Suspension propulsion coil integrated ground stator module and manufacturing method thereof

Abstract

The application relates to the technical field of high-speed magnetic suspension transportation, and discloses a suspension propulsion coil integrated ground stator module and a manufacturing method thereof. The module comprises a shell and a zero-flux coil, a shielding support plate, a propulsion coil, a bolt bushing, a high-voltage connector socket, a first insulation support positioning cushion block and a second insulation support positioning cushion block which are integrally cast in the shell. The propulsion coil is arranged on the second insulation support positioning cushion block, and the inner side of the propulsion coil is positioned through the horizontal positioning part of the second insulation support positioning cushion block. The first insulation support positioning cushion block is arranged in the non-insulation space at the four corners of the outer side of the propulsion coil and the middle of the propulsion coil. The shielding support plate is arranged on the first insulation support positioning cushion block and connected with the high-voltage connector socket. The zero-flux coil is arranged on the shielding support plate and positioned through the coil positioning part of the shielding support plate. The bolt bushing penetrates through the shielding support plate and protrudes from the surface of the shell by a predetermined height.

Description

Technical Field

[0001] The present invention relates to the technical field of high-speed magnetic levitation transportation, and in particular to a levitation propulsion coil integrated ground stator module and a manufacturing method thereof. Background Art

[0002] The superconducting electric suspension-linear motor system, which is composed of an ironless figure-8 zero-flux coil and a propulsion coil and a superconducting magnet, has the advantages of self-stabilization of suspension guidance, a large suspension gap, high power density and low loss. It has broad application prospects in magnetic levitation rail transportation, especially in ultra-high-speed low-vacuum tube maglev trains. Integrating the ironless figure-8 zero-flux coil and the propulsion coil in the same ground stator module can greatly improve the production efficiency of the stator module and reduce the cost of track laying.

[0003] The superconducting electric suspension-electromagnetic propulsion system has high requirements for the consistency of the stator coil size and position. Large assembly errors will cause the traveling wave magnetic field generated by the stator coil to be distorted, thereby causing the train to produce obvious vehicle-track coupling vibration, which will have an adverse effect on the suspension propulsion system. Therefore, ensuring the precise positioning and consistency of the zero-flux coil and propulsion coil in the stator module is crucial to the stability of the suspension propulsion system.

[0004] Currently, the most common method for maintaining the position accuracy of the cast coil in the module is to wind the coil and fix it on the coil skeleton or the core tooth slot, then fix the skeleton to the casting mold or casting shell through various connection structures, and finally perform integrated resin casting. This method is widely used in ground modules and dry-type transformers of conventional electromagnetic suspension systems. However, this method makes the internal connection structure of the module complicated. After the epoxy resin is used for unified casting, the bonding surface can easily become loose and cracked due to the inconsistent thermal expansion coefficients of the connecting supports and the epoxy resin. For high-voltage propulsion coils with strict insulation requirements and subjected to alternating electromagnetic forces, the bonding points of different materials can easily form insulation weak points, thereby inducing partial discharge and insulation breakdown. Summary of the Invention

[0005] The present invention provides a suspended propulsion coil integrated ground stator module and a manufacturing method thereof, which can solve the technical problems in the prior art.

[0006] The present invention provides a suspended propulsion coil integrated ground stator module, wherein the module includes a shell and a zero-magnetic flux coil, a shielding support plate, a propulsion coil, a bolt bushing, a high-voltage connector socket, a first insulating support positioning pad and a second insulating support positioning pad, which are all integrally cast in the shell. The propulsion coil is arranged on the second insulating support positioning pad and the inner side of the propulsion coil is positioned by the horizontal positioning part of the second insulating support positioning pad. The first insulating support positioning pad is arranged at the four corners of the outside of the propulsion coil and in the non-insulated space in the middle of the propulsion coil. The shielding support plate is arranged on the first insulating support positioning pad and is connected to the high-voltage connector socket. The zero-magnetic flux coil is arranged on the shielding support plate and is positioned by the coil positioning part of the shielding support plate. The bolt bushing passes through the shielding support plate and protrudes a predetermined height from the surface of the shell.

[0007] Preferably, a first reinforcement layer is provided between the shell and the propulsion coil, and a second reinforcement layer is provided between the shell and the zero flux coil.

