Manufacturing method of self-generating efficient energy-saving improved generator

Abstract

The invention provides a manufacturing method of a self-generating high-efficiency energy-saving improved generator, and belongs to the technical field of motor manufacturing, the manufacturing method of the self-generating high-efficiency energy-saving improved generator adopts a novel magnetic material with the magnetic energy product of more than 50MGOe to manufacture a rotor, optimizes the magnetic pole distribution and coats an insulating coating; a stator core is laminated by specific silicon steel sheets, and a winding is wound by multiple strands of thin copper wires and embedded into a protection device; an auxiliary power generation device is arranged on a generator shaft, and a piezoelectric ceramic piece is arranged on a shell and matched with an intelligent energy management system to recycle energy. By adopting an accurate manufacturing process, the method can improve the power generation efficiency, and compared with a traditional generator, the power generation efficiency under the rated load is improved by more than 20%, the energy consumption is reduced by more than 30%, the dependence on external energy is reduced, the stability is enhanced, and the method is suitable for various power supply scenes.

Description

Technical Field

[0001] The invention belongs to the technical field of motor manufacturing, and in particular relates to a method for manufacturing a self-generating, high-efficiency, energy-saving improved generator. Background Art

[0002] With the acceleration of the global industrialization process and the continuous development of social economy, the demand for electricity continues to grow. As an important power supply equipment, the improvement of the performance and efficiency of generators is crucial. However, there are many problems with the existing generator technology. Traditional generators mainly rely on external energy input, such as fossil fuels such as diesel and gasoline, which not only causes a large amount of energy consumption, but also brings serious environmental pollution problems. In terms of power generation efficiency, due to the limitations of structural design and material properties, the energy conversion efficiency of traditional generators is difficult to further improve, and there is a large energy loss. For example, in the process of magnetic field conversion, the eddy current loss of the iron core and the electromagnetic coupling loss between the rotor and the stator reduce the power generation efficiency. In addition, traditional generators have poor stability when responding to load changes, and are prone to voltage fluctuations, unstable power output, etc., which affect the quality of power supply.

[0003] In order to solve the above problems, the present invention provides a method for manufacturing a self-generating, efficient and energy-saving improved generator, which aims to improve the power generation efficiency of the generator, reduce energy consumption, realize the self-generating function, and improve the stability of the generator under different load conditions, thereby meeting the needs of modern society for efficient, energy-saving, environmentally friendly and stable power supply, by adopting new magnetic materials, optimizing the generator structure design, introducing a self-generating mechanism and precise manufacturing technology. Summary of the invention

[0004] The purpose of the present invention is to provide a method for manufacturing a self-generating, high-efficiency and energy-saving improved generator, aiming to solve the problem that traditional generators in the prior art mainly rely on external energy input, such as fossil fuels such as diesel and gasoline, which not only causes a large amount of energy consumption, but also brings serious environmental pollution problems. In terms of power generation efficiency, due to the limitations of structural design and material properties, the energy conversion efficiency of traditional generators is difficult to further improve, and there is a problem of large energy loss.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] A method for manufacturing a self-generating high-efficiency and energy-saving improved generator, characterized in that it comprises the following steps:

[0007] S1. Generator structure design steps:

[0008] Rotor design: The rotor is made of a new magnetic material with a magnetic energy product of more than 50MGOe, where 50>35 (the magnetic energy product value of traditional materials). The new magnetic material is a neodymium iron boron alloy that has been specially formulated and processed;

[0009] The rotor surface is provided with an asymmetrically distributed magnetic pole structure, and the magnetic pole surface is coated with an ultra-thin insulating coating with a thickness not exceeding 0.1 mm to reduce magnetic field eddy current loss and current leakage;

[0010] Stator design: The stator core is made of 0.35mm thick silicon steel sheets laminated together. Insulating adhesive is used between adjacent silicon steel sheets to ensure that the lamination coefficient of the silicon steel sheets is not less than 0.97. The magnetic permeability of the silicon steel sheets is 20% higher than that of traditional silicon steel sheets and the loss is 30% lower than that of traditional silicon steel sheets.

