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1、1.5MW直驱式风力发电机绝缘系统的研究李强军1 姜其斌1 陈红生2 邢国华1 薛长志2 (1株洲时代新材料科技股份有限公司，湖南 株洲，412007；2株洲南车电机股份有限公司，湖南 株洲，412001)摘要：分析了风力发电机的运行环境对绝缘系统及其材料的特殊要求，开展了1.5MW直驱式风力发电机绝缘系统及其材料的研究，研制了适合1.5MW直驱式风力发电机定子绝缘系统要求的聚酯亚胺无溶剂浸渍树脂。对不同浸渍树脂和电磁线组成的风力发电机绝缘系统进行了模拟线棒性能试验，探讨了绝缘系统的耐盐雾性、耐高低温湿热交替性能和介质损耗因数及击穿电压等性能。试验结果表明，由聚酯亚胺无溶剂浸渍树脂、聚酯薄膜粉
2、云母带与聚酰亚胺薄膜熔融绕包电磁线组成的风力发电机绝缘系统具有较低的介质损耗因数、良好的耐盐雾性和高低温绝缘性能，是目前风力发电机绝缘系统绝缘性能最优异的绝缘系统之一。关键词：风力发电机；绝缘系统；聚酯亚胺；浸渍树脂；聚酰亚胺薄膜Research of insulation system for direct-drive wind turbineLi Qiang-jun1,Jiang Qi-bin1,Chen Hong-sheng2 ,Xing Guo-hua1 ,Xue Chang-zhi2(1.Zhuzhou Times New Material Techonolgy CO.,LTD，Zh
3、uzhou 412007,China；2.Zhuzhou CSR Electric CO.,LTD，Zhuzhou，412007, China)Abstract: Special requirements of wind turbine running environment on insulation system and materials were analyzed and polyester-imide solvent impregnated resin suited for the insulation system of wind turbines were studied. Te
4、sts of performance simulation of bars were carried out on wind turbine insulation system composed of various impregnated resin and magnetic wires to examine the salt spray resistance,high/low temperature resistant moist heat alternating performance,dielectric dissipation factor and breakdown voltage
5、s,ect.of the system.It is shown that the wind turbine insulation system consisted of solvent-free polyesterimide impregnating resin,mica tape with polyester and molten polyimide lappde magnetic wire has lower dielectric dissipation factor,good salt spray resistance and high and low temperature insul
6、ation performance and is one of the best insulation systems with excellent insulation properties.Key words: wind turbines;insulation system;polyester-imide;impregnated resin；polyamide film1 前言风能的开发和利用在欧美发达国家发展非常迅速，风力发电的应用技术已日趋成熟。近年来，我国的风力发电事业也得到了快速发展。根据风力发电“十一五”发展规划以及风力发电远景规划，我国风力发电规划各阶段风电装机容量需求：200
7、52010年，每年平均装机容量需求达到60万千瓦；20102015年，每年平均装机容量需求达到120万千瓦；20152020年，每年平均装机容量需求达到200万千瓦 12 。目前我国风力发电场近80的风力发电机组为进口设备，存在价格贵、售后服务难保证的缺点。国家“十一五”规划中明确提出，新建风力发电场的设备国产化率必须达到70以上。其中作为风力发电装备的最关键部件，风力发电机的研制尤为关键，电机运行的可靠性和运行寿命主要取决于绝缘系统的设计及其材料的应用。由于风力发电机使用的特殊地理环境（戈壁、草原、海边等），风力发电机所用绝缘系统及其绝缘材料有着特殊要求，如防震、抗潮、耐盐雾及在低压、大电流
8、绝缘系统的机械强度和因机械性能下降引发的绝缘性能衰退以及特殊环境下运行绝缘系统的耐候性问题等 37 。本文针对这一系列情况进行分析总结，研究了聚酯亚胺高分子树脂在直驱式风力发电机上的应用，提出采用聚酰亚胺薄膜熔融粉云母带绕包电磁线浸渍聚酯亚胺高分子树脂的绝缘系统，并对这种绝缘系统进行了力学性能、耐盐雾性、耐高低温湿热交替性能和介质损耗因数及击穿电压等性能的研究，获得了良好的结果。这种绝缘系统能有效增强直驱式永磁风力发电机定子绝缘系统运行可靠性与运行寿命，对于今后风力发电机的发展具有重要意义。2 实验部份2.1模拟线棒绝缘系统组成材料电磁线：3.55mm10.00mm聚酰亚胺薄膜熔融聚酯薄膜粉云
9、母带绕包电磁线、3.55mm10.00mm聚酰亚胺薄膜熔融玻璃丝包电磁线、3.55mm10.00mm聚酯薄膜粉云母带绕包电磁线；浸渍漆：聚酯亚胺无溶剂浸渍树脂、聚酯无溶剂浸渍树脂和环氧改性聚酯无溶剂浸渍树脂；绕包材料：0.14mm20mm环氧少胶粉云母带。2.2模拟线棒的制作工艺流程在2根电磁线上手工半叠绕包2层少胶带平包1层聚酯热收缩带制作模拟线圈，在1055温度下预热2h，拿出冷却至605，入浸渍罐抽真空（1mbar以下）2h，输入浸渍树脂保持1h，之后通氮气加压至3个大气压保持1h，降压、滴漆后，模拟线棒绕包聚四氟乙烯薄膜和热收缩带，放入烘箱165固化2h，最后拆去热收缩带及聚四氟乙烯薄
