Aero-generator protection resistor structure and installation method thereof

Abstract

The application relates to the technical field of aviation electric machines, in particular to an aviation generator protection resistor structure and a mounting method thereof. The structure comprises a ring groove which is arranged on a hollow shaft of a generator and extends along the circumference of the hollow shaft; a protection resistor wire is wound in the ring groove, and the protection resistor wire is fixed in the ring groove through binding lines; and an insulating layer is arranged between the inner wall of the ring groove and the protection resistor wire. The protection resistor is directly mounted on the hollow shaft of a three-stage aviation generator, the use scene of the protection resistor is wider, the axial length of the electric machine can be effectively shortened, the weight can be reduced, the centrifugal force can be reduced, and the reliability of the electric machine can be improved.

Description

Technical Field

[0001] This invention relates to the field of aviation motor technology, specifically to a protective resistor structure for an aviation generator and its installation method. Background Technology

[0002] Three-phase full-wave rectifier circuits are widely used in the design of three-stage aircraft generators. The circuit diagram is shown below. Figure 1 As shown, the resistor R in the circuit is a load resistor, which is a type of resistor used to limit the current in the circuit. It is connected to the output terminal of the full-wave rectifier circuit to play the role of filtering and voltage regulation, which can effectively reduce the impact of the power supply on the load and improve the stability and reliability of the circuit.

[0003] In the prior art, see Figure 2 and Figure 3 As shown, where, Figure 3 The protective resistor structure includes a rectifier bracket 1, slot insulation 2 for insulation between the rectifier bracket and the protective resistor, protective resistor leads 3, binding wires 4 for securing the protective resistor leads, and insulating gaskets 5 for insulation between the rectifier bracket and the protective resistor. The installation method of the protective resistor is as follows: First, design the rectifier bracket, which has a groove for installing the protective resistor. Assemble the rectifier bracket on the hollow shaft. Place slot insulation and insulating gaskets in the groove for installing the protective resistor to insulate the resistor wires from the rectifier bracket. Then, wind the protective resistor wires into the groove of the rectifier bracket as required, and finally secure them with binding wire.

[0004] The existing protective resistor structure and installation method have the following drawbacks: (1) The rectifier bracket is large and occupies a lot of space. In this installation method, the rectifier bracket is large and occupies a lot of space, which will lead to an increase in the overall size of the motor.

[0005] (2) Increase the axial dimension of the motor. The rectifier bracket needs to be press-fitted onto the hollow shaft. The hollow shaft needs to be designed with sufficient length and a stop for installing the rectifier bracket, which will increase the length of the hollow shaft and thus increase the axial dimension of the motor.

[0006] (3) Increase the overall mass of the motor. The installation of the protection resistor depends on the rectifier bracket. At present, the rectifier bracket is often made of materials with low density, such as aluminum alloy rods and titanium alloy rods. While meeting the strength requirements, the weight of the bracket itself is minimized. Therefore, the existence of the rectifier bracket will increase the overall mass of the motor.

[0007] (4) The protective resistor is subjected to greater centrifugal force and has lower safety and reliability. Since the rectifier bracket is installed on the hollow shaft, a certain thickness needs to be designed, and its radial dimension will increase. The centrifugal force that the protective resistor is subjected to when it is installed on the rectifier bracket will inevitably be greater than the centrifugal force that it is subjected to when the protective resistor is directly installed on the hollow shaft. Since the motor speed is very high, a small increase in the radial dimension may cause a large increase in centrifugal force. Summary of the Invention

[0008] To address the aforementioned technical problems, this invention provides a protective resistor structure for an aircraft generator and its installation method. This structure directly places the protective resistor on the hollow shaft of a three-stage aircraft generator, which can effectively shorten the axial length of the generator, reduce weight, decrease centrifugal force, and improve the reliability of the aircraft generator.

[0009] The first objective of this invention is to provide a protective resistor structure for an aircraft generator, which is disposed on the hollow shaft of the generator and includes: A circumferential groove is formed on the hollow shaft of the generator; The protective resistor wire is wound inside the annular groove, and the protective resistor wire is secured to the annular groove by binding wire; An insulating layer is provided between the inner wall of the annular groove and the protective resistor wire.

[0010] Preferably, the insulating layer is an insulating gasket, which is disposed on the inner wall of the annular groove.

[0011] The second objective of this invention is to provide an application of an aircraft generator protection resistor structure in the three-phase full-wave rectifier circuit structure of an aircraft generator.

