A tool for potting epoxy resin for range extender

Abstract

The present invention discloses a range extender encapsulation epoxy resin tooling, which belongs to the technical field of range extender generators, and includes a lower base plate and an upper base plate, wherein the surface of the lower base plate is uniformly provided with first threaded holes in sequence, a groove is provided on one side of the upper base plate, a center hole is provided in the central area of ​​the groove, four side holes are provided on the peripheral surface of the center hole, and second threaded holes are uniformly provided on the surface of the upper base plate around the groove in sequence, the lower base plate and the upper base plate are screwed and fixed with the first threaded hole and the second threaded hole in sequence by screws, a filling port is provided on the surface of the tooling in the middle hole, and a flow guide channel is provided at the filling port. The principle of the present invention is simple and easy to implement, and epoxy resin can be poured upward from the bottom of the stator coil, and the air in the coil can be effectively discharged during the pouring process, reducing the risk of pores appearing inside after the encapsulation is completed.

Description

Technical Field

[0001] The invention relates to the technical field of range extender generators, and in particular to an epoxy resin potting tooling for a range extender. Background Art

[0002] With the development of new energy vehicles, various new energy vehicle solutions have also emerged, including pure electric, hybrid and range extender solutions. Among them, the range extender solution is to add a generator on the basis of the original engine to form a range extender system. At this time, the engine does not directly output power, but transmits energy to the main drive motor and battery pack through the generator. This can improve the efficiency of the range extender and reduce fuel consumption. Because the generator and the engine are close to each other, this structure has higher environmental problems for the generator, so the thermal management requirements for the generator are higher. For the motor stator, adding an impregnant between the wire packages is a process to increase the thermal conductivity of the wire package. Most motors use the process of dipping paint, and the thermal conductivity of the insulating paint is generally around 0.2. In the working environment of the range extender, it cannot solve the problem of stator heat dissipation very well. Therefore, in order to reduce the temperature rise of the wire package, an impregnation material epoxy resin with a thermal conductivity much higher than that of the insulating paint is usually used, and the thermal conductivity can reach about 1.2. Thereby reducing the thermal failure of the motor and increasing the life.

[0003] The current potting method used is to pour epoxy resin from top to bottom. The epoxy resin penetrates into the wire package from top to bottom. This method is difficult to control the bubbles and filling saturation in the wire package. During the potting process, it may cause uneven effect on the stator of the range extender generator and the filling saturation cannot be guaranteed. Summary of the invention

[0004] The purpose of the present invention is to provide a tooling for range extender encapsulation epoxy resin, which has a simple principle and is easy to implement. It can enable epoxy resin to be poured upward from the bottom of the stator winding package. During the encapsulation process, the air in the winding package can be effectively discharged, reducing the risk of air holes appearing inside after encapsulation.

[0005] The present invention provides the following technical solution: an epoxy resin tooling for encapsulating a range extender, comprising a lower base plate, an upper base plate and a middle hole tooling, wherein the surface of the lower base plate is uniformly provided with first threaded holes in sequence, a groove is provided on one side of the upper base plate, a center hole is provided in the central area of ​​the groove, four side holes are respectively provided on the surface of the groove around the center hole, second threaded holes are uniformly provided on the surface of the upper base plate around the groove, the lower base plate and the upper base plate are screwed and fixed with the first threaded hole and the second threaded hole in sequence by screws, a filling port is provided on the surface of the middle hole tooling, and a guide channel is provided at the filling port, the middle hole tooling is bonded to the surface of the upper base plate, and the guide channel is connected to the center hole set on the upper base plate.

[0006] Preferably, the number of the first threaded holes and the second threaded holes opened on the lower base plate and the upper base plate is the same and is at least four.

[0007] Preferably, the diameter of the guide channel is at least 2 cm, and the diameter of the central hole is at least 3 cm.

[0008] Preferably, a limiting block is bonded to the inner wall of the groove, and the height of the limiting block is the same as the depth of the groove and is at least 1 cm.

[0009] Preferably, the tooling in the middle hole is an integrated structure made of nylon material.

[0010] Preferably, the top peripheral portion of the upper base plate is an inclined surface, and the surface of the upper base plate below the inclined surface is provided with anti-slip grooves.

[0011] Technical effects and advantages of the present invention:

[0012] 1. The principle of the present invention is simple and easy to implement. The middle hole tooling, the upper base plate and the lower base plate form a complete potting tooling. During the potting process, the epoxy resin can flow out through the four side holes of the upper base plate after passing through the guide channel. In this way, the epoxy resin is poured from the bottom net of the stator coil. During the potting process, the air in the coil can be effectively discharged, reducing the risk of pores inside after potting, and effectively improving the filling saturation.

[0013] 2. The tooling in the middle hole is made of nylon material, which has good mechanical strength and outstanding fatigue resistance. When plugged into the open end of the stator, the tooling in the middle hole can be expanded by preheating and finally fit tightly with the inner wall of the stator, thereby completing the fixation, preventing the epoxy resin material from leaking out, and facilitating removal. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a structural schematic diagram of the present invention;

[0015] Figure 2 It is a schematic diagram of the upper base plate structure of the present invention;

[0016] Figure 3 It is a schematic diagram of the lower base structure of the present invention;

[0017] Figure 4 It is a schematic diagram of the structure of the screw connection part of the upper base plate and the lower base plate of the present invention;

[0018] Figure 5 It is a schematic diagram of the connection relationship between the present invention and the stator.