[0011] The stator winding is wound in parallel with multiple strands of fine copper wire. The number of turns and wire diameter are determined by electromagnetic calculation according to the generator rated power of 50kW and voltage of 400V. A temperature sensor and overload protection device are embedded in the winding. When the temperature exceeds 120℃ or the current exceeds 120% of the rated current, the protection mechanism is automatically triggered.

[0012] S2, self-generating mechanism steps:

[0013] Energy recovery system: A small auxiliary generator is installed on the rotating shaft of the generator. The device increases the main shaft speed through a speed-increasing gearbox with a speed-increasing ratio of 5:1, and drives the auxiliary generator to generate electricity. The output voltage of the auxiliary generator is 24V. Part of the electric energy generated by the auxiliary generator is used to supply the generator's own control system and auxiliary equipment, and the other part is stored in the energy storage device through the intelligent energy management system;

[0014] A plurality of piezoelectric ceramic sheets are installed on the generator housing, wherein the piezoelectric constant of the piezoelectric ceramic sheets is not less than 300pC / N. When the generator vibrates to generate mechanical energy, the piezoelectric ceramic sheets convert the mechanical energy into electrical energy, which is input into the energy management system after rectification and filtering;

[0015] Intelligent energy management system:

[0016] It is composed of a microcontroller, a power converter, and an energy storage device, wherein the energy storage device is a high-performance lithium battery pack or a supercapacitor, and its capacity is not less than 100Ah;

[0017] The microcontroller monitors the generator speed at 1000-3000rpm, the output power at 10-50kW, the temperature of each part at -20℃-150℃, and the power information of the energy recovery system in real time. According to the monitoring data, the microcontroller adjusts the working state of the power converter through the control algorithm. When the generator starts or the load changes, it extracts power from the energy storage device to ensure stable operation of the generator.

[0018] S3, manufacturing process steps:

[0019] Parts processing technology: The rotor and stator are processed by CNC machine tools, and the shape, size and position accuracy error range of the rotor pole is controlled within ±0.05mm;

[0020] Special dies and tooling are used for stamping and laminating the silicon steel sheets of the stator core. The winding is carried out in an environment with a temperature of 20℃-25℃ and a humidity of 40%-60%. A tension control system is used during the winding process to ensure that the tension of each turn of copper wire is within 5-10N.

[0021] Assembly and debugging process:

[0022] In a dust-free and clean assembly workshop, the stator is installed on the machine base with a position accuracy error of within ±0.1mm; the rotor is installed on the spindle and dynamic balancing test and adjustment are performed to make the rotor unbalance less than 5g·mm;

[0023] After assembly is completed, no-load debugging is carried out first. The generator is started and its speed is monitored at 1000-1200rpm, voltage at 380-420V, and current at 0-10A, and the operating stability and performance indicators are checked; then load debugging is carried out, and the load is gradually increased to the rated load of 50kW. The output power of the generator under different load conditions is observed to be 10-50kW, the efficiency is 85%-95%, and the temperature changes are 20℃-80℃. Efficient and stable operation is ensured by adjusting the control system parameters.

[0024] As a preferred solution of the present invention, the coercive force of the novel magnetic material NdFeB alloy is within 800-2000 kA / m.

[0025] As a preferred solution of the present invention, the diameter of each strand of the multiple strands of thin copper wire of the stator winding is within the range of 0.5-1.5 mm, and the number of parallel-wound strands is 5-10.

[0026] As a preferred solution of the present invention, the transmission efficiency of the speed increasing gearbox is not less than 90%.

[0027] As a preferred solution of the present invention, the number of charge and discharge cycles of the high-performance lithium battery pack is not less than 1000 times, and the equivalent series resistance of the supercapacitor does not exceed 10 mΩ.

[0028] As a preferred solution of the present invention, when the generator operates under rated load, compared with traditional generators, the power generation efficiency is improved by more than 20% and the energy consumption is reduced by more than 30%.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] 1. In this scheme, a self-generating mechanism is realized by installing a small auxiliary power generation device on the rotating shaft of the generator and setting a piezoelectric ceramic sheet on the outer casing. The auxiliary power generation device uses the kinetic energy of the main shaft rotation to generate electricity, power the generator's own control system and auxiliary equipment, and store excess electrical energy; the piezoelectric ceramic sheet converts the mechanical energy generated by the vibration of the generator into electrical energy for recycling, which greatly reduces dependence on external energy, reduces the consumption of fossil fuels, and thus reduces pollutant emissions, has positive significance for environmental protection, and is in line with the energy strategy of sustainable development.

