A coil holder for a generator rotor and a generator rotor assembly

Abstract

A kind of coil holder for generator rotor and generator rotor assembly belong to the technical field of generator rotor structure, wherein the coil holder for generator rotor, including the coil holder body of press mounting positioning between two claw poles, the end face of coil holder body is provided with the wire inlet seat and wire outlet seat of the two ends of coil along the circumferential direction and radial direction of coil holder body are clamped and limited, the beneficial effects of the present application are that, the coil holder can guarantee that copper wire is not forced to throw out and swing along circumferential direction when high-speed operation, can avoid the stress concentration of the wire inlet end and wire outlet end of coil, reduce the risk of rotor excitation coil wire breakage, the coil holder is applied to generator rotor assembly, improves the reliability of rotor operation.

Description

Technical Field

[0001] This invention relates to the field of generator rotor structure technology, and in particular to a coil frame for a generator rotor and a generator rotor assembly. Background Technology

[0002] As a primary power supply component in automobiles, the alternator's rotor, as the main rotating part, is characterized by high operating speeds and rapid acceleration / deceleration, especially in vehicles with high gear ratios. Under rapid acceleration, the rotor generates relative centrifugal force and inertial force, the magnitude of which depends on the magnitude of the acceleration.

[0003] Meanwhile, during operation, the excitation coils of the rotor assembly experience varying centrifugal forces due to their different distances from the center. Currently, most rotor faults reported in the aftermarket are due to broken wires in the outer excitation coils. When the excitation coil breaks, the generator excitation circuit is disconnected, the vehicle's warning functions fail, and safety risks are posed.

[0004] Currently, the main measures to prevent rotor excitation coil breakage are reducing the rotational displacement of the excitation coil and reducing stress concentration in the coil. However, since the coil is only fixed by the rotor claw poles, it will inevitably undergo fretting deformation under high-speed vibration conditions. When the coil undergoes fretting deformation, fatigue fracture will occur at the stress concentration points of the copper wire.

[0005] To prevent the copper wire from being ejected at high speed, existing technologies often use multiple bends to limit its movement. This structure leads to stress concentration at the bends. During high-speed operation, these bends are prone to fatigue fracture. Therefore, reducing stress concentration during coil assembly is crucial. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention provides a coil frame for a generator rotor, which ensures that the copper wires will not be thrown out or circumferentially oscillate during high-speed operation, avoids stress concentration at the coil inlet and outlet ends, reduces the risk of rotor excitation coil breakage, and improves the reliability of rotor operation when applied to the generator rotor assembly.

[0007] To achieve the above objectives, the technical solution adopted by the present invention to solve its technical problem is as follows: the generator rotor coil frame includes a coil frame body press-fitted and positioned between two claw poles, and the end face of the coil frame body is provided with an inlet seat and an outlet seat for locking and limiting the two ends of the coil along the circumference and radial direction of the coil frame body.

[0008] The coil includes a copper wire wound around the outside of the coil frame body, with insulating sleeves fitted at both ends of the copper wire. The insulating sleeves are snapped and positioned to the inlet or outlet socket.

[0009] The claw pole is provided with multiple positioning grooves at equal intervals along the circumference. The coil frame body includes a cylindrical winding part. One end face of the winding part is provided with an inlet seat, an outlet seat, and multiple positioning blocks that engage with the multiple positioning grooves along the circumference.

[0010] The inlet and outlet terminals have the same structure and are integrally injection molded with the coil frame body; the inlet or outlet terminal includes an anti-swing baffle provided along the outer periphery of the coil frame body, the anti-swing baffle clamps the end of the coil into its interior, and the anti-swing baffle is provided with a wire clamping seat to limit the swing of the end of the coil.

[0011] The anti-slip baffle has a snap-fit ​​groove with an outer opening in the middle. The width of the outer groove is smaller than the width of the inner groove. The outer diameter of the coil end is larger than the width of the outer groove and smaller than the width of the inner groove.

