A compact high-voltage generator with excellent heat dissipation performance

Abstract

The application provides a compact high-voltage generator with excellent heat dissipation performance, and belongs to the technical field of high-voltage generators, and solves the technical problems of complex structure and poor heat dissipation performance of the existing generator. The application comprises a water-cooled generator shell, the rear end of the water-cooled generator shell is provided with a rear end cover, the front end of the water-cooled generator shell is provided with a linkage heat dissipation end assembly, the rear end cover and the linkage heat dissipation end assembly are provided with a stator assembly, a rotor shaft is rotatably arranged in the stator assembly, the two ends of the rotor shaft are rotatably arranged between the rear end cover and the linkage heat dissipation end assembly, a plurality of rotor assemblies are arranged on the rotor shaft, the plurality of rotor assemblies are arranged in the stator assembly, an electric control box is arranged above the water-cooled generator shell, and a mounting base is arranged below the water-cooled generator shell. The application has a water-cooled main heat dissipation system and an air-cooled auxiliary heat dissipation system, has good heat dissipation effect, is deeply integrated, has a modular structure, significantly reduces the volume, and is stable in operation and reduces the maintenance cost.

Description

A compact high-voltage generator with excellent heat dissipation performance Technical Field

[0001] This invention belongs to the field of high-voltage generator technology, and relates to a compact high-voltage generator, particularly a compact high-voltage generator with excellent heat dissipation performance. Background Technology

[0002] With the development of new energy power generation, ship electric propulsion, and data center backup power, higher requirements are being placed on the power density, operating efficiency, and reliability of generators. High-voltage generators (usually referring to those with an output voltage of 6kV and above) are widely used because they can reduce transmission losses and simplify power distribution systems.

[0003] However, as high-voltage generators develop towards compactness and high power density, they face severe heat dissipation challenges, mainly manifested in:

[0004] (1) High insulation requirements: The high-voltage coil requires a thicker insulation layer, which seriously hinders the conduction of internal heat to the stator core and the outside.

[0005] (2) Load concentration: The compact design leads to a sharp increase in losses (copper loss, iron loss) per unit volume, and heat is more likely to accumulate.

[0006] (3) Limitations of traditional cooling methods: Traditional surface cooling of the casing or single axial ventilation is no longer effective in removing the large amount of heat generated inside the stator windings, especially in the slots. Heat accumulation will lead to accelerated aging of the insulation material, and local overheating may even cause insulation breakdown, seriously threatening the safety and lifespan of the motor.

[0007] Therefore, how to design an efficient and reliable cooling system under the constraints of high voltage and small size is a technical problem that urgently needs to be solved in this field.

[0008] Based on this, we propose a compact high-voltage generator with excellent heat dissipation performance. Summary of the Invention

[0009] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a compact high-voltage generator with excellent heat dissipation performance. The technical problem to be solved by this invention is: how to construct a dual heat dissipation system of water-cooled main heat dissipation and air-cooled auxiliary heat dissipation in the compact structure of a high-voltage generator to improve heat dissipation efficiency; at the same time, through deep integration and modular design, the size of the equipment is reduced, stable operation is ensured, and maintenance costs are reduced.

[0010] The objective of this invention can be achieved through the following technical solutions:

[0011] A compact high-voltage generator with excellent heat dissipation performance includes a water-cooled generator housing. The rear end of the water-cooled generator housing is provided with a rear end cover, and the front end of the water-cooled generator housing is provided with a linkage heat dissipation end assembly. A stator assembly is provided between the rear end cover and the linkage heat dissipation end assembly. The stator assembly is located inside the water-cooled generator housing. A rotor shaft is rotatably provided inside the stator assembly, and the two ends of the rotor shaft are respectively rotatably disposed between the rear end cover and the linkage heat dissipation end assembly. A plurality of rotor assemblies are provided on the rotor shaft and distributed inside the stator assembly. An electrical control box is provided on the top of the water-cooled generator housing, and a mounting base is provided on the bottom of the water-cooled generator housing.

[0012] The working principle of this invention is as follows: When an external power drives the linkage heat dissipation end assembly to rotate, the rotor shaft rotates between the rear end cover and the linkage heat dissipation end assembly. The rotor assembly fixed on it rotates synchronously inside the stator assembly. The magnetic field of the rotating rotor assembly moves relative to the stator winding of the stationary stator assembly, cutting the magnetic field lines, thereby generating an induced electromotive force in the stator assembly and outputting high-voltage electrical energy.

[0013] The key to its heat dissipation performance lies in the linkage heat dissipation end component. The built-in fan of the linkage heat dissipation end component actively drives the cooling airflow through the inside of the water-cooled generator housing when the shaft rotates, forcibly cooling the heat-generating stator and rotor components, thus achieving efficient heat dissipation in a compact structure.

[0014] The control box is responsible for regulating, controlling, and protecting the generated electrical energy, while the mounting base provides stable support for the entire generator.

[0015] The water-cooled generator housing can be connected to an external water pump for circulating water cooling.

[0016] The water-cooled generator housing includes a generator housing body, with mounting flanges at both the front and rear ends of the generator housing body. The inner layer of the generator housing body is provided with a spirally arranged cooling spiral channel. The generator housing body is provided with a water inlet connector and a water outlet connector, which are respectively connected to the two ends of the cooling spiral channel.

[0017] With the above structure, external cooling water is pumped in through the inlet connector and enters the specially designed cooling spiral channel inside the casing. The cooling water flows along this spiral path, which greatly extends the path and residence time of the water flow inside the casing. This allows the cooling water to fully and evenly absorb the heat generated by the internal stator and rotor components during operation and conducted to the generator casing. The heated water then flows out from the outlet connector, completing one cycle. The spiral channel design significantly increases the heat exchange area and efficiency. The cooling channel is directly built into the pressurized generator casing, resulting in a compact structure and a more direct heat dissipation path. The dual heat dissipation system works in tandem: this water cooling system is combined with the forced air cooling of the linked heat dissipation end components to form a powerful heat dissipation system of "water cooling as the main heat dissipation + air cooling as the auxiliary heat dissipation," ensuring the continuous and stable operation of the high-voltage generator in a compact space.

[0018] The rear end cover includes a rear end cover body, on which several circumferentially distributed rear end cover fixing through holes are provided. The rear end cover body is detachably mounted on the mounting flange located at the rear end of the generator housing body through the several rear end cover fixing through holes. A rear end stator mounting protrusion is provided on the front side of the rear end cover body. An air inlet is provided on the rear side of the rear end stator mounting protrusion. A filter screen is provided on the rear side of the air inlet. A bearing mounting hole is provided in the middle of the rear end stator mounting protrusion. A mounting bearing is fixed at the rear end of the rotor shaft. The mounting bearing is located inside the bearing mounting hole.

