A resistance band unit and a fan-shaped resistance band structure

Abstract

The present invention discloses a resistor band unit and a fan-shaped resistor band structure, belonging to the technical field of brake resistors, comprising a resistor band unit formed by bending a unit body at each group of insulating block fixing holes and bending directions of adjacent groups of insulating block fixing holes are opposite, and also proposes a fan-shaped resistor band structure, which is formed by resistance welding of a plurality of resistor band units through connecting sections; by optimizing the structure of the fan-shaped resistor band and controlling the bending radius and bending angle of the bending part in each resistor band unit, the fan-shaped resistor band can maintain structural continuity and make the sparseness of the resistor band in a radial large radius area similar to that in a radial small radius area, thereby achieving the effect of balanced resistance in a ventilation area within the fan-shaped resistor band, making the wind speed in the ventilation area relatively uniform, and improving the heat dissipation uniformity of the fan-shaped resistor band.

Description

Technical Field

[0001] The invention belongs to the technical field of brake resistors, and in particular relates to a resistor band unit and a fan-shaped resistor band structure. Background Art

[0002] Braking resistors are used in heavy-duty electric wheeled mining vehicles. Their main function is to participate in deceleration braking and control vehicle speed. Braking resistors usually include more than three fan-shaped braking resistor units, which are formed by continuous radially arranged resistor bands. Heat will continue to be generated between the closely arranged resistor bands, and the heat needs to be taken away by a fan.

[0003] The radially arranged resistance bands have a larger ventilation resistance in the radial small radius area because they are arranged more densely, while the ventilation resistance is smaller in the radial large radius area because they are arranged relatively sparsely. The wind speed in the small radius area is lower than that in the large radius area, resulting in relatively poor heat dissipation in this area, which causes the resistance temperature in the small radius area to be higher. Summary of the invention

[0004] The present invention optimizes the radially arranged resistor belt structure to solve the problem that the ventilation resistance of the radial small radius area of ​​the resistor belt is larger than that of the radial large radius area, resulting in higher temperature in the radial small radius area and uneven overall temperature of the resistor belt.

[0005] Provided is a resistor band unit and a fan-shaped resistor band structure, comprising:

[0006] A unit body, wherein the unit body is provided with a plurality of groups of insulating block fixing holes along the length direction, and a connecting section is provided at each end of the unit body;

[0007] The resistance band unit is formed by bending the unit body at each group of insulating block fixing holes, and the bending directions of the insulating block fixing holes of adjacent groups are opposite, and the bending parts at both ends of the resistance band unit each form a plurality of first bending parts and a plurality of second bending parts, and the total number of the second bending parts is greater than the first bending parts;

[0008] The angular deviation values ​​of the bending angles of the first bending portion and the bending angles of the second bending portion are both ≤2°, the radius deviation ratios of the bending radius of the first bending portion and the bending radius of the second bending portion are both ≤5%, and the distance from the connecting section to the adjacent second bending portion accounts for 2 / 5 to 3 / 5 of the total distance from the first bending portion to the second bending portion.

[0009] As a further solution of the present invention: the unit body is further provided with a plurality of groups of porcelain column fixing holes along the length direction, and the porcelain column fixing holes and the insulating block fixing holes are arranged in an alternating manner, and each group of insulating block fixing holes and each group of porcelain column fixing holes are respectively provided with at least one in the width direction of the unit body.

[0010] As a further solution of the present invention: two ceramic column fixing holes adjacent to the same second bending portion are penetrated by insulating ceramic columns, and the travel between the two ceramic column fixing holes is limited by the insulating ceramic columns.

[0011] As a further solution of the present invention: the connecting section includes a bending section and a welding section, and the bending section is arranged between the welding section and the ceramic column fixing hole.

[0012] As a further solution of the present invention: the number of the first bending parts is 1, and the number of the second bending parts is 2.

[0013] A second aspect of the present invention provides a fan-shaped resistance band structure, which is formed by resistance welding a plurality of the above-mentioned resistance band units through connecting segments.

[0014] As a further solution of the present invention: the welding area of ​​the resistance welding is the welding section in the connecting section, and the welding method of the resistance welding is spot welding or seam welding.

[0015] As a further solution of the present invention: the distance between the insulating block fixing holes on two adjacent first bending portions is equal to the distance between the insulating block fixing holes on two adjacent second bending portions.