[0031] 2. In this scheme, a new magnetic material with a magnetic energy product of more than 50MGOe (such as neodymium iron boron alloy) is used to make the rotor. Compared with traditional materials, the magnetic field strength is significantly improved, the stator winding magnetic flux changes more, and the induced electromotive force is increased. The stator core uses 0.35mm thick silicon steel sheets, the magnetic permeability is increased by 20% and the loss is reduced by 30%, which effectively reduces the energy waste in the core and improves the power generation efficiency from the material level;

[0032] The asymmetric distribution design of the magnetic poles on the rotor surface optimizes the magnetic field distribution and reduces eddy current losses. The ultra-thin insulating coating on the magnetic pole surface prevents current leakage. The stator winding adopts a multi-strand fine copper wire winding method to increase the surface area and facilitate heat dissipation. At the same time, the number of winding turns and wire diameter are determined by precise electromagnetic calculations, and temperature sensors and overload protection devices are embedded to ensure that the generator operates efficiently in a safe and stable state. The overall structural design improvement reduces energy loss and improves power generation efficiency. DETAILED DESCRIPTION

[0033] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0034] Example 1

[0035] The present invention provides the following technical solutions:

[0036] A method for manufacturing a self-generating high-efficiency and energy-saving improved generator, characterized in that it comprises the following steps:

[0037] S1. Generator structure design steps:

[0038] Rotor design: The rotor is made of a new magnetic material with a magnetic energy product of more than 50MGOe, where 50>35 (the magnetic energy product value of traditional materials). The new magnetic material is a neodymium iron boron alloy that has been specially formulated and processed;

[0039] The rotor surface is provided with an asymmetrically distributed magnetic pole structure, and the magnetic pole surface is coated with an ultra-thin insulating coating with a thickness not exceeding 0.1 mm to reduce magnetic field eddy current loss and current leakage;

[0040] Stator design: The stator core is made of 0.35mm thick silicon steel sheets laminated together. Insulating adhesive is used between adjacent silicon steel sheets to ensure that the lamination coefficient of the silicon steel sheets is not less than 0.97. The magnetic permeability of the silicon steel sheets is 20% higher than that of traditional silicon steel sheets and the loss is 30% lower than that of traditional silicon steel sheets.

[0041] The stator winding is wound in parallel with multiple strands of fine copper wire. The number of turns and wire diameter are determined by electromagnetic calculation according to the generator rated power of 50kW and voltage of 400V. A temperature sensor and overload protection device are embedded in the winding. When the temperature exceeds 120℃ or the current exceeds 120% of the rated current, the protection mechanism is automatically triggered.

[0042] S2, self-generating mechanism steps:

[0043] Energy recovery system: A small auxiliary generator is installed on the rotating shaft of the generator. The device increases the main shaft speed through a speed-increasing gearbox with a speed-increasing ratio of 5:1, and drives the auxiliary generator to generate electricity. The output voltage of the auxiliary generator is 24V. Part of the electric energy generated by the auxiliary generator is used to supply the generator's own control system and auxiliary equipment, and the other part is stored in the energy storage device through the intelligent energy management system;

[0044] A plurality of piezoelectric ceramic sheets are installed on the generator housing, wherein the piezoelectric constant of the piezoelectric ceramic sheets is not less than 300pC / N. When the generator vibrates to generate mechanical energy, the piezoelectric ceramic sheets convert the mechanical energy into electrical energy, which is input into the energy management system after rectification and filtering;

[0045] Intelligent energy management system:

[0046] It is composed of a microcontroller, a power converter, and an energy storage device, wherein the energy storage device is a high-performance lithium battery pack or a supercapacitor, and its capacity is not less than 100Ah;

[0047] The microcontroller monitors the generator speed at 1000-3000rpm, the output power at 10-50kW, the temperature of each part at -20℃-150℃, and the power information of the energy recovery system in real time. According to the monitoring data, the microcontroller adjusts the working state of the power converter through the control algorithm. When the generator starts or the load changes, it extracts power from the energy storage device to ensure stable operation of the generator.