10、膜，得到模拟线棒。2.3绝缘系统评定试验内容2.3.1绝缘系统盐雾性试验绝缘系统盐雾性试验按GB/T 2423.17-1993恒定湿热试验和GB/T 1771-2007耐中性盐雾性能测定标准进行。模拟线棒试样：3.55mm10mm聚酰亚胺薄膜熔融聚酯薄膜粉云母带绕包电磁线、3.55mm10mm聚酰亚胺薄膜熔融玻璃丝包电磁线、3.55mm10mm聚酯薄膜粉云母带绕包电磁线，同时浸渍聚酯亚胺无溶剂浸渍树脂，烘焙固化，分别记为A、B、C。试验条件为喷雾温度：1535，相对湿度：9095，盐溶液浓度：51，盐溶液PH值：7.01。试验时间周期，如图1所示：4个喷雾周期，每周期2h。每完成一次喷雾后再在
11、相对湿度90%95、温度40的环境中连续储存166h。图1 绝缘系统模型盐雾试验2.3.2模拟线棒绝缘系统交变湿热评定试验模拟线棒绝缘系统交变湿热评定试验按GB/T2423.41993交变湿热试验方法标准进行。模拟线棒试样：3.55mm10mm聚酰亚胺薄膜熔融聚酯薄膜粉云母带绕包电磁线分别浸渍聚酯亚胺无溶剂浸渍树脂、聚酯无溶剂浸渍树脂和环氧改性聚酯无溶剂浸渍树脂，烘焙固化，分别记为D、E、F。模拟线棒交变湿热评定试验时间周期如图2所示。升温阶段：在2h内升温到40，湿度95；高温高湿阶段：在40下保温12h，降温阶段：在3h降温到23，低温高湿阶段：在23下保温7h。每个周期测量一次绝缘电阻，
12、共测试9个周期。图2 绝缘系统模型交变湿热试验2.3.3风电线圈绝缘系统产品质量评定按照JB/T50122中型高压电机少胶整浸线圈产品质量分等标准评定。模拟线棒试样：3.55mm10mm聚酰亚胺薄膜熔融聚酯薄膜粉云母带绕包电磁线浸渍聚酯亚胺无溶剂浸渍树脂，共5个试样。绝缘系统评定试验内容按要求进行下述评定试验：模拟线棒绝缘整体性检查；模拟线棒tanUn曲线测量：在常态及155下，分别测量0.2Un、0.4Un、0.6Un、0.8Un、1.0Un下的tan及tan值；模拟线棒击穿电压：在155烘箱中进行，采用连续升压方式。3 结果与讨论3.1绝缘系统盐雾性试验模拟线棒4个盐雾试验周期后，检测模拟
13、线棒的外观、绝缘电阻、极化指数、常态介质损耗因数、热态155介质损耗因数、常态介质损耗因数增量、局部放电试验和工频击穿电压。试验结果如表1所示。试验结果表明，A模拟线棒的绝缘系统在盐雾试验前后绝缘电阻、介质损耗因数、介质损耗因数增量和极化指数比其他两种系统模拟线棒变化小，说明A绝缘系统耐盐雾性能优异。表1 模拟线棒盐雾性试验结果检测项目ABC盐雾试验前盐雾试验后盐雾试验前盐雾试验后盐雾试验前盐雾试验后绝缘电阻2.510121.010127.510114.010112.010111.51011极化指数（R10min/R1min3.086.002.673.003.253.67常态介质损耗tan（2
14、kV时）10-21.221.442.426.332.542.83热态155介质损耗tan（2kV时）10-27.468.4911.3714.1711.0314.05常态介质损耗增量tan最小值3.010-406.010-41.510-32.010-48.010-4最大值1.610-21.510-21.910-22.510-21.510-22.110-2局部放电试验2kV局放量（PC）9.9310.332.4841.2510.4220.173kV局放量（PC）3819.75069.894307.945907.1996.238884.0起始局放电压kV2.111.792.101.751.871.6
15、8工频击穿电压kV29.124.018.3外观经交变盐雾试验后，绝缘物无腐蚀物析出，漆膜无粉化、龟裂、脱落。注：常态介质损耗因数增量（tan），每0.5kV间距，从0.5kV至3kV3.2模拟线棒的高低温交替高湿试验模拟线棒在采用对每个周期进行绝缘电阻检测，检测结果见表2。表2 模拟线棒的高低温交替高湿性能试验样品编号交变湿热试验前检验结果第1个周期第2个周期第3个周期第4个周期D-15.510115.210102.710101.6510101.651010D-23.810112.510101.710101.110101.061010E-13.810111.510101.010107.1810
16、93.7109E-23.810114.010101.310108.01093.0109F-14.410112.010101.6510105.01091.2109F-25.810115.010101.0210106.31091.24109样品编号第5个周期第6个周期第7个周期第8个周期第9个周期D-11.1810109.51098.51097.81097.8109D-28.21098.01097.01096.01096.0109E-18.61083.61087.61081.61079.8106E-29.61082.51087.11081.51071.0107F-19.81083.51088.51
17、077.81075.5107F-29.51083.31087.31076.91075.3107试验结果表明，模拟线棒经受9个周期的高低温交替高湿条件考验，聚酯树脂浸渍体系和环氧改性聚酯树脂浸渍体系绝缘系统的绝缘电阻从试验前的1011下降到107，而聚酯亚胺树脂浸渍体系绝缘系统的绝缘电阻从试验前的1011下降到109，绝缘体系绝缘电阻达到优等结构的要求。3.3模拟线棒绝缘系统的性能测试模拟线棒浸渍聚酯亚胺无溶剂浸渍树脂后，测量模拟线棒树脂在所包绝缘材料中含量，检验树脂对模拟线棒绝缘系统的渗透性。此模拟线棒绝缘系统中树脂含量为25%，说明浸渍树脂能有效地浸渍云母带，并且浸渍树脂具有低温快固化特性，
18、在烘焙过程中保证了浸渍树脂流失较少，从而保证了模拟线棒绝缘系统良好的整体性能。模拟线棒tanUn曲线：Un=2kV，tan=（tan0.6Untan0.2Un）/2，得到模拟线棒的tan、tan试验结果见表3。表3 模拟线棒的tan及tan测量项目测试条件最大值（10-2）平均值（10-2）优等品指标（10-2）tan230.2Un1.3281.1901.51.0Un1.4741.3241550.2Un6.7336.3560.6Un6.8736.4998tan230.0440.0380.251550.0760.071对模拟线棒进行击穿电压试验，试验结果见表4：表4 模拟线棒击穿电压模拟线棒号击
19、穿电压kV击穿电压（平均值）kV124.024.4228.5322.2425.5522.0由表3、表4可知，模拟线棒23下0.2Un、1550.6Un的tan及23tan均达到JB/T50133中优等品水平，模拟线棒击穿电压的平均值为24.4kV，达到JB/T50133中优等品水平，模拟线棒绝缘系统体系较好。表明通过减少弱键、降低分子自由度，从而获得介质损耗变化低的绝缘系统是可行的。4 结论采用含亚胺基中间体封端不饱和聚酯树脂，通过增加分子间作用力、减少弱键、降低分子自由度和增加分子降解活化能，降低了浸渍树脂的介质损耗因数，大大提高了发电机绝缘系统的耐湿热性、耐盐雾性能和电性能。通过模拟线棒试
