Built-in speed-increasing rotor generator

Abstract

The invention discloses a generator with a built-in speed-increasing rotor. The generator comprises a generator shell, a rotor assembly and a stator assembly. A two-stage planetary gear speed increasing device is integrated in the rotor assembly and comprises a shared sun gear, a first-stage planetary gear set (a first-stage planet carrier, a planet gear and a gear ring) and a second-stage planetary gear set (a second-stage planet carrier, a planet gear and a gear ring). The common sun gear is rotationally installed in the shell and meshed with the first-stage planet gear and the second-stage planet gear. Input rotating speed is input through the first-stage planet carrier and is output through the first-stage gear ring after being accelerated through the common sun gear, the first-stage gear ring and the second-stage planet carrier are fixedly connected into a whole, the first-stage gear ring is located in the second-stage gear ring and drives the second-stage planet gear set to accelerate for the second time, and the outer side of the second-stage gear ring is wrapped with the permanent magnet and acts with the stator assembly to generate power. And the two-stage device is connected with the shell through a transition bearing seat. The rotor speed-increasing integration is realized, the axial size is shortened, the power generation efficiency is improved, and the rotor is suitable for wind power, hydropower and other scenes.

Description

Technical Field

[0001] This invention belongs to the field of generator technology, specifically relating to a built-in speed-increasing rotor generator. Background Technology

[0002] In modern industry and the energy sector, generators, as core equipment for converting mechanical energy into electrical energy, directly impact the efficiency and reliability of the system. Traditional generators typically employ a pure-shaft rotor structure, where the rotor is directly connected to the input shaft and rotated by an external power source to generate a magnetic field change, inducing current in the stator windings. This structure is simple and reliable, but it has significant limitations in applications requiring high speeds to improve power generation efficiency. For example, wind turbines or hydro turbines typically have low input speeds, making it difficult to directly drive the rotor to the ideal high speed. To address this issue, existing technologies often employ external speed increasers, which involve adding an independent gearbox or transmission device outside the generator to convert low-speed input into high-speed output to drive the rotor. While this external speed increaser solution can improve speed, it introduces several drawbacks. First, the external speed increaser significantly increases the system's size and weight, resulting in a bulky generator unsuitable for space-constrained environments such as electric vehicles, drones, or compact wind power systems. Second, the external speed increaser introduces an additional transmission link, increasing mechanical losses and reducing energy conversion efficiency by approximately 5%-10%. In addition, the maintenance of external speed increasers is complex and they are susceptible to environmental factors such as dust, humidity and vibration, which can lead to an increased failure rate and affect the reliability and lifespan of the generator.

[0003] From a structural perspective, the rotor design of traditional generators is limited to a single shaft system and lacks integrated speed-changing functionality, creating a bottleneck in the pursuit of high power density. Power density, the output power per unit volume or weight, is a core objective of modern generator design. External speed increasers, by separating the speed increaser from the generator, extend the shaft length and add connecting components such as couplings and bearings, which amplify vibration and noise issues. At high speeds, vibration can lead to rotor eccentricity or bearing wear, potentially causing mechanical failures. While existing built-in speed increase designs have been attempted, they are mostly single-stage speed increasers or simple gear sets with limited speed ratios, typically only 1.5-2 times, which cannot meet the demands of high-efficiency power generation. Furthermore, these designs do not adequately optimize shared components for multi-stage speed increases, resulting in complex structures, increased weight, and difficulties in achieving lightweight design.

[0004] In the field of new energy, such as wind power and tidal power, generators face the contradiction between low-speed input and high-output requirements. Although external speed increasers can alleviate this, energy loss directly reduces power generation efficiency. In the fields of aviation and shipbuilding, space and weight constraints are more stringent, making it difficult for pure shaft generators to adapt, leading to compromises in system design. Internationally, although Siemens' integrated variable speed generators have made progress, they still rely on external modules and have not achieved true built-in multi-stage speed increase. In general, the existing technical problems include: (1) external speed increasers result in non-compact structures and excessive size; (2) insufficient rotor speed leads to low power generation efficiency; (3) the built-in speed increase design is immature, lacking multi-stage shared optimization and lightweight features; (4) the integration degree between permanent magnets and speed increasers is low, affecting power density. These problems urgently require innovative solutions to promote the development of generators towards high efficiency, compactness, and lightweight design. Summary of the Invention

[0005] In view of this, the present invention aims to solve the technical problems of existing generators requiring external speed increasers, resulting in non-compact structures, large sizes, and low power generation efficiency. It provides a built-in speed-increasing rotor generator that integrates a two-stage planetary gear speed-increasing device inside the rotor to achieve high-speed rotor rotation, thereby improving power generation efficiency and making the overall structure more compact.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A built-in speed-increasing rotor generator includes a generator housing and a rotor assembly and a stator assembly disposed within the generator housing. The rotor assembly integrates a two-stage planetary gear speed-increasing device, which includes a common sun gear, a first-stage planetary gear set, and a second-stage planetary gear set. The first-stage planetary gear set includes a first-stage planet carrier, first-stage planetary gears, and a first-stage ring gear. The second-stage planetary gear set includes a second-stage planet carrier, second-stage planetary gears, and a second-stage ring gear. The common sun gear is rotatably mounted within the generator housing and meshes with both the first-stage and second-stage planetary gears. The input speed is input to the first-stage planetary gear set via the first-stage planet carrier, speed-increasing by the common sun gear, and output by the first-stage ring gear. The first-stage ring gear is fixedly connected to the second-stage planet carrier, driving the second-stage planetary gear set to rotate. After a second speed-increasing by the common sun gear, the second-stage ring gear outputs the speed. A permanent magnet is wrapped around the outer side of the second-stage ring gear, forming the magnetic field portion of the rotor assembly, which interacts with the outer stator assembly to generate electricity.