[0012] The third objective of this invention is to provide a three-phase full-wave rectifier circuit structure for an aircraft generator, mounted on the hollow shaft of the aircraft generator, comprising: The above-mentioned structure of the protection resistor for aircraft generators; The rectifier module is embedded inside the hollow shaft. The rectifier module rectifies the three-phase AC output power of the exciter into DC power, which is output through two leads. The two lead wires pass through the hollow shaft and are connected to the beginning and end of the protective resistor wire, respectively.

[0013] Preferably, the rectifier module includes: The rectifier module housing is embedded in a hollow shaft; A fixed diode bracket is disposed inside the rectifier module housing; A rotating rectifier diode is mounted on the fixed diode bracket and fixed to the bracket with screws.

[0014] Preferably, there are a total of 6 rotating rectifier diodes, which are divided into two groups: 3 common cathode group and the other 3 common anode group.

[0015] The fourth objective of this invention is to provide a three-phase full-wave rectifier circuit structure for an aircraft generator, mounted on the hollow shaft of the aircraft generator, comprising: The above-mentioned structure of the protection resistor for aircraft generators; A rectifier module is mounted on the hollow shaft; the rectifier module rectifies the three-phase AC output of the exciter into DC, which is output through two leads and connected to the beginning and end of the protective resistor wires respectively.

[0016] The fifth objective of this invention is to provide a method for installing a protective resistor structure for an aircraft generator, comprising: An insulating layer is installed inside the annular groove of the hollow shaft; The protective resistor wire is wound inside the annular groove; Finally, secure it with cable ties and connect the wires.

[0017] The sixth objective of this invention is to provide an installation method for a three-phase full-wave rectifier circuit structure for an aircraft generator, comprising: An insulating layer is installed inside the annular groove of the hollow shaft; Wrap the protective resistor wire inside the annular groove and secure it with binding wire; The rectifier module is embedded inside or nested on the hollow shaft; Connect the two leads of the rectifier module to the beginning and end of the protection resistor wire; Connect the beginning and end of the protective resistor wire to the beginning and end of the main generator excitation winding.

[0018] The present invention has at least the following beneficial effects: This invention provides a protective resistor structure for an aircraft generator and its installation method. The structure directly places the protective resistor on the hollow shaft of a three-stage aircraft generator, which can reduce the weight of the rotating shaft and the rectifier bracket. At the same time, the rectifier bracket structure can also be installed on the outside of the rotating shaft around which the protective resistor is wrapped, which will greatly shorten the axial space and reduce the weight.

[0019] This invention mounts the rectifier structure inside a hollow shaft, making it the simplest way to install the protective resistor by slotting the outside of the hollow shaft. This method is highly manufacturable and easy to operate. While providing adequate protection, other components can also be installed outside the protective resistor, effectively reducing axial space and weight.

[0020] Compared with existing technologies, the present invention has the following advantages: Small size: The protection resistor is directly installed on the hollow shaft, which eliminates the need for the rectifier bracket structure compared to the existing installation method, thus effectively reducing the size of the motor.

[0021] Axial dimension reduction: In the prior art, it is necessary to reserve the installation position of the rectifier bracket on the hollow shaft. Therefore, the rectifier bracket is omitted in this invention, which will effectively reduce the axial dimension of the hollow shaft, and the axial dimension of the generator will be reduced accordingly.

[0022] Lightweight: This installation method eliminates the need for a rectifier bracket compared to existing designs, thus reducing the overall weight of the unit.

[0023] Low centrifugal force and high reliability: This installation method directly winds the protective resistor onto the hollow shaft. Compared to existing installation methods, its radial dimension is reduced. The centrifugal force calculation formula is as follows: When the motor speed is constant, the radial dimension decreases and the centrifugal force it bears decreases, thus making the design safer and more reliable. Attached Figure Description

[0024] Figure 1 This is a full-wave rectifier circuit diagram; Figure 2 The rectifier bracket is mounted on the hollow shaft; Figure 3 The installation method for the protective resistor using the rectifier bracket; Figure 4 A view of the annular groove for the protective resistor cut into the hollow shaft; Figure 5 A schematic diagram of the annular groove structure for the protective resistor on a hollow shaft; Figure 6 The structure of a three-phase full-wave rectifier circuit for an aircraft generator is designed with the rectifier module embedded in a hollow shaft. Figure 7 A three-phase full-wave rectifier circuit structure for an aircraft generator with the rectifier module mounted on a hollow shaft. Detailed Implementation

[0025] In order to illustrate the technical means and effects adopted by the present invention to achieve the intended purpose, the following detailed description is provided in conjunction with the embodiments.