[0012] The wire clamping base is provided with a wire clamping groove with an outward opening, and the wire clamping groove is tightly engaged with the end of the coil.

[0013] The cable holder is also provided with arc-shaped baffles on both sides, and the two arc-shaped baffles and the inner side of the cable holder form an arc-shaped plate that engages with the corresponding positioning groove.

[0014] A limiting rib is provided on the inner side of the junction between the wire holder and the arc-shaped stop edge, and a limiting slot is provided on the inner side of the claw pole at the position opposite to the positioning groove. The limiting rib and the corresponding limiting slot are interference-fitted.

[0015] The inner edges of both ends of the winding section are provided with multiple L-shaped enamel-impregnation holes along their circumference, the outer edges of both ends of the winding section are provided with multiple reinforcing ribs along their circumference, the outer edges of both ends of the winding section are provided with inclined outward protective wing plates at equal intervals, and the outer edge of the winding section near the inlet seat is provided with an inclined inlet groove.

[0016] A generator rotor assembly includes a generator rotor coil frame and claw poles press-fitted to both ends of the coil frame. A rotor shaft is mounted on the two claw poles and the middle of the coil frame. A slip ring is mounted on one end of the rotor shaft. A wire groove is provided at equal intervals along the circumference on the surface of the claw poles near the slip ring. The end of the coil is attached to the surface of the claw pole along the wire groove and then welded to the slip ring.

[0017] The beneficial effects of this invention are:

[0018] 1. This invention provides a coil frame for a generator rotor. By setting an inlet seat and an outlet seat at the inlet and outlet ends of the coil frame, the inlet and outlet seats can limit the two ends of the coil radially and circumferentially, ensuring that the two ends of the coil will not be thrown out radially or swing circumferentially when running at high speed. At the same time, it can also ensure that there are no bending or stress concentration problems at the ends of the copper wire during the winding assembly process, reducing the risk of rotor excitation coil breakage and improving the reliability of rotor operation.

[0019] 2. The present invention can initially limit the radial position of the coil end by setting anti-spinning baffles on the inlet and outlet terminals. The limiting ribs set in the middle of the inner side of the inlet and outlet terminals are interference-fitted with the limiting grooves in the circumferential direction of the claw pole to further limit the radial position of the coil end. After the coil end is welded to the slip ring on the rotor shaft along the surface of the claw pole, reliable radial positioning of the coil end is achieved, which prevents the two ends of the coil from being thrown out radially when the rotor is running at high speed.

[0020] 3. The present invention provides an inclined inlet groove on the outer periphery of the coil frame body, which allows the copper wire to enter along the inlet groove. The wire clamping seat provided in the middle of the inlet seat and outlet seat can clamp and limit the two ends of the coil along the circumference of the coil frame, thus avoiding the problem of stress concentration in the coil caused by the two ends of the coil swinging along the circumference when the rotor is running at high speed. Attached Figure Description

[0021] The following is a brief explanation of the contents of each of the accompanying drawings and the markings in the drawings:

[0022] Figure 1 This is an isometric view of the coil frame in this invention;

[0023] Figure 2 for Figure 1 A bottom view;

[0024] Figure 3 for Figure 1 Schematic diagram of the structure of the center cable holder;

[0025] Figure 4 for Figure 1 Schematic diagram of the center cable outlet;

[0026] Figure 5 This is a schematic diagram of the structure inside the claw pole in this invention;

[0027] Figure 6 This is a schematic diagram of the outer side of the claw pole in this invention;

[0028] Figure 7 This is an isometric view of the generator rotor assembly in this invention;

[0029] Figure 8 for Figure 7Full sectional view;

[0030] Figure 9 for Figure 7 A schematic diagram of the structure of the intermediate frequency amplifier section, showing the connection between the coil end, the claw pole, and the coil frame.