[0016] As a further solution of the present invention: the insulating porcelain column is arranged in the middle between the first bending portion and the second bending portion.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] 1. By optimizing the structure of the fan-shaped resistance belt, a filling section is added in the unit interval of the radial large radius area of ​​the fan-shaped resistance belt, so that the fan-shaped resistance belt can maintain structural continuity and make the density of the resistance belt in the radial large radius area close to that of the resistance belt in the radial small radius area, thereby achieving the effect of balanced resistance in the ventilation area of ​​the fan-shaped resistance belt.

[0019] 2. Control the bending radius and bending angle of the bending part in each resistance band unit so that the resistance band spacing in the radial small radius area and the radial large radius area is the same or similar, further improving the density uniformity between the fan-shaped resistance band structures, achieving global resistance balancing in the ventilation area within the fan-shaped resistance band, making the wind speed in the ventilation area relatively uniform, and improving the heat dissipation uniformity of the fan-shaped resistance band structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to facilitate understanding by those skilled in the art, the present invention is further described below with reference to the accompanying drawings.

[0021] Figure 1 It is a schematic diagram of the overall structure of a fan-shaped resistance strip structure;

[0022] Figure 2 A schematic diagram of the structure of a resistance band unit provided by the present invention;

[0023] Figure 3 A schematic diagram of the structure of the unit body provided by the present invention;

[0024] Figure 4 for Figure 1 A magnified schematic diagram of the S region is provided.

[0025] In the figure: 1, unit body; 2, insulating block fixing hole; 3, porcelain column fixing hole; 4, connecting section; 41, bending section; 42, welding section; 5, first bending section; 6, second bending section; 7, insulating porcelain column; 8, reinforcing rib. DETAILED DESCRIPTION

[0026] In order to make the purpose, technical scheme and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention, that is, the embodiments described are only part of the embodiments of the present invention, rather than all of the embodiments. The components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0027] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without making creative work are within the scope of protection of the present invention.

[0028] See also Figure 1-4 As shown, in an embodiment of the present invention, it includes a unit body 1, and the unit body 1 has multiple groups of insulating block fixing holes 2 along the length direction, each group of insulating block fixing holes 2 is provided with at least one, and is arranged along the width direction of the unit body 1; a connecting section 4 is provided at each end of the unit body 1, which is used to connect with the connecting section 4 of the adjacent unit body 1 so that the resistance band structure forms a continuous whole.

[0029] The resistor band unit is formed by bending the unit body 1 at each group of insulating block fixing holes 2, and the bending directions of the insulating block fixing holes 2 of adjacent groups are opposite. The fan-shaped resistor band structure is formed by connecting a number of resistor band units to each other through connecting segments, and the insulating block fixing holes 2 can pass through the insulating block metal columns set on the outer frame of the resistor grid, so that the position of the resistor band is fixed, and the resistor band is defined as a fan-shaped structure in an arc state. In addition, the arc range formed by the connecting segments 4 after the entire connection is completed can approximately divide the fan-shaped resistor band structure into a radial large radius area and a radial small radius area.

[0030] A plurality of first bending portions 5 and a plurality of second bending portions 6 are formed at the bending portions at both ends of the resistance band unit, and the total number of the second bending portions 6 is greater than the first bending portions 5; the angle deviation values ​​of the bending angles of the first bending portions 5 and the second bending portions 6 are both ≤2°, and the radius deviation ratios of the bending radii of the first bending portions 5 and the bending radii of the second bending portions 6 are both ≤5%.

[0031] When the angle deviation between the bending angle of the first bending portion 5 and the bending angle of the second bending portion 6 is greater than 2°, since the resistor band unit has a long distance, a deviation of more than 2° will cause the unit body 1 to have a larger gap distance deviation between the resistor band units as the extension stroke increases, and eventually destroy the overall gap uniformity. Similarly, when the radius deviation ratio between the bending radius of the first bending portion 5 and the bending radius of the second bending portion 6 is greater than 5%, it will directly lead to a significant reduction in the overall gap uniformity of the fan-shaped resistor band.

[0032] By controlling the bending angle and bending radius of the first bending portion 5 and the second bending portion 6 in the resistance band unit to be close or the same; and because the insulating blocks on the outer frame of the resistance grid are of the same specification and are evenly arranged, the bending angle and bending radius of the first bending portion 5 and the second bending portion 6 formed in the fan-shaped resistance band structure are also close or the same, so that the resistance band spacing in the radial small radius area and the radial large radius area is the same or close, the sparse uniformity between the fan-shaped resistance band structures is improved, and the global resistance balance of the ventilation area in the fan-shaped resistance band is achieved, so that the wind speed in the ventilation area is relatively uniform, and the heat dissipation uniformity of the fan-shaped resistance band is improved.