[0019] With the above structure, the rear end cover body is detachably installed on the mounting flange at the rear end of the generator housing body through the circumferentially distributed rear end cover fixing through holes, forming a sealed cavity at the rear end of the generator.

[0020] Stator positioning and fixing: The rear stator mounting protrusion on the front side of the rear cover body is used to accurately align and install the rear end of the stator assembly, ensuring the stable positioning of the stator within the housing;

[0021] Bearing support and rotation: The bearing mounting hole in the middle of the rear stator mounting protrusion is used to install and fix the mounting bearing at the rear end of the rotor shaft, providing stable and reliable rotational support for the rotor shaft;

[0022] Auxiliary heat dissipation and protection: The air inlet on the rear stator mounting protrusion is the key entrance to the air-cooled heat dissipation channel inside the generator. External cooling air enters through this hole under the drive of the built-in fan of the linkage heat dissipation component, flows through the internal heat-generating components for cooling, and the filter screen behind it can effectively prevent dust and other impurities from entering the generator, ensuring clean and safe operation.

[0023] The rear cover not only completes the enclosure and support of the generator's rear structure, but its air inlet and filter design also work in conjunction with the linked heat dissipation components to form a complete forced air cooling airflow circuit.

[0024] The linked heat dissipation end assembly includes a main heat dissipation cover, a side heat dissipation cover at the rear of the main heat dissipation cover, and a flange at the rear of the side heat dissipation cover. The flange is detachably mounted on a mounting flange located at the front end of the generator housing. Filter screens are provided inside the ventilation holes of the main heat dissipation cover and the side heat dissipation cover. An air guide frame is provided inside the side heat dissipation cover. A heat dissipation fan is rotatably mounted in the middle of the air guide frame. The heat dissipation fan is located inside the main heat dissipation cover. A front stator mounting protrusion is provided at the rear of the flange. A linkage shaft is fixed to the front end of the main shaft of the heat dissipation fan. A linkage flange is fixed to the end of the linkage shaft. The rear end of the main shaft of the heat dissipation fan is fixedly connected to the front end of the rotor shaft.

[0025] With the above structure, the connection and sealing are as follows: the end flange is detachably installed on the mounting flange at the front end of the generator housing body, and together with the rear end cover, it forms a complete sealed housing for the generator.

[0026] The front stator mounting protrusion is used to precisely install and fix the front end of the stator assembly, and works in conjunction with the rear stator mounting protrusion to ensure that the stator assembly is stably centered.

[0027] Power transmission and power generation drive: External power is input through the linkage flange to drive the linkage shaft to rotate; the linkage shaft directly drives the main shaft of the cooling fan, and the rear end of the main shaft is fixedly connected to the front end of the rotor shaft; therefore, while the external power drives the cooling fan to rotate, it also synchronously drives the rotor shaft and the rotor assembly on it to rotate, thereby starting the power generation process.

[0028] Forced air cooling startup: When the cooling fan rotates at high speed with the main shaft, it starts to work as a built-in centrifugal fan or axial fan; a negative pressure is formed in the middle of the cooling fan, and cold air enters the generator from the air inlet. The airflow flows through the heated stator and rotor assemblies, carrying away the heat, and is finally discharged through the ventilation holes of the end cooling main cover and end cooling side cover, thereby achieving efficient cooling of the generator core.

[0029] The linkage heat dissipation end component ingeniously realizes the mechanical coupling of power transmission and cooling fan; its core principle is: external power drives the cooling fan to rotate, achieving two goals at once - it directly drives the generator rotor to generate electricity, and at the same time, it generates the forced airflow necessary to cool the generator as a fan; it forms a "wind-water" coordinated heat dissipation system with the water-cooled generator casing.

[0030] The stator assembly includes, from front to back, an end seat, a stator side frame one, a stator side frame two, a stator side frame three, a cage-type double side frame ...

[0031] Using the above structure, a stable installation platform and magnetic circuit skeleton are constructed: the end seat, stator side frame one, stator side frame two, stator side frame three and cage-type double side frame are assembled in a specific order, which together form a solid mechanical skeleton and magnetic circuit body that supports the stator winding;

[0032] Forming and encapsulating the rotor chamber: Stator side frame two and stator side frame three are combined to form a rotor mounting frame, which is closed on both sides with cover plates, thereby creating a precise, sealed cylindrical chamber therein to accommodate and ensure that the rotor assembly rotates concentrically with it;

[0033] Achieving overall positioning and fixation: The stator side brackets at both ends of the assembly are respectively fixed to the front stator mounting protrusion and the rear stator mounting protrusion. This design ensures precise axial and radial alignment and reliable fixation of the entire long stator assembly within the housing;

[0034] Easy to manufacture, assemble, and maintain: All components are detachably connected. The modular design greatly simplifies the manufacturing process, reduces the difficulty of assembling large components, and facilitates future maintenance, winding replacement, or internal cleaning.

[0035] The working principle of the stator assembly is reflected in its innovative mechanical structure design. Through a modular frame system that is precisely layered, rigidly connected, and easy to disassemble and assemble, it achieves efficient support for the stator windings in a limited space, provides precise space for rotor operation, and ensures stable integration with the front and rear end covers of the generator, thus laying a solid physical foundation for the stable generation of high-voltage power.

[0036] The stator side frame one has several circumferentially distributed capacitors I inside. The cage-type double side frame has a group of several circumferentially distributed capacitors II on both sides inside. The stator side frame two has several circumferentially distributed stator coil assemblies I inside. The stator side frame three has several circumferentially distributed stator coil assemblies II inside. The number of stator coil assemblies I and stator coil assemblies II are the same and they are directly opposite each other. Between the stator side frame two and the stator side frame three, there are several circumferentially distributed stator coil assemblies III. The stator coil assemblies III are located on the periphery of the stator coil assemblies I, and the stator coil assemblies III and stator coil assemblies I are staggered. The capacitors I and stator coil assemblies I are electrically connected in a one-to-one correspondence. The capacitors II and stator coil assemblies II are electrically connected in a one-to-one correspondence.

[0037] The above structure features a modular and distributed electrical layout:

[0038] Layered coil arrangement: Stator coil assembly one, stator coil assembly two, and stator coil assembly three are precisely and layered within a "rotor mounting frame" module composed of stator side frame two and stator side frame three. This layout optimizes the magnetic field distribution and facilitates winding heat dissipation.