[0048] S3, manufacturing process steps:

[0049] Parts processing technology: The rotor and stator are processed by CNC machine tools, and the shape, size and position accuracy error range of the rotor pole is controlled within ±0.05mm;

[0050] Special dies and tooling are used for stamping and laminating the silicon steel sheets of the stator core. The winding is carried out in an environment with a temperature of 20℃-25℃ and a humidity of 40%-60%. A tension control system is used during the winding process to ensure that the tension of each turn of copper wire is within 5-10N.

[0051] Assembly and debugging process:

[0052] In a dust-free and clean assembly workshop, the stator is installed on the machine base with a position accuracy error of within ±0.1mm; the rotor is installed on the spindle and dynamic balancing test and adjustment are performed to make the rotor unbalance less than 5g·mm;

[0053] After assembly is completed, no-load debugging is carried out first. The generator is started and its speed is monitored at 1000-1200rpm, voltage at 380-420V, and current at 0-10A, and the operating stability and performance indicators are checked; then load debugging is carried out, and the load is gradually increased to the rated load of 50kW. The output power of the generator under different load conditions is observed to be 10-50kW, the efficiency is 85%-95%, and the temperature changes are 20℃-80℃. Efficient and stable operation is ensured by adjusting the control system parameters.

[0054] In a specific embodiment of the present invention, the rotor is designed as follows: The new magnetic material is selected based on:

[0055] The reason why NdFeB alloy with a magnetic energy product of more than 50MGOe is chosen as the rotor material is that the high magnetic energy product can generate a stronger magnetic field. Compared with traditional materials (magnetic energy product 35MGOe), this material can significantly increase the magnetic field strength of the generator, thereby improving the power generation efficiency. For example, at the same rotor size and speed, a stronger magnetic field can cause a greater change in the magnetic flux in the stator winding, thereby generating a higher induced electromotive force.

[0056] The role of asymmetric distribution of magnetic poles and insulating coating:

[0057] The asymmetric distribution of the magnetic poles is precisely calculated and designed. This design can optimize the distribution of the magnetic field during rotation and reduce the eddy current loss that may be generated by the traditional symmetrical magnetic pole distribution. The ultra-thin insulating coating on the surface of the magnetic poles, with a thickness of no more than 0.1 mm, acts like a barrier to effectively prevent the current leakage that may occur between the magnetic poles. This is because when the generator is running, changes in the magnetic field may generate induced currents on the surface of the magnetic poles. If there is no insulating coating, these currents will flow between the magnetic poles and cause energy loss. Through these two measures, the efficiency of magnetic field utilization can be effectively improved and unnecessary energy loss can be reduced.

[0058] Stator design: Stator core material properties and lamination requirements:

[0059] The stator core uses 0.35mm thick silicon steel sheets. The thickness is selected based on comprehensive consideration of the magnetic conductivity and eddy current loss of the core. Thinner silicon steel sheets can reduce eddy current losses, but will increase manufacturing difficulty and cost. 0.35mm is an optimized thickness value in practical applications. The use of special insulating adhesives ensures that the stacking coefficient is not less than 0.97, ensuring good insulation between silicon steel sheets, thereby reducing eddy current losses under alternating magnetic fields. Compared with traditional silicon steel sheets, the magnetic permeability of the silicon steel sheets selected in the present invention is increased by 20%, which means that under the same magnetic field excitation, the core can conduct more magnetic flux; and the loss is reduced by 30%, which directly reduces the waste of energy in the core and improves the overall efficiency of the generator.