[0026] The main objective of this invention is to provide a protective resistor structure for an aircraft generator and its installation method. This structure directly mounts the protective resistor onto the hollow shaft of the generator, making it applicable to a wider range of scenarios and effectively shortening the axial length of the generator, reducing weight, and decreasing centrifugal force.

[0027] The aircraft generators targeted in this invention are mainly three-stage aircraft generators.

[0028] To achieve the above objectives, see Figures 4-7As shown, a protective resistor structure for an aircraft generator is disposed on the hollow shaft of the generator, comprising: A circumferential groove is formed on the hollow shaft 100 of the generator; The protective resistor wire 200 is wound around the annular groove and secured to the annular groove with a binding wire; An insulating layer 201 is provided between the inner wall of the annular groove and the protective resistor wire.

[0029] The insulating layer 201 is an insulating pad, which is disposed on the inner wall of the annular groove. The two ends of the protective resistor wire are output through the protective resistor lead wire 203.

[0030] It should be noted that the insulating layer is disposed on the inner wall of the annular groove, including the bottom and side walls of the annular groove.

[0031] The present invention provides an aircraft generator protection resistor structure for optimizing the installation method of the protection resistor. Specifically, the present invention provides an installation method for the aircraft generator protection resistor structure, including: installing an insulating layer in the annular groove of a hollow shaft; winding the protection resistor wire in the annular groove; and finally securing it with binding wire and connecting the circuit.

[0032] In practical applications, this aircraft generator protection resistor structure involves designing a hollow shaft with a pre-reserved mounting position for the protection resistor. An annular groove is created at this position, and an insulating gasket is placed within the groove to insulate the resistor from the hollow shaft. The protection resistor wire is then wound directly into the groove on the hollow shaft according to design requirements and secured with binding wire. This structure effectively reduces the size, axial dimension, and overall weight of the aircraft generator, while also reducing the centrifugal force on the protection resistor during generator rotation, thus improving the generator's safety and reliability.

[0033] Currently, many high-power oil-cooled motors use hollow shafts with large inner diameters. Many rotating rectifier structures are installed inside these hollow shafts. Therefore, if a protective resistor needs to be installed, the simplest and most convenient method is to slot the outside of the hollow shaft, as provided by this invention. This method offers excellent manufacturability and operability. While providing protection, other components can also be installed on the outside of the protective resistor, effectively reducing axial space and weight.

[0034] This invention provides an application of an aircraft generator protection resistor structure in the three-phase full-wave rectifier circuit structure of an aircraft generator.

[0035] See Figure 6As shown, a three-phase full-wave rectifier circuit structure for an aircraft generator is installed on the hollow shaft 100 of the aircraft generator. It includes: the aircraft generator protection resistor structure provided above; and a rectifier module embedded inside the hollow shaft 100. The rectifier module rectifies the three-phase AC output of the exciter into DC, and the DC is output through two leads 304. The two leads pass through the hollow shaft 100 and are respectively connected to the beginning and end of the protection resistor wire 203. The protection resistor wire 203 is connected to the beginning and end of the excitation winding of the main generator.

[0036] The rectifier module includes: a rectifier module housing 300, which is embedded in a hollow shaft 100; a fixed diode bracket 301, which is disposed in the rectifier module housing 300; and a rotating rectifier diode 302, which is disposed on the fixed diode bracket 301 and fixed to the bracket 301 by screws 303.

[0037] There are a total of 6 rotating rectifier diodes, divided into two groups: 3 common cathode group and 3 common anode group.

[0038] The rectifier module provided by this invention is embedded inside a hollow shaft 100 and rotates together with the hollow shaft 100, causing the rectifier module to rotate. It can also be called a rotating rectifier module. It mainly includes a housing 300, six diodes 302, a terminal block, lead wires 304, and fastening devices such as a fixing bracket 301. The rotating rectifier module is fixed inside the housing by fastening devices such as brackets and screws, forming an integral unit with the housing. This integral unit is completely embedded inside the hollow shaft. Various fixing methods are available, including fixing pins, key connections, and interference fits, selected according to the product's structure. The six diodes in the rectifier module are divided into two groups: three common cathode diodes and three common anode diodes. The exciter's output current, a three-phase AC current, is connected to the rotating rectifier module through a terminal block. When the rectifier module circuit is working, the diode with the highest anode voltage in the common cathode group will conduct, and the diode with the lowest cathode voltage in the common anode group will conduct. At any given moment, the upper arm diode in the highest voltage phase and the lower arm diode in the lowest voltage phase are conducting, thus achieving full-wave rectification from AC to DC.