[0031] The markings in the above figures are as follows: 1. Coil frame body, 11. Winding part, 12. L-shaped enamel impregnation hole, 13. Wire inlet groove, 2. Wire inlet seat, 21. Anti-spinning baffle, 211. Snap-fit ​​groove, 22. Wire clamp seat, 221. Wire clamp groove, 23. Arc-shaped baffle, 24. Limiting rib, 3. Wire outlet seat, 4. Coil, 41. Copper wire, 42. Insulating sleeve, 5. Claw pole, 51. Positioning groove, 52. Limiting rib groove, 53. Wire pressing groove, 6. Positioning block, 7. Reinforcing rib, 8. Wing plate, 9. Rotor shaft, 10. Slip ring. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0033] In the description of this invention, it should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0034] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0035] The specific implementation scheme of this invention is as follows: Figure 1 and Figure 2As shown, a coil frame for a generator rotor includes a coil frame body 1 press-fitted and positioned between two claw poles 5. The end face of the coil frame body 1 is provided with an inlet seat 2 and an outlet seat 3 for clamping and limiting the two ends of the coil 4 along the circumference and radial direction of the coil frame body 1. This ensures that the two ends of the coil 4 will not be thrown out radially or swing circumferentially when running at high speed. At the same time, it can also ensure that there is no bending or stress concentration at the end of the copper wire 41 during the winding assembly process, reducing the risk of the rotor excitation coil 4 breaking and improving the reliability of rotor operation.

[0036] Specifically, such as Figure 3 and Figure 4 As shown, the coil 4 includes a copper wire 41 wound around the outside of the coil 4 frame body 1. The two ends of the copper wire 41 are fitted with insulating sleeves 42. The insulating sleeves 42 are snapped and positioned with the inlet seat 2 or the outlet seat 3. The insulating sleeves 42 protect the copper wire 41 inside. Moreover, since the copper wire 41 passes through the inlet seat 2 or the outlet seat 3, it is inevitable that there will be a slight bend. By fitting insulating sleeves 42 at both ends of the copper wire 41, the problem of stress concentration, friction wear or even wire breakage caused by the copper wire 41 directly contacting the inlet seat 2 or the outlet seat 3 during the high-speed operation of the rotor is avoided.

[0037] Specifically, such as Figure 5 , Figure 7 and Figure 8 As shown, the claw pole 5 is provided with multiple positioning grooves 51 at equal intervals along the circumference. The bottom of the positioning grooves 51 is smoothly transitioned to avoid stress concentration. The coil frame body 1 includes a cylindrical winding part 11. One end face of the winding part 11 is provided with an inlet seat 2, an outlet seat 3 and multiple positioning blocks 6 that engage with the multiple positioning grooves 51 along the circumference. The inlet seat 2 and outlet seat 3 can be arranged opposite each other to maximize the distance between them, which facilitates the entry and exit of the copper wire 41. The inlet seat 2, outlet seat 3 and multiple positioning blocks 6 are equally spaced along the circumference of the winding part 11 and engage with the corresponding positioning grooves 51, thus serving as the positioning claw pole 5.

[0038] Specifically, such as Figure 3 and Figure 4As shown, the inlet seat 2 and outlet seat 3 have the same structure and are integrally injection molded with the coil 4 frame body 1, resulting in high overall structural strength and greater stability. The specific structure of the inlet seat 2 or outlet seat 3 includes an anti-swing baffle 21 arranged along the outer periphery of the coil 4 frame body 1. The anti-swing baffle 21 holds the end of the coil 4 (insulating sleeve 42) inside, limiting the end of the coil 4 radially along the coil 4 frame body 1 and preventing the end of the coil 4 from being thrown outwards during high-speed rotor rotation. The anti-swing baffle 21 also has a wire-clamping seat 22 that limits the swing of the end of the coil 4 (insulating sleeve 42), limiting the end of the coil 4 circumferentially along the coil 4 frame body 1 and preventing the end of the coil 4 from swinging circumferentially along the coil 4 frame body 1 during high-speed rotor rotation. The inlet seat 2 or outlet seat 3 with the above structure can reduce the bending of the coil 4 after assembly and during operation, avoiding stress concentration problems in the coil 4.