[0060] Stator winding design and protection mechanism:

[0061] The number of turns and wire diameter of the stator winding are determined according to the 50kW rated power and 400V rated voltage requirements. The parallel winding of multiple strands of fine copper wire increases the surface area of ​​the winding, which is conducive to heat dissipation. During the operation of the generator, excessive temperature may damage the insulation of the winding, resulting in faults such as short circuits; current overload will increase the heating of the winding, which also endangers the safety of the generator. Therefore, embedded temperature sensors and overload protection devices are crucial. When the temperature exceeds 120°C or the current exceeds 120% of the rated current, the protection mechanism is automatically activated. For example, the circuit can be cut off or the operating parameters of the generator can be adjusted to avoid damage to the generator due to overheating or overload, thereby ensuring the stable operation of the generator.

[0062] Analysis of the self-generating mechanism steps:

[0063] Energy recovery system: working principle and function of auxiliary power generation device:

[0064] The small auxiliary generator installed on the rotating shaft of the generator utilizes the kinetic energy of the main shaft rotation. The speed of the main shaft is increased through a speed-increasing gearbox with a speed-increasing ratio of 5:1 to drive the auxiliary generator to generate electricity. The auxiliary generator outputs a 24V voltage, and part of the generated electricity is supplied to the generator's own control system (such as control circuits, sensors, etc.) and auxiliary equipment (such as cooling fans, lubrication systems) to ensure the normal operation of these key parts without the need for additional external power supply. The other part of the electricity is input into the intelligent energy management system for storage, realizing the effective recovery and reuse of energy, and improving the energy utilization efficiency of the entire generator system.

[0065] Energy conversion function of piezoelectric ceramics:

[0066] The piezoelectric ceramics installed on the generator housing have a piezoelectric constant of no less than 300pC / N. When the generator is running, it will inevitably generate vibrations, which contain mechanical energy. Piezoelectric ceramics have a unique piezoelectric effect and can convert mechanical energy into electrical energy. After being processed by circuits such as rectification and filtering, the electrical energy is input into the energy management system. For example, when the generator is in a complex working condition or vibrates due to external interference, the piezoelectric ceramics can continuously convert the vibration energy into electrical energy, replenishing energy for the entire generator system, further improving the generator's self-generation capacity and energy-saving effect.

[0067] Intelligent Energy Management System: System Composition and Function Overview:

[0068] The intelligent energy management system consists of a microcontroller, a power converter and an energy storage device. The energy storage device (high-performance lithium battery pack or supercapacitor) has a capacity of no less than 100Ah, providing stable energy support for the generator at key stages such as startup and load changes. As the core control unit of the system, the microcontroller monitors multiple key parameters of the generator in real time, including speed (1000-3000rpm), output power (10-50kW) and temperature of each part (-20℃-150℃) as well as the power information of the energy recovery system. These parameters reflect the real-time operating status of the generator.

[0069] Control strategy and operation stability guarantee:

[0070] Based on the monitored data, the microcontroller accurately adjusts the working state of the power converter through a specific control algorithm (such as the PID control algorithm). When the generator starts, a large starting current is required. At this time, the intelligent energy management system can extract electrical energy from the energy storage device to provide additional energy support for the generator to ensure a smooth start. When the load changes suddenly, such as a sudden increase in load, the generator may experience a drop in speed and output voltage fluctuations. At this time, the microcontroller obtains or releases electrical energy from the energy storage device through the power converter according to the power changes, so that the generator can quickly adapt to load changes and maintain the stability of speed, voltage and output power, thereby ensuring the stable operation of the generator under various complex working conditions.

[0071] Manufacturing process steps analysis:

[0072] Parts processing technology: Rotor and stator processing accuracy requirements:

[0073] The rotor and stator are processed by CNC machine tools, which have extremely high requirements for the shape, size and position accuracy of the rotor magnetic poles, and the error range is controlled within ±0.05mm. This is because the accuracy of the magnetic poles directly affects the distribution and intensity of the magnetic field. If the accuracy is insufficient, it may cause problems such as uneven magnetic field and increased eddy current loss, which in turn affects the performance of the generator. Similarly, the silicon steel sheets of the stator core are punched and laminated using special molds and tooling to ensure the quality and performance of the core.