[0008] Preferably, the shielding support plate is a flat plate formed by composite pressing of an insulating glass fiber laminate and a conductive shielding layer, and the conductive shielding layer is conductively connected to the metal flange of the high-voltage connector socket through a wire.

[0009] Preferably, the second insulating support and positioning pad also includes an umbrella-shaped insulating positioning leg, which is arranged at the bottom of the insulating support and positioning pad for supporting and positioning the insulating support and positioning pad, and the umbrella-shaped insulating positioning leg includes an upper umbrella-shaped part and a lower cylindrical part.

[0010] Preferably, the second insulating support and positioning pad further includes an arc-shaped support portion for supporting the propulsion coil and forming linear contact with the propulsion coil.

[0011] Preferably, the shell, the first insulating support and positioning spacer, and the second insulating support and positioning spacer are made of resin.

[0012] The present invention also provides a method for manufacturing a ground stator module integrated with a suspension propulsion coil, the method comprising:

[0013] A second insulating support and positioning pad is provided at a first predetermined position in the casting mold, and a high-voltage connector socket is provided at a second predetermined position;

[0014] A propulsion coil is provided on the second insulating support and positioning pad, and the inner side of the propulsion coil is positioned by a horizontal positioning portion of the second insulating support and positioning pad;

[0015] First insulating support and positioning pads are provided at the four corners of the outer side of the propulsion coil and in the non-insulated space in the middle of the propulsion coil;

[0016] A shielding support plate is provided on the first insulating support and positioning pad, and the shielding support plate is connected to the high-voltage connector socket;

[0017] A zero magnetic flux coil is provided on the shielding support plate and the zero magnetic flux coil is positioned by a coil positioning portion of the shielding support plate;

[0018] providing a bolt bushing at a third predetermined position in the casting mold;

[0019] In the casting mold, the zero flux coil, shielding support plate, propulsion coil, bolt bushing, high-voltage connector socket, first insulating support positioning pad and second insulating support positioning pad are all integrally cast in the shell, wherein the bolt bushing passes through the shielding support plate and protrudes a predetermined height from the surface of the shell.

[0020] Preferably, the method further comprises:

[0021] providing a first strengthening layer between the bottom surface of the casting mold and the propulsion coil;

[0022] A second reinforcement layer is provided on the zero flux coil.

[0023] Preferably, providing a second insulating support positioning block at a first predetermined position in the casting mold includes:

[0024] The cylindrical portion of the umbrella-shaped insulating leg of the second insulating support positioning pad is arranged in the positioning countersunk hole at the first predetermined position in the casting mold, and the umbrella-shaped portion of the umbrella-shaped insulating leg is located outside the positioning countersunk hole.

[0025] Preferably, the second insulating support and positioning pad is further provided with an arc-shaped support portion, which supports the propulsion coil and forms a linear contact with the propulsion coil.

[0026] Through the above technical solution, the zero-flux coil and the propulsion coil in the integrated ground stator module are completely isolated in the thickness direction by the shielded support plate, and neither the zero-flux coil nor the propulsion coil requires the use of a coil skeleton for shaping, support and positioning, which greatly simplifies the internal structure and improves the insulation reliability; and it has the advantages of being simple and easy to implement and easy to maintain product consistency, and is suitable for fast and batch assembly production. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings are included to provide a further understanding of the embodiments of the present invention, constitute a part of the specification, illustrate the embodiments of the present invention, and together with the description, explain the principles of the present invention. Obviously, the drawings described below are only some embodiments of the present invention, and those skilled in the art can derive other drawings based on these drawings without inventive effort.

[0028] Figures 1A-1B A schematic diagram of a ground stator module integrated with a suspension propulsion coil according to an embodiment of the present invention is shown;

[0029] Figure 2 A schematic diagram of the insulating support and positioning structure of a propulsion coil according to an embodiment of the present invention is shown;

[0030] Figure 3 It shows a schematic structural diagram of a second insulating support and positioning spacer according to an embodiment of the present invention;

[0031] Figure 4 It shows a schematic diagram of the installation of a propulsion coil according to an embodiment of the present invention;

[0032] Figure 5 A schematic diagram of installing a bolt bushing and a shield support plate in a mold according to an embodiment of the present invention is shown;

[0033] Figure 6 A schematic diagram of assembling a zero flux coil and a surface strengthening layer in a mold according to an embodiment of the present invention is shown.