20、验探讨了采用聚酰亚胺薄膜熔融聚酯薄膜粉云母带绕包电磁线浸渍聚酯亚胺无溶剂浸渍树脂，适合于直驱式永磁风力发电机的绝缘系统。参考文献：1 陆燕荪.发电和输变电设备制造业“十一五”发展重点及2020年展望.发电设备J.2003（5）：372 顾其荣.大风歌唱响.风光无限.电线电缆行业通讯J.2008，（7）：9223 张东林，石霄峰，孙雅玲，等.哈电H级电机新型绝缘技术, 第八届绝缘材料与绝缘技术学术会议论文集C, 昆明.2002（10）：268271.4 付岚贵. 大型发电机绝缘技术分析论证.绝缘材料通讯J.1999（2）：34355 蒲顺兴.最近国内外大电机定子线圈绝缘的发展.绝缘材料通讯J.1
21、996（6）：676 陈宗旻.真空压力浸渍用少胶粉云母带的分析对比.绝缘材料J.2001（4）：28297 尹默，白双建，周英霞，等.新型高压绝缘子在高压电机中的应用。绝缘材料通讯J.1999（5）：20258 李强军,姜其斌.H级不饱和聚酯亚胺无溶剂浸渍漆的研究,绝缘材料J,2005(3):11149 FengLiu,Zhen Wang,Huili Yang,et al. Synthesis of Novel Maleimide-Terminated Thioetherimide Oligomer and Its Bulk Copolymerizayion with Reactive Sol
22、vents PolymerJ.Polymer,2006,47(3):937945.作者简介：李强军（1977- ），湖南人，工程师，主要从事高电压绝缘材料及结构的设计与应用研究工作（TEL: 0733-7626986,E-MAIL: ）。Editors note: Judson Jones is a meteorologist, journalist and photographer. He has freelanced with CNN for four years, covering severe weather from tornadoes to typhoons. Follow him
23、 on Twitter: jnjonesjr (CNN) - I will always wonder what it was like to huddle around a shortwave radio and through the crackling static from space hear the faint beeps of the worlds first satellite - Sputnik. I also missed watching Neil Armstrong step foot on the moon and the first space shuttle ta
24、ke off for the stars. Those events were way before my time.As a kid, I was fascinated with what goes on in the sky, and when NASA pulled the plug on the shuttle program I was heartbroken. Yet the privatized space race has renewed my childhood dreams to reach for the stars.As a meteorologist, Ive sti
25、ll seen many important weather and space events, but right now, if you were sitting next to me, youd hear my foot tapping rapidly under my desk. Im anxious for the next one: a space capsule hanging from a crane in the New Mexico desert.Its like the set for a George Lucas movie floating to the edge o
26、f space.You and I will have the chance to watch a man take a leap into an unimaginable free fall from the edge of space - live.The (lack of) air up there Watch man jump from 96,000 feet Tuesday, I sat at work glued to the live stream of the Red Bull Stratos Mission. I watched the balloons positioned
27、 at different altitudes in the sky to test the winds, knowing that if they would just line up in a vertical straight line we would be go for launch.I feel this mission was created for me because I am also a journalist and a photographer, but above all I live for taking a leap of faith - the feeling
28、of pushing the envelope into uncharted territory.The guy who is going to do this, Felix Baumgartner, must have that same feeling, at a level I will never reach. However, it did not stop me from feeling his pain when a gust of swirling wind kicked up and twisted the partially filled balloon that woul