[0039] The anti-spinning baffle 21 has a snap-fit ​​groove 211 with an outer opening in the middle. The edge of the snap-fit ​​groove 211 is smoothly transitioned. The width of the outer groove opening of the snap-fit ​​groove 211 is smaller than the width of the inner groove opening. The outer diameter of the end of the coil 4 (insulating sleeve 42) is larger than the width of the outer groove opening of the snap-fit ​​groove 211 but smaller than the width of the inner groove opening of the snap-fit ​​groove 211. Due to the setting of the snap-fit ​​groove 211, the end of the coil 4 can be squeezed into the snap-fit ​​groove 211, and after being snapped in, it can prevent the end of the coil 4 from being thrown outward, thus achieving the limitation of the end of the coil 4 along the radial direction of the coil 4 frame body 1. In addition, the orientation of the snap-fit ​​groove 211 in the inlet seat 2 and outlet seat 3 can be set according to the winding direction to reduce the bending angle of the copper wire 41. The winding section 11 has an inclined inlet groove 13 on its outer side near the inlet seat 2, which facilitates the copper wire 41 to enter along the inlet groove 13. The orientation of the inlet groove 13 matches the snap-fit ​​groove 211 of the inlet seat 2 to reduce the bending angle of the copper wire 41. Alternatively, an inclined outlet groove can be provided on the outer side of the winding section 11 near the outlet seat 3, so that the orientation of the outlet groove matches the snap-fit ​​groove 211 of the outlet seat 3 to reduce the bending angle of the copper wire 41 when it exits.

[0040] The wire clamping base 22 is provided with an outward-facing wire clamping groove 221, which engages tightly with the end of the coil 4 (insulating sleeve 42). This clamps and limits the two ends of the coil 4 along the circumference of the coil 4 frame, preventing stress concentration caused by the circumferential swing of the two ends of the coil 4 when the rotor is running at high speed. The wire clamping groove 221 is opposite to the clamping groove 211, allowing the end of the coil 4 to pass through vertically, further preventing the copper wire 41 from bending during assembly.

[0041] The wire clamp 22 has two opposing arc-shaped baffles 23 on its sides. These two arc-shaped baffles 23, together with the inner side of the wire clamp 22, form an arc-shaped plate that engages with the corresponding positioning groove 51, thus positioning the claw electrode 5. Figure 3 , Figure 4 and Figure 8 As shown, a limiting rib 24 is provided on the inner side of the junction of the wire holder 22 and the arc-shaped stop 23, and a limiting groove 52 is provided on the inner side of the claw pole 5 at the position opposite to the positioning groove 51. The limiting rib 24 and the corresponding limiting groove 52 are interference-fitted. The limiting rib 24 not only increases the structural strength and stability of the wire inlet seat 2 or the wire outlet seat 3, but also the interference fit between the limiting rib 24 and the limiting groove 52 can make the claw pole 5 firmly positioned. After the copper wire 41 at the end of the coil 4 is welded and positioned, the end of the coil 4 can be further radially limited, which further avoids the situation where the end of the coil 4 is thrown outward during the high-speed rotation of the rotor.

[0042] After the copper wire 41 is wound, the coil 4 frame body 1 is placed into the insulating varnish tank, so that the insulating varnish enters the snap-fit ​​groove 211, which can firmly bond the end of the coil 4 (insulating sleeve 42) to the anti-spin baffle 21 and the wire clamping seat 22. This can fix the end of the coil 4 radially and circumferentially, further avoiding the problem of the end of the coil 4 swinging out radially and circumferentially, and further improving the reliability of the rotor operation.