[0039] Distributed integration of capacitors in proximity: Unlike the traditional centralized capacitor arrangement, this design directly and disperses capacitor one and capacitor two within the stator side frame one and the cage-type double-sided frame, close to the corresponding coil groups. Capacitor one is electrically connected to stator coil assembly one in a one-to-one correspondence, and capacitor two is electrically connected to stator coil assembly two in a one-to-one correspondence, forming multiple independent "coil-capacitor" pairing units.

[0040] Core electrical function principle:

[0041] Power generation and filtering: The stator coil assembly cuts the rotor magnetic field to generate high-voltage alternating current. The capacitors connected to it one-to-one mainly serve the functions of filtering, power factor compensation, and suppressing voltage spikes. Compared with centralized filtering, the one-to-one distributed connection method can more effectively reduce line inductance, improve filtering efficiency, and enhance power quality, making it particularly suitable for high-voltage and high-frequency applications.

[0042] Phase and magnetic field optimization: The staggered distribution of stator coil assembly three and stator coil assembly one suggests a careful design in the winding phase or magnetic pole arrangement, with the aim of optimizing the sinusoidal nature of the air gap magnetic field and reducing torque ripple and electromagnetic noise.

[0043] Co-design with the heat dissipation system:

[0044] The heat dissipation path of the built-in capacitors: The distributed capacitors are located directly within the stator frame, allowing them to directly benefit from the spiral water cooling of the water-cooled generator housing through conduction. They are also situated within the forced airflow path driven by the linked heat dissipation components. This solves the heat dissipation problem of the high-voltage capacitors themselves generating heat during operation, improving their reliability and lifespan.

[0045] Compact integration: By embedding electrical components such as capacitors inside the generator, external space is greatly saved, which is a key part of achieving the overall "compact" design of the generator.

[0046] Through the distributed, modular, and one-to-one integrated design of capacitors and coils, electrical performance and heat dissipation efficiency are optimized. This not only ensures stable and high-quality output of high-voltage power, but also reflects the core design logic of this generator as a "compact high-voltage generator with excellent heat dissipation performance" through its deep synergy with the physical structure and heat dissipation system.

[0047] The cover plates respectively abut against the outer sides of several stator coil assemblies one and several stator coil assemblies two. The end seat is rotatably provided with a bearing one, and the rotor shaft is fixed inside the inner ring of the bearing one. The rotor shaft passes through the end seat, stator side frame one, cover plate, stator side frame two, stator side frame three, cover plate, cage double side frame, cover plate, stator side frame two, stator side frame three, cover plate, cage double side frame, cover plate, stator side frame three, stator side frame two, cover plate, stator side frame one and end seat in sequence.

[0048] With the above structure, the axial fixing and heat conduction functions of the cover plate are as follows:

[0049] Mechanical fixing: The cover plates abut against the outer sides of stator coil assembly one and stator coil assembly two, respectively. Its main working principle is to provide axial clamping force to prevent these coil assemblies from axially moving under electromagnetic force or vibration, and to ensure their stable positioning within the "rotor mounting frame" formed by stator side frame two and stator side frame three.

[0050] Thermal conduction interface: As the metal component that directly contacts the heating coil, the cover plate becomes the key path for the conduction of heat from the coil to the outside. Heat is transferred to the stator side frame through the cover plate, and is finally carried away by the spiral water cooling of the water-cooled generator housing and the air cooling driven by the linkage heat dissipation end assembly, thus enhancing the heat dissipation effect.

[0051] The auxiliary support function of the end seat and bearing:

[0052] Auxiliary bearing support: A bearing is installed inside the end seats at both ends of the stator assembly, and the rotor shaft is fixed in its inner ring. This design provides an additional, intermediate rotational support point for the long rotor shaft, in addition to the main bearing support of the linkage heat dissipation end assembly and the rear end cover.

[0053] Reducing deflection and vibration: Due to the long stator assembly, the rotor shaft is prone to deflection and vibration when rotating at high speeds. The bearings in these two end seats provide auxiliary support, significantly improving the overall rigidity of the rotor shaft, suppressing bending deformation and vibration, and ensuring that the rotor assembly maintains precise alignment and stable rotation in the long stator chamber. This is crucial for power generation efficiency and smooth operation.

[0054] The through-type structure of the rotor shaft integrates functions:

[0055] Penetration and integration: The rotor shaft passes through all stator components in sequence.

[0056] Ensuring coaxiality and structural rigidity: All components are assembled around and supported by the same rotor shaft. This through-type design is the foundation for ensuring extremely high coaxiality of the entire motor from one end to the other. At the same time, it also strings all modular stator components together, forming a rigid whole through fastening at both ends to resist various stresses and deformations during operation.

[0057] The rotor assembly includes a rotor disk and a bushing. The bushing is fitted onto the rotor shaft, and the bushing has two mounting screws that penetrate the bushing and the rotor shaft perpendicularly. The rotor disk has a mounting seat in the middle, and the mounting seat has two mounting through holes. The mounting seat is fitted onto the bushing, and the mounting screws penetrate the two mounting through holes respectively. Rotor bearings are fixed at both ends of the bushing. The two rotor bearings are respectively fixed on the stator side bracket two and stator side bracket three of the rotor mounting frame at corresponding positions. Locking nuts one and two are screwed onto both ends of the bushing. The two rotor bearings are respectively located between locking nuts one and two on the same side. Copper spacers are provided on both sides of the rotor disk. A limiting plate is provided on the outer side of each copper spacer. A group of several circumferentially distributed positive magnets and a group of several circumferentially distributed negative magnets are provided on both sides of the rotor disk. The positive and negative magnets are alternately distributed and abut against the outer end face of the copper spacers and against the outer arc surface of the limiting plate.

[0058] The above structure utilizes modular assembly and power transmission principles:

[0059] Core drive connection: The rotor disc is mounted on the bushing via its mounting seat, and is secured to the bushing and rotor shaft by two vertically penetrating mounting bolts. This bushing-bolt-rotor disc assembly structure constitutes a rigid torque transmission unit, ensuring that external power can be transmitted from the rotor shaft to the entire rotor disc without loss.

[0060] Axial positioning and locking: Locking nuts one and two at both ends of the bushing are used to precisely tighten and fix the rotor bearing, thereby determining the final position of the entire rotor assembly in the axial direction and preventing axial movement during operation.

[0061] Built-in bearing support and stable rotation principle:

[0062] Direct stator frame support: Instead of being mounted on the traditional front and rear end covers, the two rotor bearings are directly mounted on the "rotor mounting bracket" formed by stator side bracket two and stator side bracket three. This built-in support design allows the long rotor shaft to be supported at multiple points.

[0063] Enhanced rigidity and stability: This multi-point support structure greatly enhances the overall rigidity of the rotor system, effectively suppressing the deflection and vibration of the rotor shaft during high-speed rotation, and ensuring a constant and precise air gap between the rotor disk and the magnets on it and the stator assembly.