[0034] Description of Reference Numerals

[0035] 1 Epoxy resin housing; 2 Zero flux coil; 3 Shield support plate;

[0036] 4 Propulsion coil; 5 Bolt bushing; 6 High-voltage connector socket;

[0037] 7. First insulating support and positioning pad; 8. Second insulating support and positioning pad; 9. Casting mold;

[0038] 11 first strengthening layer; 12 second strengthening layer; 31 coil positioning portion;

[0039] 81 horizontal positioning portion; 82 umbrella-shaped insulating positioning leg; 83 arc-shaped supporting portion;

[0040] 91 bolt bushing locating pin; 92 boss. DETAILED DESCRIPTION

[0041] It should be noted that, in the absence of conflict, the embodiments in this application and the features in the embodiments can be combined with each other. The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings 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. The following description of at least one exemplary embodiment is actually only illustrative and is in no way intended to limit the present invention and its application or use. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0042] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0043] Unless otherwise specifically stated, the relative arrangement of the parts and steps, the numerical expressions and the numerical values ​​set forth in these embodiments do not limit the scope of the present invention. At the same time, it should be understood that, for ease of description, the sizes of the various parts shown in the drawings are not drawn according to the actual proportional relationship. The techniques, methods and equipment known to those of ordinary skill in the relevant art may not be discussed in detail, but where appropriate, the techniques, methods and equipment should be considered as part of the authorization specification. In all examples shown and discussed here, any specific values ​​should be interpreted as being merely exemplary and not as limiting. Therefore, other examples of the exemplary embodiments may have different values. It should be noted that similar numbers and letters represent similar items in the following figures, and therefore, once an item is defined in one figure, it does not need to be further discussed in subsequent figures.

[0044] Figures 1A-1B A schematic diagram of a ground stator module integrated with a suspension propulsion coil according to an embodiment of the present invention is shown. Figure 1A This is a schematic diagram of the zero flux coil part of the integrated ground stator module. Figure 1B Schematic diagram of the propulsion coil part of the integrated ground stator module.

[0045] As shown in Figures 1-6, an embodiment of the present invention provides a suspended propulsion coil integrated ground stator module, wherein the module includes a shell 1 and a zero magnetic flux coil 2, a shielding support plate 3, a propulsion coil 4, a bolt bushing 5, a high-voltage connector socket 6, a first insulating support positioning pad 7 and a second insulating support positioning pad 8, which are all integrally cast in the shell 1. The propulsion coil 4 is arranged on the second insulating support positioning pad 8 and the inner side of the propulsion coil 4 is positioned by the horizontal positioning portion 81 of the second insulating support positioning pad 8. The first insulating support positioning pad 7 is arranged at the four corners of the outside of the propulsion coil 4 and in the non-insulated space in the middle of the propulsion coil 4. The shielding support plate 3 is arranged on the first insulating support positioning pad 7 and is connected to the high-voltage connector socket 6. The zero magnetic flux coil 2 is arranged on the shielding support plate 3 and is positioned by the coil positioning portion 31 of the shielding support plate 3. The bolt bushing 5 passes through the shielding support plate 3 and protrudes a predetermined height from the surface of the shell 1.

[0046] Since the bolt bushing 5 is disposed through the shielding support plate 3, it can also provide a prefabricated support surface as an auxiliary support, together with the first insulating support positioning pad 7, to position and support the shielding support plate 3. By arranging the bolt bushing 5 to protrude from the surface of the housing 1 by a predetermined height, it can be ensured that the lower surface of the housing does not contact the installation wall surface.

[0047] Through the above technical solution, the zero-flux coil and the propulsion coil in the integrated ground stator module are completely isolated in the thickness direction by the shielded support plate, and neither the zero-flux coil nor the propulsion coil requires the use of a coil skeleton for shaping, support and positioning, which greatly simplifies the internal structure and improves the insulation reliability; and it has the advantages of being simple and easy to implement and easy to maintain product consistency, and is suitable for fast and batch assembly production.