[0043] Specifically, such as Figure 1 and Figure 2 As shown, the inner edges of both ends of the winding section 11 are provided with multiple L-shaped impregnation holes 12 along its circumference, allowing the insulating varnish to quickly enter between the copper wire 41 and the winding section 11, so that the insulating varnish fully wets the copper wire 41 and makes it firmly bonded to the winding section 11; the outer edges of both ends of the winding section 11 are provided with inclined outward protective wing plates 8 at equal intervals, forming a diffusion shape from the middle of the winding section 11 to both ends after the copper wire 41 is wound on the winding section 11. When the two claw poles 5 are pressed onto the two ends of the coil 4 frame body 1, the protective wing plates 8 at both ends of the coil 4 frame body 1 and the two claw poles 5 are bonded together. The inner wall end face of pole 5 is pressed tightly, pressing the protective wing plate 8 from an inclined state to a horizontal state. At this time, the copper wire 41 is squeezed, increasing the clamping force of the copper wire 41 and making the copper wire 41 firmly fixed on the winding part 11. Multiple reinforcing ribs 7 are provided on the outer side of both ends of the winding part 11 along its circumference. This not only improves the structural strength of the coil 4 frame body 1, but also, when the two claw poles 5 are pressed onto the two ends of the coil 4 frame body 1, the reinforcing ribs 7 are pressed into the inner side of the protective wing plate 8, which plays a role in resisting and squeezing the copper wire 41 wound on the winding part 11, further increasing the clamping force of the copper wire 41.

[0044] like Figure 7 , Figure 8 and Figure 9As shown, a generator rotor assembly includes the aforementioned generator rotor coil 4 frame, and claw poles 5 press-fitted at both ends of the coil 4 frame. A rotor shaft 9 is mounted on the middle of the two claw poles 5 and the coil 4 frame. A slip ring 10 is mounted on one end of the rotor shaft 9. The surface of the claw pole 5 near the slip ring 10 is provided with circumferentially spaced pressure grooves 53. The pressure grooves 53 are smoothly transitioned and are arranged opposite to the positioning grooves 51. The end of the coil 4 is attached to the surface of the claw pole 5 along the pressure grooves 53 and then welded to the slip ring 10. The setting of the pressure grooves 53 can make the end of the coil 4 bend gently, reducing the stress concentration problem at the end of the coil 4.

[0045] The assembly method for the above-mentioned generator rotor assembly is as follows:

[0046] Step 1: Copper wire 41 winding: 1) Pass the copper wire 41 through the snap-fit ​​groove 211 of the inlet seat 2 and enter the winding part 11 of the coil frame body 1 along the inlet groove 13; 2) The copper wire 41 starts to wind along the outside of the winding part 11, and after the winding is formed, it comes out from the snap-fit ​​groove 211 of the outlet seat 3; 3) The inlet end and outlet end of the copper wire 41 are fitted with insulating sleeves 42, so that the insulating sleeves 42 are snapped into the snap-fit ​​groove 211 of the inlet seat 2 or the outlet seat 3 and enter the wire clamping groove 221 of the wire clamping seat 22.

[0047] Step 2: Impregnation: Place the coil frame 1 with copper wire 41 wound on it into the insulating varnish tank, so that the insulating varnish can quickly enter between the copper wire 41 and the winding part 11 through the L-shaped impregnation hole 12, so that the insulating varnish can fully impregnate the copper wire 41 and make it firmly adhere to the winding part 11. At the same time, the insulating varnish enters the snap-fit ​​groove 211, which can make the insulating sleeve 42 firmly adhere to the anti-spin baffle 21 and the wire clamp 22.

[0048] Step 3: Assemble the claw pole 5 and rotor shaft 9: 1) Press and rivet the rotor shaft 9 to one of the claw poles 5, and assemble the coil 4 frame body 1, which has been impregnated with insulating varnish and dried, onto the rotor shaft 9; 2) Connect one end of the coil 4 frame body 1 to the claw pole 5, and install another claw pole 5 at the other end of the coil 4 frame body 1, and assemble the claw pole 5 onto the rotor shaft 9; 3) Use a pressing and riveting device to press the two claw poles 5 to the protective wing plates 8 at both ends of the coil 4 frame body 1, press the two protective wing plates 8 from the inclined state to the horizontal state, so that the copper wire 41 is squeezed and firmly fixed on the winding part 11.