[0064] High-efficiency magnetic circuit generation and auxiliary heat dissipation principle:

[0065] Alternating magnetic pole arrangement: On both sides of the rotor disk, positive and negative magnets are arranged alternately and evenly in a circular pattern. This forms a high-intensity, alternating rotating magnetic field, which is the source of cutting the stator windings and generating induced electromotive force.

[0066] Magnet Fixing and Thermal Management: The magnet is fixed in place by copper spacers and an outer limiting plate. The copper spacers not only serve as insulation and mechanical separation, but their high thermal conductivity also allows them to quickly dissipate the heat generated by the magnet during operation to the rotor disk. This heat is then carried away by the forced cooling airflow generated by the linked heat dissipation end assembly, achieving effective thermal management of the magnet and preventing it from demagnetizing due to overheating.

[0067] Both sides of the rotor disk are provided with integrally formed rotor disk side ring covers. Several circumferentially distributed partition plates are provided between the rotor disk side ring covers and the rotor disk. The rotor disk side ring covers, the rotor disk, and two adjacent partition plates form a magnet placement area. The positive magnet and the negative magnet are engaged and placed inside the corresponding magnet placement area.

[0068] With the above structure, the magnet can be precisely positioned and securely installed.

[0069] Precise partitioning: Several circumferentially distributed partition plates are set between the rotor disk side ring cover and the rotor disk body, forming multiple independent magnet placement areas on both sides of the rotor disk. Each placement area is a precisely sized slot.

[0070] Error prevention and stability: Positive and negative magnets are locked together and placed in these independent placement areas. This structure fundamentally prevents circumferential movement or radial displacement of the magnets under high-speed rotation, ensuring the accuracy and permanence of the alternating arrangement of magnetic poles, and providing a magnetic field basis for generating stable and efficient high-voltage alternating current.

[0071] Structural reinforcement and heat dissipation optimization:

[0072] Integrated Enhanced Rigidity: The rotor disk side ring cover is integrally molded with the rotor disk, forming an extremely robust composite disk body. This significantly enhances the overall rigidity of the rotor disk, enabling it to better withstand centrifugal and electromagnetic forces during high-speed rotation and reducing deformation.

[0073] Increased heat dissipation area and thermal conductivity: The baffle plate and rotor disk side ring cover, being metal structures, increase the contact area with the internal copper baffles and magnets. Together, they form an extended heat conduction network from the inside of the magnet to the surface of the rotor disk, which can more quickly and evenly dissipate the heat generated by the magnet's operation, and then dissipate it through the surface of the rotor disk into the cooling airflow driven by the linked heat dissipation end components, achieving efficient thermal management of the magnet.

[0074] Easy assembly and maintenance: The modular magnet placement area design simplifies and streamlines the magnet installation process, improving assembly efficiency and accuracy. It also facilitates magnet inspection and replacement during maintenance.

[0075] Compared with existing technologies, this compact high-voltage generator with excellent heat dissipation performance has the following advantages:

[0076] It adopts a dual system of "water-cooled main heat dissipation + air-cooled auxiliary heat dissipation". The spiral water-cooling channel has a large area and high efficiency; the linked air-cooling starts automatically with the rotor. The two work together to ensure continuous and efficient cooling of core components under compact high pressure, thereby improving operational reliability and lifespan.

[0077] Through deep integration, the cooling fan and power shaft are combined into one, and a distributed internal capacitor design is adopted, eliminating external accessories, significantly reducing the size, increasing power density, and adapting to occasions with limited installation space.

[0078] The modular stator frame and rotor with built-in multi-point support structure enhance overall rigidity, effectively suppress vibration and deformation at high speeds, and maintain a constant small air gap, thereby ensuring high power generation efficiency, low noise and stable operation.

[0079] By adopting a distributed layout of "one-to-one correspondence between coil and capacitor", the filter capacitor is placed close to the corresponding coil, which greatly shortens the filter circuit, improves the filtering effect and power factor compensation capability, optimizes the voltage waveform of high voltage output, and reduces harmonics.

[0080] Both the stator and rotor adopt a detachable modular structure. The stator is assembled from the side frame, and the rotor magnets are clamped into the prefabricated slot. This design facilitates production quality control and makes subsequent maintenance and component replacement easier, reducing maintenance costs. Attached Figure Description

[0081] Figure 1 is a three-dimensional structural diagram of the present invention.

[0082] Figure 2 is an exploded structural diagram of the present invention.

[0083] Figure 3 is a schematic diagram of the structure of the linkage heat dissipation end component of the present invention.

[0084] Figure 4 is a schematic diagram of the structure of the rear end cover in this invention.

[0085] Figure 5 is a schematic diagram of the structure of the water-cooled generator housing in this invention.

[0086] Figure 6 is an exploded three-dimensional structural diagram of the stator assembly and rotor assembly in this invention.

[0087] Figure 7 is an exploded front view of the stator assembly and rotor assembly in this invention.

[0088] Figure 8 is a schematic diagram of the rotor assembly in this invention.

[0089] In the diagram: 1. Linkage cooling end assembly; 2. Water-cooled generator housing; 3. Mounting base; 4. Rear end cover; 5. Electrical control box; 6. Stator assembly; 7. Main end cooling cover; 8. Side end cooling cover; 9. End flange; 10. Front stator mounting protrusion; 11. Air guide frame; 12. Cooling fan; 13. Linkage flange; 14. Linkage shaft; 15. Rear end cover body; 16. Rear end cover fixing through hole; 17. Rear end stator mounting protrusion; 18. Air inlet; 19. Bearing mounting hole; 20. Water inlet connector; 21. Generator housing body; 22. Cooling spiral channel; 23. Water outlet connector. 24. Rotor shaft; 25. End seat; 26. Stator side frame one; 27. Capacitor one; 28. Cover plate; 29. ​​Stator side frame two; 30. Stator coil assembly one; 31. Rotor assembly; 32. Stator side frame three; 33. Stator coil assembly two; 34. Cage double-sided frame; 35. Capacitor two; 36. Rotor disc; 37. Rotor disc side ring cover; 38. Forward magnet; 39. Reverse magnet; 40. Copper spacer; 41. Mounting screw; 42. Limiting plate; 43. Locking nut one; 44. Locking nut two; 45. Rotor bearing; 46. Shaft sleeve; 47. Mounting seat; 48. Spacer plate. Detailed Implementation

[0090] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0091] As shown in Figures 1-8, this compact high-voltage generator with excellent heat dissipation performance includes a water-cooled generator housing 2. The rear end of the water-cooled generator housing 2 is provided with a rear end cover 4, and the front end of the water-cooled generator housing 2 is provided with a linkage heat dissipation end assembly 1. A stator assembly 6 is provided between the rear end cover 4 and the linkage heat dissipation end assembly 1. The stator assembly 6 is located inside the water-cooled generator housing 2. A rotor shaft 24 is rotatably provided inside the stator assembly 6, and the two ends of the rotor shaft 24 are respectively rotatably provided between the rear end cover 4 and the linkage heat dissipation end assembly 1. Several rotor assemblies 31 are provided on the rotor shaft 24, and the several rotor assemblies 31 are distributed inside the stator assembly 6. An electrical control box 5 is provided above the water-cooled generator housing 2, and a mounting base 3 is provided below the water-cooled generator housing 2.

