or pure aluminum to the lead joint in the present invention is for convenience. For the welding between coils, due to the difficulty of welding copper-aluminum composite conductors, a suitable welding process has not yet been found (mainly due to the lack of suitable solder), and it is impossible to make welding joints with the same strength as the base metal. Therefore, in the present invention Add lead headers to facilitate soldering between coils.

The aluminum material in the copper-aluminum composite conductor is pure aluminum or aluminum alloy, which can be adjusted according to the requirements of electrical conductivity and strength. The copper material in the copper-aluminum composite conductor is pure copper.

The aluminum core layer in the copper-aluminum composite conductor is pure aluminum or aluminum alloy, and the copper ring layer is pure copper.

The thickness of the copper layer in the copper-aluminum composite conductor can be adjusted according to the operating frequency of different motors. The thickness of the copper layer used in the high-frequency motor is small, and the thickness of the copper layer used in the low-frequency motor is large. The thickness of the copper layer is generally in the range of 0.2-2mm.

A preparation method of a novel composite material conductor coil for a motor, comprising the following steps:

Step 1: The copper-aluminum composite conductor is formed by continuous casting and tying; during continuous casting, the copper ring layer crystallizes first, and the inner aluminum core layer crystallizes later; during continuous casting, the temperature and time of continuous casting are controlled, and the copper-aluminum diffusion layer ( 2-2) The thickness is 0.1-2mm;

Step 2: The outer surface of the copper-aluminum composite conductor is covered with coil insulation; the insulation is divided into inter-turn insulation and outer insulation; the inter-turn insulation is wrapped by sintering or directly wrapped to the surface of the copper-aluminum composite conductor; outer insulation wrapping Outside the copper-aluminum composite conductor with inter-turn insulation;

Step 3: The head and tail of the copper-aluminum composite material conductor in each coil are connected to the upper lead joint; the lead joint is connected to the copper-aluminum composite material conductor by the method of continuous casting.

The copper-aluminum composite conductor in the step 1 is subjected to heat treatment after continuous casting and continuous tying, and the heat treatment temperature is 380-420°C.

The above temperature range is to reduce the hardness of the copper-aluminum composite material conductor, which is convenient for the flat wire to make the coil.

Beneficial effects of the present invention: on the premise of ensuring the same current carrying capacity, the coil described in the present invention is lower in cost and lighter in weight than copper coils. The use of the coil described in the invention can reduce the cost and weight of the motor.

Description of drawings

Fig. 1, the structural representation of the present invention;

Figure 2, the sectional view of the AA direction in Figure 1;

Figure 3, the cross-sectional view of the BB direction in Figure 1;

List of reference numbers:

Among them, 1-lead joint, 2-copper-aluminum composite material conductor, 3-coil insulation, 2-1-copper ring layer, 2-2-copper-aluminum diffusion layer, 2-3-aluminum core layer.

Detailed ways

The present invention will be further clarified below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and not to limit the scope of the present invention. It should be noted that the words "front", "rear", "left", "right", "upper" and "lower" used in the following description refer to the directions in the drawings, and the words "inner" and "outer" ” refer to directions towards or away from the geometric center of a particular part, respectively.

As shown in FIG. 1 , a new type of composite material conductor coil for a motor in this embodiment is composed of a lead head 1 , a copper-aluminum composite material conductor 2 and a coil insulation 3 .

As shown in FIG. 2 , the copper-aluminum composite material conductor 2 is sequentially provided with a copper ring layer 2-1, a copper-aluminum diffusion layer 2-2, an aluminum core layer 2-3, and a copper-aluminum diffusion layer 2-2 from the outside to the inside. The thickness of the copper-aluminum composite conductor 2 is 0.5-30 microns; the aluminum core layer 2-3 in the copper-aluminum composite conductor 2 is pure aluminum or aluminum alloy, and the copper ring layer 2-1 is pure copper; The thickness is 0.2-2mm.

The density of the copper-aluminum composite conductor 2 is 4.25g/cm3, and the resistivity is 0.0237Ωmm2/m; the density of pure copper is 8.9g/cm3, and the resistivity is 0.0185Ωmm2/m; when the current-carrying requirements are guaranteed, when the cut-off of pure copper is When the area is 5x15mm, copper-aluminum composite conductors with an equal length of 6x16mm cross-section can be used instead.

As shown in FIG. 3 , the lead joint 1 is made of pure copper or pure aluminum, and the lead joint 1 and the copper-aluminum composite conductor 2 are metallurgically bonded.