[0033] The distance from the connecting section 4 to the adjacent second bending portion 6 accounts for 2 / 5 to 3 / 5 of the total distance from the first bending portion 5 to the second bending portion 6. Through this arrangement, a filling section can be added every unit distance in the radial large radius area, and the filling section is formed by the unit body 1 between the two adjacent second bending portions 6 connected to the connecting section 4 after the two adjacent connecting sections 4 are connected.

[0034] By optimizing the structure of the fan-shaped resistance belt, a filling section is added to the radial large radius area of ​​the fan-shaped resistance belt within the unit interval, so that the fan-shaped resistance belt can maintain structural continuity and increase the compactness of the relatively sparse radial large radius area, thereby making the density of the resistance belt in the radial large radius area similar to that of the resistance belt in the radial small radius area, thereby achieving the effect of balanced resistance in the ventilation area within the fan-shaped resistance belt and improving the heat dissipation uniformity of the fan-shaped resistance belt.

[0035] See also Figure 3As shown, the unit body 1 is further provided with a plurality of groups of ceramic column fixing holes 3 along the length direction, and the ceramic column fixing holes 3 and the insulating block fixing holes 2 are arranged in an alternate arrangement, and after the insulating block fixing holes 2 are bent, the two ceramic column fixing holes 3 adjacent to the second bending portion 6 are arranged correspondingly; each group of insulating block fixing holes 2 and each group of ceramic column fixing holes 3 are respectively provided with at least one in the width direction of the unit body 1. Increasing the number of each group of insulating block fixing holes 2 and ceramic column fixing holes 3 in the width direction can improve the stability of the fan-shaped resistor strip structure.

[0036] See also Figure 1 , Figure 2 and Figure 4 As shown, two porcelain column fixing holes 3 adjacent to the same second bending portion 6 are penetrated by insulating porcelain columns 7, and the travel between the two porcelain column fixing holes 3 is limited by the insulating porcelain columns 7. Since there is a certain distance between the first bending portion 5 and the second bending portion 6, a fixing device needs to be set between the fan-shaped resistance belt structure to prevent the resistance belt from shaking and contacting the resistance belts on the adjacent two sides to cause a short circuit. In the present invention, the insulating porcelain column 7 and the setting structure of the insulating porcelain column 7 can not only improve the stability of the fan-shaped resistance belt structure within the overall range, but also stabilize the filling section in a suspended state, so that each filling section has two restraining forces in different directions, preventing the resistance belts from sticking and short-circuiting, power-on whistling, and other problems caused by high temperature, high wind speed, vibration deformation, etc.

[0037] Furthermore, the insulating ceramic column 7 is arranged in the middle between the first bending part 5 and the second bending part 6; the insulating ceramic column 7 is arranged in this position, so that the fan-shaped resistance band structure can obtain the maximum structural stability and reduce the shaking degree of the resistance band. Therefore, after the position of the insulating ceramic column 7 is limited, the distance from the connecting section 4 to the adjacent second bending part 6 accounts for 1 / 2 to 3 / 5 of the total distance from the first bending part 5 to the second bending part 6; the connecting section 4 is arranged in this range to ensure the uniformity of the resistance band in the radial large radius area and the radial small radius area, and at the same time, the extended filling section in the suspended state will not be severely bent.

[0038] The connecting section 4 includes a bending section 41 and a welding section 42. A plurality of resistance band units are formed by resistance welding through the connecting section 4, and the welding area of ​​the resistance welding is the welding section 42 in the connecting section 4. The resistance welding method is spot welding or seam welding to form a series connection of resistances. The bending section 41 serves as a transition section between the ceramic column fixing hole 3 and the welding section 42. The bending section 41 forms two angles, so that after the two welding sections 42 are welded, the bending sections 41 can suddenly expand to a certain distance, thereby preventing the formation of a transitional adhesion state between the resistance bands on both sides, resulting in unstable resistance value.

[0039] See also Figure 2 and Figure 3As shown, the surface of the unit body 1 is provided with reinforcing ribs 8, which are punched into prismatic, long strip and louver shapes by a pressing die to strengthen the strength of the resistance band. The reinforcing ribs 8 are bounded by the first bending portion 5 and the second bending portion 6, and the pressing directions of adjacent reinforcing ribs 8 on the surface of the unit body 1 are opposite, so that the directions of the reinforcing ribs 8 on the surface of the fan-shaped resistance band structure after formation are the same, so as to achieve the principle of the same direction of the ribs punched in the resistance band.