[0092] When an external power drives the linkage heat dissipation end assembly 1 to rotate, the rotor shaft 24 rotates between the rear end cover 4 and the linkage heat dissipation end assembly 1. The rotor assembly 31 fixed on it rotates synchronously inside the stator assembly 6. The magnetic field of the rotating rotor assembly 31 moves relative to the stator winding of the stationary stator assembly 6, cutting the magnetic field lines, thereby generating an induced electromotive force in the stator assembly 6 and outputting high-voltage electrical energy.

[0093] The key to its heat dissipation performance lies in the linkage heat dissipation end component 1. The built-in fan of the linkage heat dissipation end component 1 actively drives the cooling airflow through the water-cooled generator housing 2 when the shaft rotates, and forces the heat-generating stator assembly 6 and rotor assembly 31 to cool them, thus achieving efficient heat dissipation in a compact structure.

[0094] The electrical control box 5 is responsible for regulating, controlling, and protecting the generated electrical energy, while the mounting base 3 provides stable support for the entire generator.

[0095] The water-cooled generator housing 2 can be connected to an external water pump for circulating water cooling.

[0096] The water-cooled generator housing 2 includes a generator housing body 21. Both the front and rear ends of the generator housing body 21 are provided with mounting flanges. The inner layer of the generator housing body 21 is provided with a spiral cooling channel 22. The generator housing body 21 is provided with a water inlet connector 20 and a water outlet connector 23. The water inlet connector 20 and the water outlet connector 23 are respectively connected to the two ends of the cooling spiral channel 22.

[0097] External cooling water is pumped in through the inlet connector 20 and enters the specially designed cooling spiral channel 22 inside the housing. The cooling water flows along this spiral path, which greatly extends the path and residence time of the water flow in the housing, so that the cooling water can fully and evenly absorb the heat generated by the internal stator assembly 6 and rotor assembly 31 during operation and conduct it to the generator housing body 21. The hot water after absorbing heat finally flows out from the outlet connector 23, completing one cycle.

[0098] The spiral channel design significantly increases the heat exchange area and efficiency; the cooling channel is directly built into the pressure-bearing generator housing 21, which is compact and provides a more direct heat dissipation path.

[0099] Dual heat dissipation system synergy: The water cooling system is combined with the forced air cooling of the linkage heat dissipation end component 1 to form a powerful heat dissipation system of "water cooling main heat dissipation + air cooling auxiliary heat dissipation", ensuring that the high-voltage generator can operate continuously and stably in a compact space.

[0100] The rear end cover 4 includes a rear end cover body 15. The rear end cover body 15 has several circumferentially distributed rear end cover fixing through holes 16. The rear end cover body 15 is detachably mounted on the mounting flange located at the rear end of the generator housing body 21 through the several rear end cover fixing through holes 16. The front side of the rear end cover body 15 has a rear end stator mounting protrusion 17. The rear end stator mounting protrusion 17 has an air inlet hole 18. The rear side of the air inlet hole 18 has a filter screen. The middle part of the rear end stator mounting protrusion 17 has a bearing mounting hole 19. The rear end of the rotor shaft 24 is fixed with a mounting bearing, which is located inside the bearing mounting hole 19.

[0101] The rear end cover body 15 is detachably mounted on the mounting flange at the rear end of the generator housing body 21 through the circumferentially distributed rear end cover fixing through holes 16, forming a sealed cavity at the rear end of the generator.

[0102] Stator positioning and fixing: The rear stator mounting protrusion 17 on the front side of the rear cover body 15 is used to accurately align and install the rear end of the stator assembly 6, ensuring the stable positioning of the stator within the housing;

[0103] Bearing support and rotation: The bearing mounting hole 19 in the middle of the rear stator mounting protrusion 17 is used to install and fix the mounting bearing at the rear end of the rotor shaft 24, providing stable and reliable rotational support for the rotor shaft;

[0104] Auxiliary heat dissipation and protection: The air inlet 18 on the rear stator mounting protrusion 17 is the key entrance to the air-cooled heat dissipation channel inside the generator. External cooling air enters through this hole under the drive of the built-in fan of the linkage heat dissipation component 1, flows through the internal heat-generating components (stator assembly 6, rotor assembly 31) for cooling, and the filter screen on the rear side can effectively prevent dust and other impurities from entering the generator, ensuring clean and safe operation.

[0105] The rear cover 4 not only completes the enclosure and support of the generator's rear structure, but its air inlet 18 and filter screen are also designed in conjunction with the linkage heat dissipation end component 1 to form a complete forced air cooling airflow circuit, which is an indispensable component to ensure that the generator achieves excellent heat dissipation performance in a compact structure.

[0106] The linkage heat dissipation end assembly 1 includes an end heat dissipation main cover 7, an end heat dissipation side cover 8 on the rear side of the end heat dissipation main cover 7, an end flange 9 on the rear side of the end heat dissipation side cover 8, and an end flange 9 detachably mounted on a mounting flange located at the front end of the generator housing body 21. Filter screens are provided inside the ventilation holes of the end heat dissipation main cover 7 and the end heat dissipation side cover 8. An air guide frame 11 is provided inside the end heat dissipation side cover 8. A heat dissipation fan 12 is rotatably mounted in the middle of the air guide frame 11. The heat dissipation fan 12 is located inside the end heat dissipation main cover 7. A front stator mounting protrusion 10 is provided on the rear side of the end flange 9. A linkage shaft 14 is fixed to the front end of the main shaft of the heat dissipation fan 12, and a linkage flange 13 is fixed to the end of the linkage shaft 14. The rear end of the main shaft of the heat dissipation fan 12 is fixedly connected to the front end of the rotor shaft 24.

[0107] Structural connection and sealing: The end flange 9 is detachably installed on the mounting flange at the front end of the generator housing body 21, and together with the rear end cover 4, it forms a complete sealed housing of the generator.

[0108] The front stator mounting protrusion 10 is used to precisely install and fix the front end of the stator assembly 6, and works in conjunction with the rear stator mounting protrusion 17 to ensure that the stator assembly is stably centered.