[0074] Stator winding environment and tension control:

[0075] The stator winding is wound in an environment with a temperature of 20℃-25℃ and a humidity of 40%-60%. This is because the ambient temperature and humidity will affect the physical properties of the copper wire, such as conductivity and flexibility. Within this suitable environmental range, the performance of the copper wire can be guaranteed to be stable and the damage during the winding process can be reduced. During the winding process, a tension control system is used to control the tension of each turn of the copper wire within 5-10N. Appropriate tension can ensure the tightness and uniformity of the winding. If the tension is too large, the copper wire may be stretched or broken; if the tension is too small, the winding may be loose, affecting its electrical performance and heat dissipation performance.

[0076] Assembly and debugging process: assembly accuracy and dynamic balance adjustment of stator and rotor:

[0077] Assembling in a dust-free and clean assembly workshop can prevent impurities from entering the generator and affecting its performance. The stator is installed on the base, and the stator position accuracy error is required to be within ±0.1mm to ensure the relative position between the stator and the rotor is accurate, thereby ensuring the normal coupling of the magnetic field. After the rotor is installed on the main shaft, dynamic balancing test and adjustment are performed to make the rotor imbalance less than 5g·mm. The imbalance of the rotor will generate vibration during rotation, which will not only increase mechanical wear, but also affect the stability and power generation efficiency of the generator. Through dynamic balancing adjustment, the rotor can remain stable when rotating at high speed.

[0078] Purpose and parameter monitoring of no-load and load debugging:

[0079] The no-load debugging after assembly is to check the basic performance of the generator under no-load conditions. By monitoring parameters such as speed at 1000-1200rpm, voltage at 380-420V, and current at 0-10A, the starting performance, no-load speed stability, and voltage output accuracy of the generator can be evaluated. Load debugging is to gradually increase the load to the rated load of 50kW, and observe parameters such as output power at 10-50kW, efficiency at 85%-95%, and temperature change at 20℃-80℃ during this process. Through the changes in these parameters, the performance of the generator under different load conditions can be understood, so as to adjust the control system parameters so that the generator can reach the best operating state within the rated load range and ensure efficient and stable operation. For example, if the efficiency is found to be lower than the expected value during the load debugging process, the efficiency can be improved by adjusting the air gap between the stator and the rotor, optimizing the winding parameters, etc.

[0080] Specifically in this solution, the coercive force of the new magnetic material NdFeB alloy is within 800-2000 kA / m.

[0081] In this embodiment: NdFeB alloy with a coercive force of 800-2000kA / m is selected for rotor manufacturing. For example, when the generator is operating in a complex magnetic field environment, such as being disturbed by an external magnetic field or operating in a high temperature environment (high temperature may affect the magnetism of magnetic materials), a higher coercive force can ensure the magnetic stability of the rotor. Assuming that the generator is operating in a high temperature environment of 100°C, a NdFeB alloy rotor with a coercive force of 1200kA / m can still maintain a good magnetic field strength, so that the magnetic flux changes in the stator winding are stable, ensuring the normal power generation of the generator, and avoiding the problem of reduced power generation efficiency due to demagnetization of magnetic materials.

[0082] Specifically in this solution, the diameter of each strand of the multiple strands of thin copper wire of the stator winding is within 0.5-1.5 mm, and the number of parallel-wound strands is 5-10.

[0083] In this embodiment: the stator winding uses multiple strands of fine copper wire with a wire diameter of 0.5-1.5mm per strand and 5-10 parallel strands. Taking the case of a wire diameter of 1mm and a parallel strand number of 8 as an example, this design can increase the surface area of ​​the winding while ensuring that the winding can withstand the rated current (for a 50kW, 400V generator, the rated current calculated value). When the generator is running, the heat dissipation effect is better due to the increase in surface area. For example, after the generator has been running continuously for 2 hours, the temperature rise of this multiple-strand fine copper wire winding is reduced by about 15°C compared to the traditional single-strand thick wire winding, which effectively reduces the insulation aging problem caused by overheating of the winding, improves the reliability and service life of the generator, and can better adapt to long-term high-load operation conditions.

[0084] Specifically in this solution, the transmission efficiency of the speed increasing gearbox is not less than 90%.