A preparation method of a novel composite material conductor coil for a motor, comprising the following steps:

Step 1: The copper-aluminum composite conductor 2 is formed by continuous casting and tying; during continuous casting, the copper ring layer 2-1 crystallizes first, and the inner aluminum core layer 2-3 crystallizes later; during continuous casting, the temperature and temperature of continuous casting are controlled. time, the thickness of the copper-aluminum diffusion layer 2-2 is 0.1-2mm;

Step 2: The outer surface of the copper-aluminum composite conductor 2 is covered with coil insulation 3; the insulation is divided into inter-turn insulation and outsourcing insulation; the inter-turn insulation is wrapped by sintering or directly wrapped to the surface of the copper-aluminum composite conductor 2; The insulation is wrapped around the copper-aluminum composite conductor 2 with inter-turn insulation;

Step 3: The head and tail of the copper-aluminum composite material conductor 2 in each coil are connected to the lead joint 1; the lead joint 1 is connected to the copper-aluminum composite material conductor 2 by a method of continuous casting.

The key component in the copper-aluminum composite conductor coil of this embodiment is the copper-aluminum composite conductor. The copper-aluminum composite conductor is formed by continuous casting and tying. The head and tail of the copper-aluminum composite conductor bar in each coil need to be connected to the lead joint, and the lead joint is pure copper or pure aluminum. The lead joint is pure copper or pure aluminum, which is convenient for welding between coils.

In this embodiment, the weight of 1m-long 5x15mm pure copper is 0.67kg, and the 1m-long 6x16mm copper-aluminum composite conductor weighs 0.41kg.

Copper is about 70 yuan/kg, and copper-aluminum composite conductors are about 72 yuan/kg.

The cost of 1m long 5x15mm pure copper is 46.9 yuan, and the cost of 1m long 6x16mm copper-aluminum composite conductor is 29.52 yuan. The weight of copper-aluminum composite conductors is reduced by 43.3%. The cost of copper-aluminum composite conductors is reduced by 41.7%.

The thickness of the copper layer of the copper-aluminum composite material conductor and the material of the inner aluminum can be adjusted according to the operating frequency of the motor, the strength of the wire, and the electrical conductivity requirements to obtain a cost-effective coil conductor.

The technical means disclosed in the solution of the present invention are not limited to the technical means disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features.

Claims (7)

1. A novel composite material conductor coil for a motor, characterized in that: it is composed of a lead head (1), a copper-aluminum composite material conductor (2) and a coil insulation (3). 2. A new type of composite material conductor coil for electric motor according to claim 1, characterized in that: the copper-aluminum composite material conductor (2) is sequentially provided with a copper ring layer (2-1), a copper ring layer (2-1), The aluminum diffusion layer (2-2), the aluminum core layer (2-3); the thickness of the copper-aluminum diffusion layer (2-2) is 0.5-30 microns. 3. A new type of composite material conductor coil for electric motors according to claim 1, characterized in that: the lead joint (1) is made of pure copper or pure aluminum, and the lead joint (1) and the copper-aluminum composite material conductor are made of pure copper or pure aluminum. (2) Metallurgical bonding between them. 4. A new type of composite material conductor coil for a motor according to claim 2, characterized in that: the aluminum core layer (2-3) in the copper-aluminum composite material conductor (2) is pure aluminum or aluminum alloy, The copper ring layer (2-1) is pure copper. 5. A new type of composite material conductor coil for motor according to claim 2, characterized in that: the thickness of the copper coil layer (2-1) is 0.2-2 mm. 6. The preparation method of a novel composite material conductor coil for a motor according to claim 1, characterized in that: comprising the following steps: Step 1: The copper-aluminum composite conductor (2) is formed by continuous casting and tying; during continuous casting, the copper ring layer (2-1) crystallizes first, and the inner aluminum core layer (2-3) crystallizes later; during continuous casting Control the temperature and time of continuous casting, and the thickness of the copper-aluminum diffusion layer (2-2) is 0.1-2mm; Step 2: The outer surface of the copper-aluminum composite conductor (2) is covered with coil insulation (3); the insulation is divided into inter-turn insulation and outsourcing insulation; the inter-turn insulation is wrapped by sintering or directly wrapped to the copper-aluminum composite conductor ( 2) surface; the outer insulation is wrapped around the copper-aluminum composite conductor (2) with inter-turn insulation; Step 3: The head and tail of the copper-aluminum composite material conductor (2) in each coil are connected to the lead joint (1); the lead joint (1) is connected to the copper-aluminum composite material conductor (2) by continuous casting. 7 . The method for preparing a new type of composite material conductor coil for electric motors according to claim 6 , wherein the copper-aluminum composite material conductor ( 2 ) in the step 1 is carried out after continuous casting and tying. 8 . Heat treatment, the heat treatment temperature is 380-420 ℃.

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