[0109] Power transmission and power generation drive: External power is input through the linkage flange 13 to drive the linkage shaft 14 to rotate; the linkage shaft 14 directly drives the main shaft of the cooling fan 12, and the rear end of the main shaft is fixedly connected to the front end of the rotor shaft 24; therefore, while the external power drives the cooling fan 12 to rotate, it also synchronously drives the rotor shaft 24 and the rotor assembly 31 on it to rotate, thereby starting the power generation process.

[0110] Forced air cooling startup: When the cooling fan 12 rotates at high speed with the main shaft, it starts to work as a built-in centrifugal fan or axial fan; a negative pressure is formed in the middle of the cooling fan 12, and cold air enters the generator from the air inlet 18 on the rear cover 4. The airflow flows through the heated stator assembly 6 and rotor assembly 31, carrying away the heat, and is finally discharged through the ventilation holes of the end cooling main cover 7 and the end cooling side cover 8, thereby achieving efficient cooling of the generator core;

[0111] The linkage heat dissipation end component 1 cleverly realizes the mechanical coupling of power transmission and cooling fan; its core principle is: external power drives the cooling fan wheel 12 to rotate, achieving two goals at once - it directly drives the generator rotor to generate electricity, and at the same time, it generates the forced airflow necessary to cool the generator as a fan; it and the water-cooled generator housing 2 constitute a "wind-water" coordinated heat dissipation system.

[0112] The stator assembly 6 includes, from front to back, an end seat 25, a first stator side frame 26, a second stator side frame 29, a third stator side frame 32, a cage-type double-sided frame 34, a second stator side frame 29, a third stator side frame 32, a cage-type double-sided frame 34, a third stator side frame 32, a second stator side frame 29, a first stator side frame 26, and an end seat 25. The end seat 25 is detachably connected to the outside of the first stator side frame 26 on the same side. The first stator side frame 26 and the second stator side frame 29 are interdependent. The stator side frame 29 and stator side frame 32 are detachably connected, and the stator side frame 29 and stator side frame 32 form a rotor mounting frame. Both sides of the rotor mounting frame are detachably equipped with cover plates 28. The cage-type double side frame 34 is detachably connected to the stator side frame 29 and stator side frame 32 on both sides respectively. The stator side frame 26 at both ends is fixed on the rear stator mounting protrusion 17 and the front stator mounting protrusion 10 respectively.

[0113] Constructing a stable installation platform and magnetic circuit skeleton: The end seat 25, stator side frame one 26, stator side frame two 29, stator side frame three 32 and cage-type double side frame 34 are assembled in a specific order to form a solid mechanical skeleton and magnetic circuit body that supports the stator winding.

[0114] Forming and encapsulating the rotor chamber: The stator side frame 29 and the stator side frame 32 are combined to form a rotor mounting frame, which is closed on both sides by cover plates 28, thereby creating a precise and sealed cylindrical chamber therein to accommodate and ensure that the rotor assembly 31 rotates concentrically with it;

[0115] Achieving overall positioning and fixation: The stator side brackets 26 at both ends of the assembly are fixed to the front stator mounting protrusion 10 and the rear stator mounting protrusion 17, respectively. This design ensures precise axial and radial alignment and reliable fixation of the entire long stator assembly inside the housing, which is crucial for maintaining a constant air gap between the stator and rotor, thus affecting power generation efficiency and operational stability.

[0116] Easy to manufacture, assemble, and maintain: All components are detachably connected. This modular design greatly simplifies the manufacturing process (segmented processing), reduces the difficulty of assembling large components, and facilitates future maintenance, winding replacement, or internal cleaning.

[0117] The working principle of stator assembly 6 is reflected in its innovative mechanical structure design. Through a modular frame system that is precisely layered, rigidly connected, and easy to disassemble and assemble, it achieves efficient support for the stator windings in a limited space, provides precise space for rotor operation, and ensures stable integration with the front and rear end covers of the generator.

[0118] The stator side frame 26 has several circumferentially distributed capacitors 27 inside. The cage-type double-sided frame 34 has a set of several circumferentially distributed capacitors 35 on both sides inside. The stator side frame 29 has several circumferentially distributed stator coil assemblies 30 inside. The stator side frame 32 has several circumferentially distributed stator coil assemblies 33 inside. The number of stator coil assemblies 30 and stator coil assemblies 33 are the same and they are directly opposite each other. Between the stator side frame 29 and the stator side frame 32, there are several circumferentially distributed stator coil assemblies 3. The stator coil assemblies 3 are located on the periphery of the stator coil assemblies 30 and are staggered with the stator coil assemblies 30. The capacitors 27 and stator coil assemblies 30 are electrically connected in a one-to-one correspondence. The capacitors 35 and stator coil assemblies 33 are electrically connected in a one-to-one correspondence.

[0119] Modular and distributed electrical layout:

[0120] Layered coil arrangement: Stator coil assembly one 30, stator coil assembly two 33, and stator coil assembly three are precisely and layered within a "rotor mounting frame" module composed of stator side frame two 29 and stator side frame three 32. This layout optimizes the magnetic field distribution and facilitates winding heat dissipation.

[0121] Distributed integration of capacitors in proximity: Unlike the traditional centralized capacitor arrangement, this design directly and disperses capacitor 27 and capacitor 35 within the stator side frame 26 and the cage-type double-sided frame 34, close to the corresponding coil groups. Capacitor 27 is electrically connected to stator coil assembly 30 in a one-to-one correspondence, and capacitor 35 is electrically connected to stator coil assembly 33 in a one-to-one correspondence, forming multiple independent "coil-capacitor" pairing units.

[0122] Core electrical function principle:

[0123] Power generation and filtering: The stator coil assembly cuts the rotor magnetic field to generate high-voltage alternating current. The capacitors connected to it one-to-one (capacitor 1 27, capacitor 2 35) mainly serve the functions of filtering, power factor compensation, and suppressing voltage spikes. This "one-to-one" distributed connection method can more effectively reduce line inductance, improve filtering efficiency, and enhance power quality compared to centralized filtering, making it particularly suitable for high-voltage and high-frequency applications.

[0124] Phase and magnetic field optimization: The staggered distribution of stator coil assembly 3 and stator coil assembly 1 30 suggests a careful design in the winding phase or magnetic pole arrangement, with the aim of optimizing the sinusoidal nature of the air gap magnetic field and reducing torque ripple and electromagnetic noise.

[0125] Co-design with the heat dissipation system:

[0126] The heat dissipation path of the built-in capacitors: The distributed capacitors are located directly within the stator frame, allowing them to directly benefit from the spiral water cooling of the water-cooled generator housing 2 through conduction. They are also within the forced airflow path driven by the linked heat dissipation component 1. This solves the heat dissipation problem of the high-voltage capacitors generating heat during operation, improving reliability and lifespan.