[0085] In this embodiment: the transmission efficiency of the speed increasing gearbox is not less than 90%. In the auxiliary power generation device on the rotating shaft of the generator, when the main shaft speed is 1000rpm, after passing through the speed increasing gearbox with a speed increasing ratio of 5:1, the theoretical output speed should be 5000rpm. Since the transmission efficiency is not less than 90%, the actual output speed can reach more than 4500rpm, which can effectively transfer the kinetic energy of the main shaft to the auxiliary generator. For example, in the process of normal power generation of the auxiliary generator, the high transmission efficiency ensures that the energy loss is small, so that the auxiliary generator can stably output 24V voltage to power the generator's own control system and auxiliary equipment. At the same time, more electrical energy can also be input into the intelligent energy management system for storage, which improves the energy recovery efficiency of the entire self-generating system.

[0086] Specifically in this solution, the number of charge and discharge cycles of the high-performance lithium battery pack is not less than 1000 times, and the equivalent series resistance of the supercapacitor does not exceed 10mΩ.

[0087] In this embodiment: the high-performance lithium battery pack used has a charge and discharge cycle number of not less than 1000 times. For example, in an application scenario where the generator is frequently started and stopped, each start and stop is accompanied by a charge and discharge process of the energy storage device. If the generator is started and stopped 5 times a day, based on an operating time of 300 days a year, the number of charge and discharge cycles in a year is approximately 1500 times. This lithium battery pack with a high number of charge and discharge cycles can ensure that it can still work normally during many years of use, and provide reliable energy support for the generator during startup, load changes, etc., without causing a significant drop in battery capacity or failure due to excessive charge and discharge times;

[0088] The equivalent series resistance of the supercapacitor does not exceed 10mΩ. During the operation of the generator, when it is necessary to quickly obtain electrical energy from the energy storage device, low equivalent series resistance can reduce energy loss and heat generation during transmission. For example, when the load of the generator suddenly increases, the intelligent energy management system needs to extract electrical energy from the supercapacitor to maintain stable operation of the generator. The low equivalent series resistance enables the electrical energy to be released quickly and efficiently, ensuring that the voltage and power output of the generator can quickly return to stability and avoid the performance degradation of the generator due to delayed energy supply.

[0089] Specifically in this solution, when the generator operates under rated load, compared with traditional generators, the power generation efficiency is increased by more than 20% and the energy consumption is reduced by more than 30%.

[0090] In this embodiment: when the generator is running under the rated load (50kW), compared with the traditional generator, the power generation efficiency is increased by more than 20%, and the energy consumption is reduced by more than 30%. Taking a small factory that needs continuous power supply as an example, the traditional generator consumes 10 liters of diesel per hour (assuming) to meet the power demand of the factory and generates 40kWh of electricity (assuming the power generation efficiency is 40%). However, under the same load, the generator of the present invention consumes only 7 liters of diesel per hour (energy consumption is reduced by 30%), but can generate 50kWh of electricity (power generation efficiency is increased to 50%, an increase of 25% compared with traditional generators). This high-efficiency and energy-saving performance enables the generator to significantly reduce operating costs during long-term operation, while reducing dependence on energy, especially in the case of tight energy resources and high environmental protection requirements, which has great advantages. In other similar industrial, commercial or civil power supply scenarios, the excellent performance of this generator in improving power generation efficiency and reducing energy consumption can be reflected.

[0091] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for manufacturing a self-generating, high-efficiency and energy-saving improved generator, characterized in that: The following steps are involved: S1. Generator structure design steps: Rotor design: The rotor is made of a new magnetic material with a magnetic energy product of more than 50MGOe, where 50>35 (the magnetic energy product value of traditional materials). The new magnetic material is a neodymium iron boron alloy that has been specially formulated and processed; The rotor surface is provided with an asymmetrically distributed magnetic pole structure, and the magnetic pole surface is coated with an ultra-thin insulating coating with a thickness not exceeding 0.1 mm to reduce magnetic field eddy current loss and current leakage; Stator design: The stator core is made of 0.35mm thick silicon steel sheets laminated together. Insulating adhesive is used between adjacent silicon steel sheets to ensure that the lamination coefficient of the silicon steel sheets is not less than 0.