[0048] For example, the zero-flux coil 2 can be an 8-shaped coil winding wound with a wire, with the upper and lower coil lead wires connected in parallel and led downward, thereby ensuring that the direction of the suspension current flows in opposite directions in the upper and lower coils. Taking Figure 1 as an example, the winding direction and current flow of the two 8-shaped coils are consistent. The propulsion coil 4 can be an ironless toroidal coil winding wound with a wire (i.e., a toroidal hollow coil), with the second insulating support and positioning pad 8 providing insulation distance at the bottom. The two lead wires of the propulsion coil 4 are led downward and connected to the integrally cast high-voltage connector socket.

[0049] According to one embodiment of the present invention, the coil positioning portion 31 may be a coil positioning pin, which is provided on the shielding support plate 3 . There may be multiple coil positioning pins, so that the zero flux coil can be positioned by multiple coil positioning pins.

[0050] According to one embodiment of the present invention, the horizontal positioning portion 81 may be a horizontal positioning pin, which is provided on the side of the second insulating support positioning pad 8, so that the propulsion coil can be positioned by the horizontal positioning pin.

[0051] According to one embodiment of the present invention, the bolt bushing 5 may be made of composite glass fiber insulation material, which is cast in the shell 1 and can transmit the alternating electromagnetic force generated by the zero flux coil 2 and the propulsion coil 4 to the fastening bolt.

[0052] According to one embodiment of the present invention, a first strengthening layer 11 is provided between the shell 1 and the propulsion coil 4 , and a second strengthening layer 12 is provided between the shell 1 and the zero flux coil 2 .

[0053] Specifically, through integrated casting, the first strengthening layer 11 and the second strengthening layer 12 and the shell 1 together constitute the surface strengthening layer of the integrated ground stator module.

[0054] For example, the first reinforcement layer and the second reinforcement layer may be glass fiber mesh cloth. The thickness of the first reinforcement layer and the second reinforcement layer may be set according to actual conditions, and the present invention is not limited thereto.

[0055] The module surface can be strengthened by providing the first strengthening layer and the second strengthening layer.

[0056] According to one embodiment of the present invention, the shielding support plate 3 is a flat plate formed by composite pressing of an insulating glass fiber laminate and a conductive shielding layer, and the conductive shielding layer is conductively connected to the metal flange of the high-voltage connector socket 6 through a wire.

[0057] The shielding support plate of the present invention can provide the flatness and hardness required for supporting the zero flux coil.

[0058] According to one embodiment of the present invention, Figure 3 As shown, the second insulating support and positioning pad 8 also includes an umbrella-shaped insulating positioning leg 82, which is arranged at the bottom of the insulating support and positioning pad 8 for supporting and positioning the insulating support and positioning pad 8. The umbrella-shaped insulating positioning leg 82 includes an upper umbrella-shaped part and a lower cylindrical part.

[0059] For example, the number of the umbrella-shaped insulating positioning legs 82 is greater than or equal to two.

[0060] By providing umbrella-shaped insulating positioning legs, the bonding area with the secondary casting resin and the insulation reliability can be improved.

[0061] According to one embodiment of the present invention, Figure 3 As shown, the second insulating support and positioning pad 8 further includes an arc-shaped support portion 83 for supporting the propulsion coil 4 and forming a line contact with the propulsion coil 4 .

[0062] According to an embodiment of the present invention, the housing 1 , the first insulating support and positioning spacer 7 , and the second insulating support and positioning spacer 8 are made of resin.

[0063] For example, the housing 1 is an epoxy resin housing, and the first insulating support and positioning pad 7 and the second insulating support and positioning pad 8 can also be made of the same epoxy resin material (formed by vacuum casting).

[0064] Using the same resin material can ensure the same insulation performance and thermal expansion coefficient as the resin shell.

[0065] An embodiment of the present invention further provides a method for manufacturing a ground stator module integrated with a suspension propulsion coil, wherein the method comprises:

[0066] S100, setting a second insulating support and positioning pad at a first predetermined position in the casting mold and a high-voltage connector socket at a second predetermined position;

[0067] S102, disposing a propulsion coil on the second insulating support and positioning pad, and positioning the inner side of the propulsion coil by a horizontal positioning portion of the second insulating support and positioning pad;

[0068] For example, the horizontal positioning portion on the side of the second insulating support and positioning pad buckles the inner side of the propulsion coil to position the propulsion coil.