[0127] Compact integration: By embedding electrical components such as capacitors inside the generator, external space is greatly saved, which is a key part of achieving the overall "compact" design of the generator.

[0128] Through the distributed, modular, and one-to-one integrated design of capacitors and coils, the electrical performance (filtering, waveform, power factor) and heat dissipation efficiency are optimized. This not only ensures stable and high-quality output of high-voltage power, but also reflects the core design logic of this generator as a "compact high-voltage generator with excellent heat dissipation performance" through its deep synergy with the physical structure and heat dissipation system.

[0129] The cover plate 28 abuts against the outer sides of several stator coil assemblies 30 and several stator coil assemblies 33 respectively. The end seat 25 is rotatably provided with a bearing 1. The rotor shaft 24 is fixed inside the inner ring of the bearing 1. The rotor shaft 24 passes through the end seat 25, stator side frame 1 26, cover plate 28, stator side frame 29, stator side frame 32, cover plate 28, cage double side frame 34, cover plate 28, stator side frame 29, stator side frame 32, cover plate 28, cage double side frame 34, cover plate 28, stator side frame 32, stator side frame 29, cover plate 28, stator side frame 1 26 and end seat 25 in sequence.

[0130] Axial fixing and heat conduction functions of cover plate 28:

[0131] Mechanical fixing: The cover plate 28 abuts against the outer side of stator coil assembly 1 30 and stator coil assembly 2 33 respectively. Its main working principle is to provide axial clamping force to prevent these coil assemblies from axially moving under electromagnetic force or vibration, and to ensure their stable positioning within the "rotor mounting frame" formed with stator side frame 2 29 and stator side frame 3 32.

[0132] Heat conduction interface: As a metal component that directly contacts the heating coil, the cover plate 28 becomes a key path for the conduction of heat from the coil to the outside. Heat is transferred to the stator side frame through the cover plate and is finally carried away by the spiral water cooling of the water-cooled generator housing 2 and the air cooling driven by the linkage heat dissipation end assembly 1, thus enhancing the heat dissipation effect.

[0133] The auxiliary support function of end seat 25 and bearing 1:

[0134] Auxiliary bearing support: A bearing is installed inside the end seats 25 at both ends of the stator assembly 6, and the rotor shaft 24 is fixed in its inner ring. This design provides an additional, intermediate rotational support point for the long rotor shaft 24, in addition to the main bearing support of the linkage heat dissipation end assembly 1 and the rear end cover 4.

[0135] Reducing deflection and vibration: Due to the long stator assembly, the rotor shaft is prone to deflection and vibration when rotating at high speed. The bearings in the two end seats 25 form an auxiliary support, which significantly improves the overall rigidity of the rotor shaft, suppresses bending deformation and vibration, and ensures that the rotor assembly 31 maintains precise alignment and stable rotation in the long stator chamber, which is crucial for power generation efficiency and smooth operation.

[0136] The through-type structure of rotor shaft 24 integrates functions:

[0137] Through and integrated: The rotor shaft 24 passes through all stator assembly components (end seats, side frames, cover plates, and cage-type double side frames) in sequence. This not only describes its physical path, but also reflects a highly integrated structural design principle.

[0138] Ensuring coaxiality and structural rigidity: All components are assembled around and supported by the same rotor shaft. This through-type design is the foundation for ensuring extremely high coaxiality of the entire motor from one end to the other. At the same time, it also "strings" all modular stator components together, forming a rigid whole through the fastening at both ends (connected to the linkage heat dissipation end assembly and the rear end cover), resisting various stresses and deformations during operation.

[0139] The rotor assembly 31 includes a rotor disk 36 and a bushing 46. The bushing 46 is fitted onto the rotor shaft 24, and the bushing 46 has two mounting screws 41 that perpendicularly penetrate the bushing 46 and the rotor shaft 24. A mounting seat 47 is located in the middle of the rotor disk 36, and the mounting seat 47 has two mounting through holes. The mounting seat 47 is fitted onto the bushing 46, and the mounting screws 41 pass through the two mounting through holes respectively. Rotor bearings 45 are fixed to both ends of the bushing 46. The two rotor bearings 45 are respectively fixed to the stator side brackets 29 and 32 of the rotor mounting bracket at corresponding positions. Both ends of the bushing 46 are screwed... The rotor disk 36 is equipped with a locking nut 43 and a locking nut 44. Two rotor bearings 45 are located between the locking nuts 43 and 44 on the same side. Copper spacers 40 are provided on both sides of the rotor disk 36. A limiting plate 42 is provided on the outer side of each copper spacer 40. A group of several circumferentially distributed positive magnets 38 and a group of several circumferentially distributed negative magnets 39 are provided on both sides of the rotor disk 36. The positive magnets 38 and negative magnets 39 are alternately distributed. The positive magnets 38 and negative magnets 39 abut against the outer end face of the copper spacer 40 and abut against the outer arc surface of the limiting plate 42.

[0140] Modular assembly and power transmission principles:

[0141] Core transmission connection: The rotor disk 36 is fitted onto the bushing 46 via its mounting base 47, and is secured to the bushing 46 and rotor shaft 24 by two vertically penetrating mounting screws 41. This bushing-screw-rotor disk assembly structure constitutes a rigid torque transmission unit, ensuring that external power can be transmitted from the rotor shaft 24 to the entire rotor disk 36 without loss.

[0142] Axial positioning and locking: Locking nuts 43 and 44 at both ends of bushing 46 are used to precisely press and fix rotor bearing 45, thereby determining the final position of the entire rotor assembly in the axial direction and preventing axial movement during operation.

[0143] Built-in bearing support and stable rotation principle:

[0144] The stator frame is directly supported: the two rotor bearings 45 are not mounted on the traditional front and rear end covers, but are directly mounted on the "rotor mounting bracket" formed by stator side bracket 29 and stator side bracket 32. The built-in support design allows the long rotor shaft 24 to be supported at multiple points (front end cover, rear end cover, and the two internal bearings here).

[0145] Enhanced rigidity and stability: This multi-point support structure significantly enhances the overall rigidity of the rotor system, effectively suppressing rotor shaft deflection and vibration during high-speed rotation, and ensuring a constant and precise air gap between the rotor disk 36 and its magnets and the stator assembly 6. This is a key mechanical guarantee for achieving high-efficiency, low-vibration, and low-noise power generation.