97. The magnetic permeability of the silicon steel sheets is 20% higher than that of traditional silicon steel sheets and the loss is 30% lower than that of traditional silicon steel sheets. The stator winding is wound in parallel with multiple strands of fine copper wire. The number of turns and wire diameter are determined by electromagnetic calculation according to the generator rated power of 50kW and voltage of 400V. A temperature sensor and overload protection device are embedded in the winding. When the temperature exceeds 120℃ or the current exceeds 120% of the rated current, the protection mechanism is automatically triggered. S2, self-generating mechanism steps: Energy recovery system: A small auxiliary generator is installed on the rotating shaft of the generator. The device increases the main shaft speed through a speed-increasing gearbox with a speed-increasing ratio of 5:1, and drives the auxiliary generator to generate electricity. The output voltage of the auxiliary generator is 24V. Part of the electric energy generated by the auxiliary generator is used to supply the generator's own control system and auxiliary equipment, and the other part is stored in the energy storage device through the intelligent energy management system; A plurality of piezoelectric ceramic sheets are installed on the generator housing, wherein the piezoelectric constant of the piezoelectric ceramic sheets is not less than 300pC / N. When the generator vibrates to generate mechanical energy, the piezoelectric ceramic sheets convert the mechanical energy into electrical energy, which is input into the energy management system after rectification and filtering; Intelligent energy management system: It is composed of a microcontroller, a power converter, and an energy storage device, wherein the energy storage device is a high-performance lithium battery pack or a supercapacitor, and its capacity is not less than 100Ah; The microcontroller monitors the generator speed at 1000-3000rpm, the output power at 10-50kW, the temperature of each part at -20℃-150℃, and the power information of the energy recovery system in real time. According to the monitoring data, the microcontroller adjusts the working state of the power converter through the control algorithm. When the generator starts or the load changes, it extracts power from the energy storage device to ensure stable operation of the generator. S3, manufacturing process steps: Parts processing technology: The rotor and stator are processed by CNC machine tools, and the shape, size and position accuracy error range of the rotor pole is controlled within ±0.05mm; Special dies and tooling are used for stamping and laminating the silicon steel sheets of the stator core. The winding is carried out in an environment with a temperature of 20℃-25℃ and a humidity of 40%-60%. A tension control system is used during the winding process to ensure that the tension of each turn of copper wire is within 5-10N. Assembly and debugging process: In a dust-free and clean assembly workshop, the stator is installed on the machine base with a position accuracy error of within ±0.1mm; the rotor is installed on the spindle and dynamic balancing test and adjustment are performed to make the rotor unbalance less than 5g·mm; After assembly is completed, no-load debugging is carried out first. The generator is started and its speed is monitored at 1000-1200rpm, voltage at 380-420V, and current at 0-10A, and the operating stability and performance indicators are checked; then load debugging is carried out, and the load is gradually increased to the rated load of 50kW. The output power of the generator under different load conditions is observed to be 10-50kW, the efficiency is 85%-95%, and the temperature changes are 20℃-80℃. Efficient and stable operation is ensured by adjusting the control system parameters.

2. The method for manufacturing a self-generating, high-efficiency and energy-saving improved generator according to claim 1, characterized in that: The coercive force of the novel magnetic material NdFeB alloy is within 800-2000 kA / m.

3. The method for manufacturing a self-generating, high-efficiency and energy-saving improved generator according to claim 2, characterized in that: The diameter of each strand of the multiple strands of thin copper wire of the stator winding is within 0.5-1.5 mm, and the number of parallel-wound strands is 5-10.

4. The method for manufacturing a self-generating, high-efficiency and energy-saving improved generator according to claim 3, characterized in that: The transmission efficiency of the speed increasing gearbox is not less than 90%.

5. The method for manufacturing a self-generating, high-efficiency and energy-saving improved generator according to claim 4, characterized in that: The high-performance lithium battery pack has a charge and discharge cycle number of not less than 1000 times, and the equivalent series resistance of the supercapacitor does not exceed 10 mΩ.

6. The method for manufacturing a self-generating, high-efficiency and energy-saving improved generator according to claim 5, characterized in that: When the generator is operated under rated load, compared with a traditional generator, the power generation efficiency is increased by more than 20% and the energy consumption is reduced by more than 30%.