[0069] Since the propulsion coil is generally wound in an inner-centered manner, the size and shape of its inner edge can be precisely controlled. Therefore, after all horizontal positioning parts fully buckle the inner edge of the propulsion coil 4, no additional position fine-tuning is required.

[0070] S104, disposing first insulating support and positioning blocks at the four corners of the outer side of the propulsion coil and in the non-insulated space in the middle of the propulsion coil;

[0071] For example, the casting mold includes bosses 92 at the center and four corners of the propulsion coil, which serve as support surfaces for the shield support plate and the zero-flux coil assembly. First insulating support and positioning blocks (prefabricated insulating blocks) of uniform thickness are placed on these bosses 92. These first insulating support and positioning blocks ensure the installation dimensions of the shield support plate in the thickness direction.

[0072] S106, arranging a shielding support plate on the first insulating support and positioning pad, and connecting the shielding support plate to the high-voltage connector socket;

[0073] S108, disposing a zero magnetic flux coil on the shielding support plate and positioning the zero magnetic flux coil through a coil positioning portion of the shielding support plate;

[0074] Among them, by arranging the zero flux coil on the positioned shielding support plate, the position accuracy in the thickness direction can be guaranteed.

[0075] S110, setting a bolt bushing at a third predetermined position in the casting mold;

[0076] The third predetermined position can be provided with a bolt bushing locating pin 91, which allows the installation position of all bolt bushings to be precisely fixed by the bolt bushing locating pin. The bolt bushing holes fit with the bolt bushing locating pin 91 prefabricated on the casting mold 9 with a small clearance, achieving reliable positioning. The bolt bushings can also have prefabricated bearing surfaces to serve as auxiliary supports for the shield support plate. Through holes are machined at corresponding positions on the bolt bushings and mated with the positioned bolt bushings, making the bolt bushings locating pins, thereby ensuring the insulation thickness and horizontal positional accuracy between the shield support plate and the propulsion coil.

[0077] S112, in the casting mold, the zero flux coil, the shielding support plate, the propulsion coil, the bolt bushing, the high-voltage connector socket, the first insulating support positioning pad and the second insulating support positioning pad are all integrally cast in the shell, wherein the bolt bushing passes through the shielding support plate and protrudes a predetermined height from the surface of the shell.

[0078] For example, a pre-formed countersunk hole of a predetermined thickness can be placed at the bottom of the casting mold 9 at each bolt bushing, creating a slight clearance between the outer cylindrical surface of the bolt bushing and the outer cylindrical surface of the bolt bushing. This ensures that the bottom surface of the bolt bushing protrudes a certain height from the lower surface of the mold after casting. By providing through-holes in the shield support plate corresponding to the bolt bushings, the bolt bushings can be inserted through the shield support plate. The through-holes and the outer cylindrical surface of the bolt bushings have a slight clearance, ensuring precise positioning in the plane.

[0079] Through the above technical solution, the zero-flux coil and the propulsion coil in the integrated ground stator module are completely isolated in the thickness direction by the shielded support plate, and neither the zero-flux coil nor the propulsion coil requires the use of a coil skeleton for shaping, support and positioning, which greatly simplifies the internal structure and improves the insulation reliability; and it has the advantages of being simple and easy to implement and easy to maintain product consistency, and is suitable for fast and batch assembly production.

[0080] According to one embodiment of the present invention, each propulsion coil is supported on four horizontal sides by at least four second insulating support positioning pads, so that the insulation distance between the propulsion coil and the bottom of the casting mold 9 and its installation position in the horizontal direction are accurately guaranteed.

[0081] That is, for a single propulsion coil, four or more second insulating support and positioning pads may be provided at the four corners / four sides to constrain all degrees of freedom of the propulsion coil.

[0082] The second insulating support positioning pads can be cast in batches using a mold, so the consistency of all propulsion coil positioning devices can be guaranteed during the production process.

[0083] According to one embodiment of the present invention, the coil positioning portion in S108 can be set by the following steps: prefabricating a plurality of positioning holes around the inner edge of the zero-flux coil on the precisely positioned shielding support plate; installing coil positioning portions (positioning pins or positioning blocks secured by the positioning pins) in the positioning holes; and completely securing the inner edge of the zero-flux coil via the coil positioning portions to ensure the horizontal position accuracy of the zero-flux coil. The inner edges of the upper and lower coils of the zero-flux coil are secured by corresponding coil positioning portions.