29、d take him to the upper end of our atmosphere. As soon as the 40-acre balloon, with skin no thicker than a dry cleaning bag, scraped the ground I knew it was over.How claustrophobia almost grounded supersonic skydiverWith each twist, you could see the wrinkles of disappointment on the face of the cu
30、rrent record holder and capcom (capsule communications), Col. Joe Kittinger. He hung his head low in mission control as he told Baumgartner the disappointing news: Mission aborted.The supersonic descent could happen as early as Sunday.The weather plays an important role in this mission. Starting at
31、the ground, conditions have to be very calm - winds less than 2 mph, with no precipitation or humidity and limited cloud cover. The balloon, with capsule attached, will move through the lower level of the atmosphere (the troposphere) where our day-to-day weather lives. It will climb higher than the
32、tip of Mount Everest (5.5 miles/8.85 kilometers), drifting even higher than the cruising altitude of commercial airliners (5.6 miles/9.17 kilometers) and into the stratosphere. As he crosses the boundary layer (called the tropopause), he can expect a lot of turbulence.The balloon will slowly drift t
33、o the edge of space at 120,000 feet (22.7 miles/36.53 kilometers). Here, Fearless Felix will unclip. He will roll back the door.Then, I would assume, he will slowly step out onto something resembling an Olympic diving platform.Below, the Earth becomes the concrete bottom of a swimming pool that he w
34、ants to land on, but not too hard. Still, hell be traveling fast, so despite the distance, it will not be like diving into the deep end of a pool. It will be like he is diving into the shallow end.Skydiver preps for the big jumpWhen he jumps, he is expected to reach the speed of sound - 690 mph (1,1
35、10 kph) - in less than 40 seconds. Like hitting the top of the water, he will begin to slow as he approaches the more dense air closer to Earth. But this will not be enough to stop him completely.If he goes too fast or spins out of control, he has a stabilization parachute that can be deployed to sl
36、ow him down. His team hopes its not needed. Instead, he plans to deploy his 270-square-foot (25-square-meter) main chute at an altitude of around 5,000 feet (1,524 meters).In order to deploy this chute successfully, he will have to slow to 172 mph (277 kph). He will have a reserve parachute that wil
37、l open automatically if he loses consciousness at mach speeds.Even if everything goes as planned, it wont. Baumgartner still will free fall at a speed that would cause you and me to pass out, and no parachute is guaranteed to work higher than 25,000 feet (7,620 meters).It might not be the moon, but Kittinger free fell from 102,800 feet in 1960 - at the dawn of an infamous space race that captured the hearts of many. Baumgartner will attempt to break that record, a feat that boggles the mind. This is one of those monumental moments I will always remember, because there is no way Id miss this.