High-efficiency flat wire generator rectifier structure and assembling method thereof

[0049] Such as Figure 4 , Figure 5 , Image 6 , Figure 7 , Figure 8 with Picture 9 Shown: The present invention includes a conductive negative plate 5, an intermediate support insulating support 7, a conductive positive plate 2, a bus bridge support 3, a positive output screw 1, a rectifier diode 4, a tubular rivet 16, a generator rear fixed cover 9, and a generator rear The fixed cover supports the boss 12 and the plastic protective cover 10. The rectifier diode 4 converts alternating current into direct current. The conductive negative plate 5 and the conductive positive plate 2 play the role of fixing the rectifier diode, conducting and dissipating heat. The bus bridge bracket 3 is connected to the stator line to converge, and the positive output screw 1 outputs current to the outside, and the generator back cover The supporting boss 12 supports and fixes the rectifier, and the plastic protective cover 10 protects the rectifier and adjusts the air duct of the generator. The intermediate supporting insulating support 7 replaces the insulating bushing 6, and is installed between the conductive positive plate 2 and the conductive negative plate 5. An open plastic protective tube 15 and an open plastic protective tube 15 are provided at the stator wire interface of the intermediate supporting insulating support 7 It is stepped and has a larger upper opening. The conductive negative plate 5 is installed under the rectifier, and is connected and fixed to the supporting boss 12 of the rear fixed cover of the generator. The lower edge of the plastic protective cover 10 is flush with the upper edge of the conductive negative plate 5, and an inner side is provided on the plastic protective cover 10. The axial air duct 13 and the outer axial air duct 14, when the generator is working, the conductive positive plate 2 enters and dissipates the air through the inner axial air duct 13 and the outer axial air duct 14 of the positive plastic protective cover 10, and the conductive negative electrode The front and inner sides of the plate 5 dissipate heat by the wind flow of the conductive positive plate 2, and the back 24 of the conductive negative plate 5 forms a radial V-shaped air duct 26 through the conductive negative plate 5 and the surface of the generator rear fixed cover 9 to dissipate heat; The inner air channel I 23 of the plate, the inner air channel II 27 of the conductive negative plate 5 and the inner axial air channel 13 of the plastic protective cover 10 correspond. The conductive positive plate 2 is provided with an outer air duct 28, on the inner side of the conductive positive plate 2, there are web heat dissipation teeth 20, and a heat dissipation rib is provided on the web heat dissipation teeth 20, and a B+ screw hole is die-cast on the conductive positive plate 2. 30 and six rectifier diode mounting holes I29. Two rectifier diodes 4 are arranged on the outside of the conductive positive plate 2, and four rectifier diodes 4 are arranged inside the conductive positive plate 2. The four rectifier diodes 4 inside are close to the heat dissipation teeth 20 of the web, on the conductive positive plate 2. There are two B+ output ports on the inside.

[0050] The conductive negative plate 5 and the rear fixed cover 9 of the generator are not attached to heat dissipation, and heat dissipation teeth 25 are provided on the back. The conductive negative plate 5 is die-casted with six external and internal three diode mounting holes Ⅱ31; on the conductive negative plate 5, there are three rectifier diodes 4 on the outside and three rectifier diodes 4 on the inside. The spacing is relatively uniform, and there is heat dissipation around it. Tooth 25.

[0051] The busbar bracket 3 is injection molded together with the busbar 18 and the M5 nut to form the stator wire connection thread 19. The busbar welding piece 22 is bent on the busbar 18, and the busbar 18 and the rectifier diode lead of the busbar bracket 3 are single Surface spot welding connection. The bus bridge bracket 3 is installed above the conductive positive plate 2 and is horizontally connected and fixed with the connecting thread 19 of the generator stator wire.

[0052] The radial V-shaped air duct 11 enters the air to cool the back of the conductive negative plate 5 and the rear fixed cover 9 of the generator, and the inner axial air duct 13 of the protective cover enters the air to cool the conductive positive plate 2 and the inner side of the conductive negative plate 5. positive.