[0049] Step 4: Assemble the slip ring 10 and connect the wires: Install the slip ring 10 on the rotor shaft 9, and then weld the end of the coil 4 to the corresponding claw pole 5 surface along the wire pressing groove 53 and connect it to the slip ring 10.

[0050] In summary, the coil frame designed in this invention can ensure that the copper wire will not be thrown out or swing around circumferentially when running at high speed, avoid stress concentration at the coil's inlet and outlet ends, reduce the risk of rotor excitation coil breakage, and improve the reliability of rotor operation when applied to the generator rotor assembly.

[0051] The above description is merely an illustration of some principles of the present invention. This specification is not intended to limit the present invention to the specific structures and applicable scope shown. Therefore, all possible modifications and equivalents that may be used fall within the scope of the patent application of this invention.

Claims

1. A coil frame for a generator rotor, characterized in that, The coil frame body is press-fitted and positioned between two claw poles. The end face of the coil frame body is provided with an inlet seat and an outlet seat for locking and limiting the two ends of the coil along the circumference and radial direction of the coil frame body. The claw pole is provided with multiple positioning grooves at equal intervals along the circumference. The coil frame body includes a cylindrical winding part. One end face of the winding part is provided with an inlet seat, an outlet seat and multiple positioning blocks that engage with the multiple positioning grooves along the circumference. The inlet and outlet have the same structure and are integrally injection molded with the coil frame body; the inlet or outlet includes an anti-swing baffle provided along the outer periphery of the coil frame body, the anti-swing baffle clamps the end of the coil into its interior, and the anti-swing baffle is provided with a wire clamping seat to limit the swing of the end of the coil. The anti-slip baffle is provided with a snap-fit ​​groove with an outer opening in the middle. The width of the outer groove is smaller than the width of the inner groove. The outer diameter of the coil end is larger than the width of the outer groove of the snap-fit ​​groove and smaller than the width of the inner groove of the snap-fit ​​groove. The winding part is provided with an inclined wire inlet groove on the outer side of the end near the wire inlet seat. The coil includes a copper wire wound around the outside of the coil frame body, and insulating sleeves are fitted at both ends of the copper wire. The insulating sleeves are snapped and positioned to the inlet or outlet socket. The wire clamp is provided with arc-shaped baffles on both sides, and the two arc-shaped baffles and the inner side of the wire clamp form an arc plate that engages with the corresponding positioning groove; a limiting rib is provided on the inner side of the junction of the wire clamp and the arc-shaped baffle, and a limiting groove is provided on the inner side of the claw pole at the position opposite to the positioning groove, and the limiting rib and the corresponding limiting groove are interference fit. The inner edges of both ends of the winding section are provided with multiple L-shaped impregnation holes along their circumference, the outer edges of both ends of the winding section are provided with multiple reinforcing ribs along their circumference, and the outer edges of both ends of the winding section are provided with inclined outward protective wing plates at equal intervals.

2. The generator rotor coil frame according to claim 1, characterized in that: The wire clamping base is provided with a wire clamping groove with an outward opening, and the wire clamping groove is tightly engaged with the end of the coil.

3. A generator rotor assembly, comprising a generator rotor coil frame as described in claim 1 or 2, characterized in that: It also includes claw poles press-fitted at both ends of the coil frame. A rotor shaft is installed between the two claw poles and the middle of the coil frame. A slip ring is installed at one end of the rotor shaft. A wire pressing groove is provided at equal intervals along the circumference on the surface of the claw pole near the slip ring. The end of the coil is attached to the surface of the claw pole along the wire pressing groove and then welded to the slip ring.

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