[0084] For example, each zero-flux coil can be equipped with at least four positioning pins or two integral positioning blocks secured by these pins to reliably constrain the zero-flux coil's planar directional degrees of freedom. Because the zero-flux coils are also wound using an internally centered method, this positioning method ensures accurate positioning and consistency.

[0085] According to one embodiment of the present invention, the method further includes:

[0086] providing a first strengthening layer between the bottom surface of the casting mold and the propulsion coil;

[0087] A second strengthening layer is provided on the zero flux coil (ie, the upper surface, the side not opposite to the shielding support layer).

[0088] The first reinforcement layer and the second reinforcement layer may be glass fiber mesh cloths. The thickness of the first reinforcement layer and the second reinforcement layer may be set according to actual conditions, and the present invention is not limited thereto.

[0089] After the upper mold plate is closed, the fiberglass mesh is completely constrained in the thickness direction to ensure that it is entirely on the outer surface of the module. Through integrated casting, the first and second reinforcement layers and the shell together constitute the surface reinforcement layer of the integrated ground stator module.

[0090] According to one embodiment of the present invention, providing a second insulating support positioning block at a first predetermined position in the casting mold includes:

[0091] The cylindrical portion of the umbrella-shaped insulating leg of the second insulating support positioning pad is arranged in the positioning countersunk hole at the first predetermined position in the casting mold, and the umbrella-shaped portion (arc-shaped umbrella-shaped portion) of the umbrella-shaped insulating leg is located outside the positioning countersunk hole.

[0092] Specifically, the bottom cylindrical portion of the umbrella-shaped insulating leg is directly inserted into the positioning countersunk hole on the bottom surface of the casting mold 9, with a small clearance fit. The two or more umbrella-shaped insulating legs in each second insulating support positioning block ensure the positioning and installation stability of the second insulating support positioning block. The curved umbrella-shaped surface above the cylindrical portion of the umbrella-shaped insulating leg also compresses the first reinforcement layer 11, preventing it from floating during casting.

[0093] Among them, the positioning countersunk holes can be pre-opened on the bottom surface of the casting mold to cooperate with the umbrella-shaped insulating positioning legs at the bottom of the second insulating support positioning pad to ensure the consistency of the installation position of the second insulating support positioning pad in each module.

[0094] According to one embodiment of the present invention, the second insulating support and positioning pad is further provided with an arc-shaped support portion, and the arc-shaped support portion supports the propulsion coil and forms a linear contact with the propulsion coil.

[0095] Through the linear contact between the arc-shaped support portion and the propulsion coil, the resin can be fully immersed in the support surface during resin pouring, thereby avoiding insulation defects such as cavitation on the support surface.

[0096] According to one embodiment of the present invention, the method further includes arranging a glass fiber mesh cloth of predetermined thickness between the zero flux coil and the shielding support plate to strengthen the bonding surface after pouring, thereby ensuring reliable bonding with the resin during pouring.

[0097] Those skilled in the art should understand that the above descriptions of materials and quantities are merely exemplary and are not intended to limit the present invention.

[0098] It can be seen from the above embodiments that the present invention has at least the following advantages compared to the prior art:

[0099] 1) The structural assembly of the integrated ground stator module described in the present invention eliminates the need for coil bobbins for shaping, supporting, and positioning the zero-flux coil and the propulsion coil, greatly simplifying the internal structure and improving insulation reliability.

[0100] 2) The positioning and support of each coil and component in this structural assembly are implemented only by the lower mold and not by the upper mold, which reduces the requirements for the coordination of the upper and lower molds;

[0101] 3) The support and positioning of each component in this structural assembly only requires the support positioning parts to be precisely matched with the prefabricated positioning pins and holes on their foundation. No post-installation fine-tuning device is required, which greatly saves assembly time. The positioning references of each component from bottom to top are all machined casting molds, which can ensure that all components have high internal positioning accuracy.

[0102] In the description of the present invention, it should be understood that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "horizontal, vertical, perpendicular, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention; the directional words "inside and outside" refer to the inside and outside relative to the outline of each component itself.