[0019] Explanation of reference numerals: 1, lower base plate; 101, first threaded hole; 2, upper base plate; 21, center hole; 22, side hole; 23, stopper; 24, second threaded hole; 25, anti-slip pattern; 26, groove; 27, inclined surface; 3, tooling in the middle hole; 31, flow guide channel; 32, filling port. 4, screw; 5, stator; 6, housing. DETAILED DESCRIPTION

[0020] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0021] The present invention provides Figure 1-5 The epoxy resin tooling for encapsulating a range extender shown in the figure comprises a lower base plate 1, an upper base plate 2 and a middle hole tooling 3. The surface of the lower base plate 1 is uniformly provided with first threaded holes 101 in sequence, a groove 26 is provided on one side of the upper base plate 2, a center hole 21 is provided in the central area of ​​the groove 26, four side holes 22 are respectively provided on the surface of the groove 26 around the center hole 21, a limiting block 23 is bonded to the inner wall of the groove 26, and the height of the limiting block 23 is the same as the depth of the groove 26 and is at least 1 cm. The limiting block 23 can form a flow limiting track, so that the epoxy resin can flow directly from the center hole 21 to the four side holes 22, so as to perform the encapsulation work more efficiently.

[0022] The surface of the upper base plate 2 around the groove 26 is uniformly provided with second threaded holes 24, and the lower base plate 1 and the upper base plate 2 are screwed and fixed with the first threaded holes 101 and the second threaded holes 24 in sequence by screws 4, wherein the number of the first threaded holes 101 and the second threaded holes 24 opened on the lower base plate 1 and the upper base plate 2 is the same and at least four, which can cooperate with the screws 4 to make the lower base plate 1 and the upper base plate 2 fit tightly to avoid gaps.

[0023] In order to facilitate the staff to match the tooling with the motor stator, the top peripheral part of the upper base plate 2 is an inclined surface 27, and the surface of the upper base plate 2 below the inclined surface 27 is provided with anti-slip grooves 25, so that a certain gap can be left between the inclined surface 27 of the upper base plate 2 and the surface of the casing 6 to facilitate manual operation.

[0024] The surface of the middle hole tooling 3 is provided with a filling port 32, and a flow guide channel 31 is provided at the filling port 32. The middle hole tooling 3 is bonded to the surface of the upper base plate 2, and the flow guide channel 31 is connected to the center hole 21 provided at the upper base plate 2, and the diameter of the flow guide channel 31 is at least 2 cm, and the diameter of the center hole 21 is at least 3 cm. The epoxy resin can flow smoothly through the center hole 21 through the flow guide channel 31, and finally enter the groove 26 of the upper base plate 2.

[0025] The tooling 3 in the middle hole is an integrated structure made of nylon material, which has good mechanical strength and outstanding fatigue resistance, and can be easily preheated and expanded to complete the assembly of the tooling 3 in the middle hole.

[0026] Working principle: When in use, the device is put into the housing 6 through the middle hole fixture 3, and the middle hole fixture 3 is inserted into the opening of the stator 5, so that the surface of the upper bottom plate 2 is fitted and fixed to the surface of the housing 6. At this time, the device is preheated as a whole, so that the middle hole fixture 3 made of nylon material expands, and finally fits tightly with the inner wall of the stator, so as to complete the stability of the basic mechanism.

[0027] The epoxy resin material is poured through the filling port 32, so that it flows into the groove 26 between the lower base plate 1 and the upper base plate 2 after passing through the guide channel 31 and the center hole 21. And because the groove 26 of the upper base plate 2 is provided with a limit block 23 for flow guidance, the epoxy resin will flow directly along the limit block 23 to the four side holes 22 after flowing into the groove 26, and finally overflow the side holes 22 into the inside of the housing 6, thereby filling the gap of the stator 5. In this way, the epoxy resin is poured from the bottom net of the coil of the stator 5, and the air in the coil can be effectively discharged during the pouring process, reducing the risk of pores inside after the potting is completed, and effectively improving the filling saturation. And it is easy to take out directly.

[0028] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A tooling for encapsulating a range extender with epoxy resin, comprising a lower base plate (1), an upper base plate (2) and a tooling in a middle hole (3), characterized in that: The surface of the lower base plate (1) is uniformly provided with first threaded holes (101), one side of the upper base plate (2) is provided with a groove (26), a central area of ​​the groove (26) is provided with a center hole (21), the surface of the groove (26) around the center hole (21) is provided with four side holes (22), the surface of the upper base plate (2) around the groove (26) is uniformly provided with second threaded holes (24), the lower base plate (1) and the upper base plate (2) are fixed by screwing with the first threaded hole (101) and the second threaded hole (24) in sequence by screws (4), the tooling (3) in the middle hole is provided with a tooling (3) ) is provided with a filling port (32) on its surface, and a flow guide channel (31) is provided at the filling port (32); the intermediate hole inner tooling (3) is bonded to the surface of the upper base plate (2), and the flow guide channel (31) is communicated with the central hole (21) provided at the upper base plate (2); a limit block (23) is bonded to the inner wall of the groove (26), and the height of the limit block (23) is the same as the depth of the groove (26) and is at least 1 cm; the top peripheral portion of the upper base plate (2) is an inclined surface (27), and the surface of the upper base plate (2) below the inclined surface (27) is provided with anti-slip grooves (25).

2. The range extender encapsulation epoxy resin tooling according to claim 1, characterized in that: The number of first threaded holes (101) and second threaded holes (24) provided on the lower base plate (1) and the upper base plate (2) is the same and is at least four.

3. The range extender encapsulation epoxy resin tooling according to claim 1, characterized in that: The diameter of the flow guiding channel (31) is at least 2 cm, and the diameter of the central hole (21) is at least 3 cm.

4. The range extender encapsulation epoxy resin tooling according to claim 1, characterized in that: The intermediate hole inner tooling (3) is an integrated structure made of nylon material.

Images