[0039] See Figure 1 As shown in the diagram, the DC output is achieved through two leads, which are connected to the beginning and end of the protective resistor, respectively, and then to the excitation winding of the main generator. It should be noted that the diodes in the rectifier module are high-value and easily damaged components. Installing a protective resistor provides current limiting, filtering, and voltage regulation, while also effectively protecting the diodes. This can be simply understood as connecting a resistor R in parallel with the rotating rectifier module.

[0040] The three-phase full-wave rectifier circuit structure for aircraft generators provided by this invention can reduce the weight of the rotating shaft and the rectifier bracket. At the same time, the rectifier bracket structure can also be installed on the outside of the rotating shaft with the protective resistor wrapped around it, which will greatly shorten the axial space and reduce the weight.

[0041] See Figure 7 As shown, a three-phase full-wave rectifier circuit structure for an aircraft generator is mounted on the hollow shaft of the aircraft generator. It includes: the aforementioned aircraft generator protection resistor structure; a rectifier module 400, which is sleeved on the hollow shaft 100; the rectifier module rectifies the three-phase AC output power from the exciter into DC power 401, which is output through two leads; these leads are connected to the beginning and end of the protection resistor leads, respectively, and then the beginning and end of the protection resistor leads are connected to the beginning and end of the main generator excitation winding. In other words, the rectifier module is mounted on the outside of the hollow shaft.

[0042] This invention provides an installation method for a three-phase full-wave rectifier circuit structure for an aircraft generator, comprising: An insulating layer is installed inside the annular groove of the hollow shaft; Wrap the protective resistor wire inside the annular groove and secure it with binding wire; The rectifier module is embedded inside or nested on the hollow shaft; Connect the two leads of the rectifier module to the beginning and end of the protection resistor wire; Connect the beginning and end of the protective resistor wire to the beginning and end of the main generator excitation winding.

[0043] This invention fixes the rectifier module inside the housing using brackets, screws, and other fastening devices, forming a single unit with the housing. This unit is entirely embedded inside a hollow shaft. Various fixing methods are available, including fixing pins, key connections, and interference fits, selected based on the product's structure. The six diodes in the rectifier module are divided into two groups: three common cathode and three common anode. The exciter's output three-phase AC current is connected to the rotating rectifier module via a terminal block. When the rectifier module circuit is operating, the diode with the highest anode voltage in the common cathode group conducts, and the diode with the lowest cathode voltage in the common anode group conducts. At any given moment, the upper arm diode in the highest voltage phase and the lower arm diode in the lowest voltage phase are conducting, thus achieving full-wave rectification from AC to DC.

[0044] This invention has been applied to the 12KVA DC power supply system of a key national aircraft model, and its effect is significantly improved compared to the traditional structural design.

[0045] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A three-phase full-wave rectifier circuit structure for an aircraft generator, characterized in that, Mounted on the hollow shaft of an aircraft generator, including: A protective resistor structure for an aircraft generator is provided on the hollow shaft of the generator, comprising: an annular groove formed circumferentially on the hollow shaft of the generator; a protective resistor wire wound around the annular groove and secured to the annular groove by a binding wire; an insulating layer provided between the inner wall of the annular groove and the protective resistor wire; the insulating layer is an insulating gasket provided on the inner wall of the annular groove. The rectifier module is embedded inside the hollow shaft. The rectifier module rectifies the three-phase AC output power of the exciter into DC power, which is output through two leads. The two leads pass through the hollow shaft and are respectively connected to the beginning and end of the protective resistor wire; The rectifier module includes: The rectifier module housing is embedded in a hollow shaft; A fixed diode bracket is disposed inside the rectifier module housing; A rotating rectifier diode is mounted on the fixed diode bracket and fixed to the bracket with screws; There are a total of 6 rotating rectifier diodes, divided into two groups: 3 common cathode group and 3 common anode group.

2. A method for installing the three-phase full-wave rectifier circuit structure of an aircraft generator as described in claim 1, characterized in that, include: An insulating layer is installed inside the annular groove of the hollow shaft; Wrap the protective resistor wire inside the annular groove and secure it with binding wire; The rectifier module is embedded inside or nested on the hollow shaft; Connect the two leads of the rectifier module to the beginning and end of the protection resistor wire; Connect the beginning and end of the protective resistor wire to the beginning and end of the main generator excitation winding.

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