[0007] Furthermore, the two-stage planetary gear speed-increasing device is connected to the generator housing via a transition bearing seat, thereby realizing the built-in speed increase of the rotor assembly.

[0008] Furthermore, the end of the first-stage planetary carrier is provided with a connecting part for connecting an external input shaft to receive external power input.

[0009] Furthermore, the shared sun gear is coaxial with the first-stage planetary carrier, and the shared sun gear and the first-stage planetary carrier are rotatably connected by bearings.

[0010] Furthermore, the primary gear ring and the secondary planetary carrier are an integral structure.

[0011] Furthermore, the primary gear ring is located within the secondary gear ring.

[0012] Furthermore, the stator assembly is arranged around the rotor assembly and fixed to the generator housing. The stator assembly includes winding coils for inducing the magnetic field generated by the rotor assembly to generate electricity.

[0013] The beneficial effects of this invention are as follows: This invention integrates a two-stage planetary gear speed-increasing device within the rotor assembly, achieving an integrated design of speed-increasing function and rotor, completely solving the problem of traditional generators relying on external speed-increasing mechanisms. This built-in structure significantly reduces the generator's axial dimension and overall volume, making it more suitable for space-constrained applications such as electric vehicles, drones, or portable wind power generation equipment. Compared to external speed-increasing solutions, the compact design of this invention can reduce the axial dimension by 20%-30%, improving system integration and portability. Simultaneously, omitting the external speed-increasing mechanism reduces mechanical losses in the transmission chain, optimizes energy conversion efficiency, and can improve power generation efficiency by more than 15%. This not only reduces energy consumption but also reduces wear on external components, extending equipment lifespan.

[0014] The increased power density is another significant advantage of this invention. Through a two-stage planetary gear speed-increasing mechanism, the input speed can be amplified by 2-4 times, allowing the rotor to operate at high speeds and enhancing the rate of magnetic field change, thereby outputting higher power within the same volume. Traditional pure-shaft generators typically have a power density of 1-2 kW / kg, while this invention, through the fixed connection between the first-stage gear ring and the second-stage planetary carrier and its integrated structural design, increases the power density to over 3-5 kW / kg. The shared sun gear is rotatably mounted within the generator housing via bearings, optimizing the dynamic balance of the multi-stage speed increase, reducing frictional resistance, lowering vibration and noise, and improving long-term operational stability.

[0015] The design, featuring a shared sun gear coaxial with the first-stage planetary carrier and connected via bearings, further simplifies the internal structure, reduces space occupation and manufacturing costs, and lowers assembly complexity by approximately 10%-15%. The layout of the first-stage gear ring within the second-stage gear ring, combined with a lightweight transition bearing housing, enhances compactness and structural stability. The integrated design of the permanent magnet encasing the outer side of the second-stage gear ring strengthens magnetic field strength and uniformity, reduces magnetic leakage, and improves electromagnetic efficiency. The transition bearing housing ensures a reliable connection between the speed-increasing device and the housing, enhancing vibration and fatigue resistance.

[0016] From an application perspective, this invention can effectively address the contradiction between low-speed input and high-output demands in new energy fields such as wind power and tidal power generation, enabling high-efficiency power generation, reducing reliance on fossil fuels, and lowering carbon emissions. In the aviation and marine industries, the compact design optimizes space utilization and improves system performance.

[0017] Overall, this invention establishes a multi-level protection scope through essential technical features such as two-stage speed increase, shared sun gear rotation installation, and integrated gear ring structure, ensuring effectiveness under different variations and providing an efficient, compact, and lightweight solution.

[0018] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description

[0019] To make the objectives, technical solutions, and advantages of the present invention clearer, the preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, wherein: Figure 1 This is a schematic diagram of the built-in speed-increasing rotor generator in this invention.

[0020] Reference numerals in the attached figures: 1-Motor housing; 2-Stator assembly; 3-Permanent magnet; 4-Two-stage planetary gear speed increaser; 5-First-stage planetary carrier; 6-Common sun gear; 7-First-stage ring gear; 8-Second-stage planetary carrier; 9-Second-stage ring gear; 10-First-stage planetary gear; 11-Second-stage planetary gear. Detailed Implementation

[0021] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0022] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the invention. To better illustrate the embodiments of the invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0023] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present invention. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0024] Example 1 like Figure 1 As shown, a built-in speed-increasing rotor generator includes a generator housing 1 and a rotor assembly and a stator assembly 2 disposed within the generator housing 1. The rotor assembly integrates a two-stage planetary gear speed-increasing device 4, which includes a common sun gear 6, a first-stage planetary gear set, and a second-stage planetary gear set. The first-stage planetary gear set includes a first-stage planet carrier 5, first-stage planetary gears 10, and a first-stage ring gear 7; the second-stage planetary gear set includes a second-stage planet carrier 8, second-stage planetary gears 11, and a second-stage ring gear 9. The common sun gear 6 is rotatably mounted within the generator housing 1 via bearings and meshes simultaneously with the first-stage planetary gears 10 and the second-stage planetary gears 11.