[0040] In one embodiment, see Figure 1 and Figure 3 As shown, a single resistance band unit includes a first bending portion 5 and two second bending portions 6. The surface of the unit body 1 includes five points A, B, C, D, and E. The first method for die-casting the reinforcing rib 8 includes the following steps:

[0041] The length of the forming die only includes the AC segment. The AB segment and the BC segment are provided with rib structures in different directions on the forming die. The AE segment resistor belt is fed once to press out the AC segment, then turned 180° with point C as the center, and then the CE segment is pressed out to complete the punching of the reinforcing rib 8 of the AE segment resistor belt.

[0042] In another embodiment, the second method of compression molding the reinforcing rib 8 comprises the following steps:

[0043] The length of the forming die includes the AE section. The AB section and the CD section are provided with rib structures in the same direction on the forming die, and the BC section and the DE section are provided with rib structures in the opposite direction to the AB section and the CD section. The resistance strip is fed once and directly formed into the AE section resistance strip to complete the punching of the reinforcement ribs 8 of the AE section resistance strip.

[0044] The mold cost of method 2 is higher than that of method 1, but the process is relatively simple and can reduce one punching process.

[0045] See also Figure 1 and Figure 3 As shown, in the fan-shaped resistor strip structure, the distance between the insulating block fixing holes 2 on two adjacent first bending portions 5 is equal to the distance between the insulating block fixing holes 2 on two adjacent second bending portions 6, so as to improve the distance uniformity between the resistor strips.

[0046] Specifically, a single resistor band unit includes a first bend portion 5 and two second bend portions 6. The number of insulating blocks in the inner diameter portion of the resistor grid outer frame is 1 / 2 of the number of insulating blocks in the outer diameter portion of the resistor grid outer frame. The fan-shaped resistor band structure in this structural state achieves excellent density uniformity and has a high heat dissipation uniformity.

[0047] The above contents are merely examples and explanations of the structure of the present invention. The technicians in this technical field may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the structure of the invention or exceed the scope defined by the claims, they should all fall within the protection scope of the present invention.

Claims

1. A fan-shaped resistance band structure, comprising a plurality of resistance band units, characterized in that: The resistance band unit comprises a unit body, wherein the unit body is provided with a plurality of groups of insulating block fixing holes along the length direction, and a connecting section is provided at each of the two ends of the unit body; The resistance band unit is formed by bending the unit body at each group of insulating block fixing holes, and the bending directions of the insulating block fixing holes of adjacent groups are opposite, and the bending parts at both ends of the resistance band unit each form a plurality of first bending parts and a plurality of second bending parts, and the total number of the second bending parts is greater than the first bending parts; The angle deviation between the bending angle of the first bending portion and the bending angle of the second bending portion is ≤2°, the radius deviation ratio between the bending radius of the first bending portion and the bending radius of the second bending portion is ≤5%, and the distance from the connecting section to the adjacent second bending portion accounts for 2 / 5 to 3 / 5 of the total distance from the first bending portion to the second bending portion; The fan-shaped resistance band structure is formed by resistance welding of a plurality of resistance band units through connecting segments.

2. A fan-shaped resistance band structure according to claim 1, characterized in that: The unit body is also provided with a plurality of groups of porcelain column fixing holes along the length direction, and the porcelain column fixing holes and the insulating block fixing holes are arranged in an alternating manner, and each group of insulating block fixing holes and each group of porcelain column fixing holes are respectively provided with at least one in the width direction of the unit body.

3. A fan-shaped resistance band structure according to claim 2, characterized in that: Two ceramic column fixing holes adjacent to the same second bending portion are penetrated by insulating ceramic columns, and the travel between the two ceramic column fixing holes is limited by the insulating ceramic columns.

4. A fan-shaped resistance band structure according to claim 3, characterized in that: The connecting section includes a bending section and a welding section, and the bending section is arranged between the welding section and the ceramic column fixing hole.

5. A fan-shaped resistance band structure according to claim 4, characterized in that: The welding area of ​​the resistance welding is the welding section in the connecting section, and the welding method of the resistance welding is spot welding or seam welding.

6. A fan-shaped resistance band structure according to claim 5, characterized in that: The distance between the insulating block fixing holes on two adjacent first bending portions is equal to the distance between the insulating block fixing holes on two adjacent second bending portions.

7. The fan-shaped resistance band structure according to claim 1, characterized in that: The surface of the unit body is provided with reinforcing ribs; the reinforcing ribs are bounded by the first bending portion and the second bending portion, and the pressing directions of adjacent reinforcing ribs on the surface of the unit body are opposite.

8. The fan-shaped resistance band structure according to claim 1, characterized in that: The number of the first bending portions is one, and the number of the second bending portions is two.

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