[0103] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used herein to describe the spatial positional relationship of a device or feature to other devices or features as shown in the figures. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figures. For example, if the device in the drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0104] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.

[0105] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A ground stator module integrated with a suspension propulsion coil, characterized in that: The module comprises a shell (1) and a zero-flux coil (2), a shielding support plate (3), a propulsion coil (4), a bolt bushing (5), a high-voltage connector socket (6), a first insulating support positioning pad (7) and a second insulating support positioning pad (8) all integrally cast in the shell (1); the propulsion coil (4) is arranged on the second insulating support positioning pad (8) and the inner side of the propulsion coil (4) is positioned by a horizontal positioning portion (81) of the second insulating support positioning pad (8); the first insulating support positioning pad (7) is arranged at the four corners of the outer side of the propulsion coil (4) and in a non-insulated space in the middle of the propulsion coil (4); the shielding support plate (3) is arranged on the first insulating support positioning pad (7) and connected to the high-voltage connector socket (6); the zero-flux coil (2) is arranged on the shielding support plate (3) and positioned by the coil positioning portion (31) of the shielding support plate (3); the bolt bushing (5) passes through the shielding support plate (3) and protrudes to a predetermined height from the surface of the shell (1); The shielding support plate (3) is a flat plate formed by composite pressing of an insulating glass fiber laminate and a conductive shielding layer, and the conductive shielding layer is conductively connected to the metal flange of the high-voltage connector socket (6) via a wire; The second insulating support and positioning pad (8) further comprises an umbrella-shaped insulating positioning leg (82), which is arranged at the bottom of the insulating support and positioning pad (8) and is used to support and position the insulating support and positioning pad (8), wherein the umbrella-shaped insulating positioning leg (82) comprises an upper umbrella-shaped portion and a lower cylindrical portion; The second insulating support and positioning pad (8) further includes an arc-shaped support portion (83) for supporting the propulsion coil (4) and forming a line contact with the propulsion coil (4).

2. The module according to claim 1, wherein: A first strengthening layer (11) is provided between the shell (1) and the propulsion coil (4), and a second strengthening layer (12) is provided between the shell (1) and the zero magnetic flux coil (2).

3. The module according to claim 1 or 2, characterized in that: The shell (1), the first insulating support and positioning pad (7), and the second insulating support and positioning pad (8) are made of resin.

4. A method for manufacturing a ground stator module integrated with a levitation propulsion coil according to claim 1, characterized in that: The method includes: A second insulating support and positioning pad is provided at a first predetermined position in the casting mold, and a high-voltage connector socket is provided at a second predetermined position; A propulsion coil is provided on the second insulating support and positioning pad, and the inner side of the propulsion coil is positioned by a horizontal positioning portion of the second insulating support and positioning pad; First insulating support and positioning pads are provided at the four corners of the outer side of the propulsion coil and in the non-insulated space in the middle of the propulsion coil; A shielding support plate is provided on the first insulating support and positioning pad, and the shielding support plate is connected to the high-voltage connector socket; A zero magnetic flux coil is provided on the shielding support plate and the zero magnetic flux coil is positioned by a coil positioning portion of the shielding support plate; providing a bolt bushing at a third predetermined position in the casting mold; In the casting mold, the zero flux coil, the shielding support plate, the propulsion coil, the bolt bushing, the high-voltage connector socket, the first insulating support positioning pad and the second insulating support positioning pad are all integrally cast into the shell, wherein the bolt bushing passes through the shielding support plate and protrudes from the surface of the shell by a predetermined height; Providing a second insulating support positioning pad at a first predetermined position in the casting mold includes: The cylindrical portion of the umbrella-shaped insulating leg of the second insulating support positioning pad is arranged in the positioning countersunk hole at the first predetermined position in the casting mold, and the umbrella-shaped portion of the umbrella-shaped insulating leg is located outside the positioning countersunk hole; The second insulating support and positioning pad is further provided with an arc-shaped support portion, which supports the propulsion coil and forms a linear contact with the propulsion coil.

5. The method according to claim 4, characterized in that The method further includes: providing a first strengthening layer between the bottom surface of the casting mold and the propulsion coil; A second reinforcement layer is provided on the zero flux coil.

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