[0025] The shared sun gear 6 is coaxial with the first-stage planetary carrier 5, and the shared sun gear 6 and the first-stage planetary carrier 5 are rotatably connected by a bearing. The end of the first-stage planetary carrier 5 has a connecting part for connecting an external input shaft to receive external low-speed power input. The input speed is input to the first-stage planetary gear set through the first-stage planetary carrier 5, and after being accelerated by the shared sun gear 6, it is output by the first-stage ring gear 7. The first-stage ring gear 7 is fixedly connected to the second-stage planetary carrier 8 and is an integral structure. The first-stage ring gear 7 is located inside the second-stage ring gear 9, driving the second-stage planetary gear set to rotate. After being accelerated a second time by the shared sun gear 6, it is output by the second-stage ring gear 9. The outer side of the second-stage ring gear 9 is wrapped with a permanent magnet 3, forming the magnetic field portion of the rotor assembly, which interacts with the outer stator assembly 2 to generate electricity. The two-stage planetary gear speed-increasing device 4 is connected to the generator housing 1 through a transition bearing seat to achieve built-in speed increase of the rotor assembly. The stator assembly 2 is arranged around the rotor assembly and fixed to the generator housing 1. The stator assembly 2 includes winding coils for inducing the magnetic field generated by the rotor assembly to generate electricity.

[0026] In this embodiment, there are multiple first-stage planetary gears 10 and second-stage planetary gears 11, which are evenly distributed on their respective planetary carriers and supported by bearings to achieve stable speed transmission; the total speed increase ratio is 3 times, which is suitable for wind power generation scenarios and improves power generation efficiency by more than 20% compared with traditional external speed increase schemes.

[0027] Example 2 Based on Example 1, by adjusting the gear module and number of teeth of the first-stage planetary gear set and the second-stage planetary gear set, a total speed ratio of 4 times is achieved, which is suitable for hydropower or tidal power generation scenarios and has a power density of over 4.5 kW / kg. At the same time, the integrated structure of the first-stage gear ring 7 and the second-stage planetary carrier 8 and the rotating installation feature of the shared sun gear 6 are maintained to ensure compactness and high efficiency.

[0028] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. An internal augmented-rotor electric generator characterized by, The application relates to a generator, which comprises a generator shell, a rotor assembly and a stator assembly arranged in the generator shell, wherein a two-stage planetary gear speed increasing device is integrated in the rotor assembly, the two-stage planetary gear speed increasing device comprises a shared sun gear, a first-stage planetary gear set and a second-stage planetary gear set, the first-stage planetary gear set comprises a first-stage planet carrier, a first-stage planet gear and a first-stage gear ring, the second-stage planetary gear set comprises a second-stage planet carrier, a second-stage planet gear and a second-stage gear ring, the shared sun gear is rotatably arranged in the generator shell and simultaneously meshes with the first-stage planet gear and the second-stage planet gear, input rotating speed is input to the first-stage planetary gear set through the first-stage planet carrier, the rotating speed is increased through the shared sun gear and then output by the first-stage gear ring, the first-stage gear ring is fixedly connected with the second-stage planet carrier, drives the second-stage planetary gear set to rotate, the rotating speed is increased twice through the shared sun gear and then output by the second-stage gear ring, the second-stage gear ring is wrapped with a permanent magnet on the outside, a magnetic field part of the rotor assembly is formed, and the stator assembly on the outside is used for power generation. The two-stage planetary gear speed increasing device is connected with the generator shell through a transition bearing seat, and the built-in speed increasing of the rotor assembly is realized. A connecting part is arranged at the end of the first-stage planet carrier, which is used for connecting an external input shaft and receiving external power input.

2. An internal augmented-rotor electric generator according to claim 1, wherein The shared sun gear is coaxial with the first-stage planet carrier, and the shared sun gear is rotatably connected with the first-stage planet carrier through a bearing.

3. An internal augmented-rotor electric generator according to claim 1, wherein The first-stage gear ring and the second-stage planet carrier are an integral structure.

4. An internal augmented-rotor electric generator according to claim 1, wherein The first-stage gear ring is located in the second-stage gear ring.

5. An internal augmented-rotor electric generator according to claim 1, wherein The stator assembly is arranged around the rotor assembly and is fixed with the generator shell, the stator assembly comprises a winding coil, and is used for inducting a magnetic field generated by the rotor assembly to generate power.

6. An internal augmented-rotor electric generator according to claim 1, wherein ​ 7. An internal augmented-rotor electric generator as set forth in Claim 1 wherein, ​

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