[0053] The inner axial air channel 13 of the plastic protective cover 10 is the same as the inner air channel I23 of the conductive positive plate 5 and the inner air channel II27 of the conductive negative plate 5, and there are other air channels on the outside.

[0054] The inner side of the plastic protective cover 10 is fixed by two B+ output points, and the outer side is fixed by forming a plastic buckle with the outer edge of the mounting hole of the junction bridge bracket to ensure that the air duct will not deviate during product assembly.

[0055] A method for assembling a high-efficiency flat wire generator rectifier: It is realized through the following steps:

[0056] (1) First develop a die-cast conductive positive plate 2. When the mold is formed, die-cast inner web heat dissipation teeth 20 to form an inner air duct 23 of the positive plate; an outer air duct 28 of the conductive positive plate on the outside, and die-cast outer two and inner Four, a total of six diode holes 29, and then die-cast conductive positive plate B+ screw hole 30; at the same time, there are six mounting holes die-casting, the diode hole I 29 and B+ screw hole 30 after die-casting need to be machined to ensure the size.

[0057] (2) Develop a die-cast conductive negative plate 5. When the mold is formed, the back 24 of the conductive negative plate has conductive negative plate heat dissipation teeth 25 to form a radial V-shaped air duct 26, and the inner side has a conductive negative plate inner air duct 27; At the same time, there are six diode holes Ⅱ31 for die-casting outside and inside three, and there are six mounting holes for die-casting at the same time;

[0058] (3) Secondly, develop an injection-molded intermediate support insulating support 7, which is formed with an open plastic protective tube 15 during mold forming, which has a stepped shape;

[0059] (4) Then develop a stamped and formed bus bar 18, on which a bus bar welding piece 22 is bent, and before the welding piece is bent into shape, an extruded bus bar welding point rib 21 is used;

[0060] (5) To develop an injection-molded bus bar bracket 3, use the bus bar 18 and M5 nuts to inject together to form the stator wire connecting thread 19, and simultaneously mold the bracket end plastic protective cover buckle 17, and six mounting holes;

[0061] (6) Then develop an injection-molded plastic protective cover 10, which is formed with an axial air duct 13 inside the protective cover and an axial air duct 14 outside the protective cover during molding. At the same time, two conductive sheets are injected and matched with the rectifier B+ screw. Two inverted buckles are formed to fit the plastic protective cover buckles 17 at the bracket end;

[0062] (7) Using the developed conductive positive plate 2 and press-fitting fixtures, press-fit six positive plate rectifier diodes 4 and two positive output screws 1 to the conductive positive plate 2 to form a positive plate assembly;

[0063] (8) Using the developed conductive negative plate 5 and press-fitting fixtures, press-fit 6 conductive negative plate rectifier diodes 4 on the conductive negative plate 5 to form a negative plate assembly;

[0064] (9) Assemble the positive plate assembly, the negative plate assembly, the intermediate insulating support 17 and the bus bar support 3 together. Three of the mounting holes are riveted into one body with three tubular rivets 16, and then the rectifier diode 4 leads are welded with a resistance welding machine On the bus bar welding tab 22 of the bus bridge bracket 3, the rectifier diode lead and the bus bar solder joint rib 21 form a welding point to form a current loop and form a rectifier;

[0065] (10) Assemble the rectifier of the present invention to the supporting boss 12 of the generator back cover, so that the conductive negative plate 5 and the generator fixed back cover 9 form a radial V-shaped air duct 11, and use 6 fixing screws to lock the rectifier on Install the regulator on the rear cover of the generator, and then assemble the developed plastic protective cover 10 on the rectifier. The two points are assembled with the B+ screw, and the outer two buckles are formed by the bracket end plastic protective cover buckles 17 Fixed undercut. The lower surface of the rectifier side of the plastic protective cover 10 is flush with the upper surface of the conductive negative plate 5 to ensure the smooth flow of the radial V-shaped air duct 11; the inner axial air duct 13 of the positive protective cover, the inner air duct I 23 and the conductive positive plate 2 The inner air duct 27II of the conductive negative plate is corresponding to ensure the smooth flow of the inner air duct and the cooling of the inner side of the conductive positive plate 2 and the conductive negative plate 5 and the cooling of the generator.