[0146] High-efficiency magnetic circuit generation and auxiliary heat dissipation principle:

[0147] Alternating magnetic pole arrangement: On both sides of the rotor disk 36, positive magnets 38 and negative magnets 39 are arranged in an alternating, circumferentially distributed manner. This forms a high-intensity, alternating rotating magnetic field, which is the source of cutting the stator winding and generating induced electromotive force.

[0148] Magnet Fixing and Thermal Management: The magnet is fixed by copper spacers 40 and an outer limiting plate 42. The copper spacers 40 not only serve as insulation and mechanical separation, but their high thermal conductivity also allows them to quickly dissipate the heat generated by the magnet during operation to the rotor disk 36. This heat is then carried away by the forced cooling airflow generated by the linked heat dissipation end assembly 1, achieving effective thermal management of the magnet and preventing it from demagnetizing due to overheating.

[0149] Both sides of the rotor disk 36 are provided with integrally formed rotor disk side ring covers 37. Several circumferentially distributed partition plates 48 are provided between the rotor disk side ring covers 37 and the rotor disk 36. A magnet placement area is formed between the rotor disk side ring covers 37, the rotor disk 36 and two adjacent partition plates 48. The positive magnet 38 and the negative magnet 39 are engaged and placed inside the corresponding magnet placement area.

[0150] Precise positioning and secure installation of magnets:

[0151] Precise partitioning: Several circumferentially distributed partition plates 48 are set between the rotor disk side ring cover 37 and the rotor disk 36 body, forming multiple independent magnet placement areas on both sides of the rotor disk. Each placement area is a precisely sized slot.

[0152] Error prevention and stability: The positive magnet 38 and the negative magnet 39 are locked together in these independent placement areas. This structure fundamentally prevents the magnets from circumferentially shifting or radially displacing under high-speed rotation, ensuring the accuracy and permanence of the alternating arrangement of magnetic poles, and providing a magnetic field basis for generating stable and efficient high-voltage alternating current.

[0153] Structural reinforcement and heat dissipation optimization:

[0154] Integrated rigidity enhancement: The rotor disk side ring cover 37 and the rotor disk 36 are integrally molded, forming an extremely robust composite disk body. This significantly enhances the overall rigidity of the rotor disk, enabling it to better withstand the centrifugal force and electromagnetic force of high-speed rotation and reduce deformation.

[0155] Increased heat dissipation area and thermal conductivity: The baffle plate 48 and the rotor disk side ring cover 37, being metal structures, increase the contact area with the internal copper baffle plate 40 and the magnet. Together, they form an extended heat conduction network from the inside of the magnet to the surface of the rotor disk, which can more quickly and evenly dissipate the heat generated by the magnet's operation, and then dissipate it through the surface of the rotor disk 36 into the cooling airflow driven by the linkage heat dissipation end assembly 1, thus achieving efficient thermal management of the magnet.

[0156] Easy assembly and maintenance: The modular magnet placement area design simplifies and streamlines the magnet installation process, improving assembly efficiency and accuracy. It also facilitates magnet inspection and replacement during maintenance.

[0157] Working principle of the invention:

[0158] I. Power Input and Drive: External power is input through the linkage flange 13 to drive the main shaft (i.e., linkage shaft 14) of the cooling fan 12 in the linkage cooling end assembly 1 to rotate.

[0159] Rotor rotation: The rotor shaft 24 at the rear end of the main shaft rotates synchronously, driving several rotor assemblies 31 fixed on it to rotate at high speed inside the stator assembly 6.

[0160] Electromagnetic induction power generation: The alternating positive magnets 38 and negative magnets 39 on both sides of the rotor assembly 31 generate a high-speed rotating magnetic field. This magnetic field cuts the stator coil assembly 1 30, stator coil assembly 2 33 and stator coil assembly 3 arranged in layers in the stator assembly 6, thereby generating an induced electromotive force in the stator winding and outputting high-voltage alternating current.

[0161] II. Modular Structure and Mechanical Integration Principles

[0162] Modular stator frame: The stator assembly 6 is detachably connected from components such as end base 25, stator side frame one 26, stator side frame two 29, stator side frame three 32, and cage-type double side frame 34. This design forms a robust skeleton supporting the coils and capacitors, and is fixed to the front stator mounting protrusion 10 and the rear stator mounting protrusion 17 by the stator side frame one 26 at both ends, ensuring the precise alignment and stability of the entire stator within the housing.

[0163] Rotor internal support and integration: The rotor assembly 31 is rigidly connected to the rotor shaft 24 via the bushing 46 and mounting screw 41. The rotor bearings 45 at both ends are directly mounted on the "rotor mounting frame" formed by the stator side frame 29 and the stator side frame 32, forming an internal multi-point support. Combined with the auxiliary bearing 1 that runs through all stator components and is located in the end seat 25, a high-rigidity, high-coaxiality rotating system is constructed, effectively suppressing the deflection and vibration of the long shaft system.

[0164] Precision assembly of magnets: The integrally formed rotor disk side ring cover 37 on both sides of the rotor disk 36 and the partition plate 48 form an independent magnet placement area, which precisely locks the positive magnet 38 and the negative magnet 39 to prevent displacement during high-speed rotation.

[0165] III. High-efficiency collaborative heat dissipation principle (dual heat dissipation system)

[0166] Active forced air cooling (auxiliary heat dissipation):

[0167] Power coupling: The cooling fan 12, which serves as the power input end, functions as a centrifugal / axial fan by rotating itself.

[0168] Airflow circulation: When the cooling fan 12 rotates at high speed with the main shaft, it starts to work as a built-in centrifugal fan or axial fan; a negative pressure is formed in the middle of the cooling fan 12, and cold air enters the generator from the air inlet 18 on the rear cover 4. The airflow flows through the heated stator assembly 6 and rotor assembly 31, carrying away the heat, and is finally discharged through the ventilation holes of the end cooling main cover 7 and the end cooling side cover 8, thereby achieving efficient cooling of the generator core and forming an efficient air-cooling circulation loop.

[0169] High-efficiency spiral water cooling (main heat dissipation):

[0170] Water circuit design: External cooling water enters the cooling spiral channel 22 inside the water-cooled generator housing 2 through the water inlet connector 20.

[0171] High-efficiency heat exchange: The spiral path greatly extends the water path and heat exchange time. The cooling water fully absorbs the heat generated by the internal stator and rotor components and conducted through the generator housing 21. The heated water flows out from the outlet joint 23, completing the circulation. This design provides direct, large-area housing temperature control.

[0172] Distributed thermal management:

[0173] Capacitor heat dissipation: The distributed capacitors 27 and 35 are directly built into the stator frame. Their heat can be conducted to the casing to participate in water cooling and is in the air cooling airflow.

[0174] Heat dissipation of magnets and coils: The heat of the magnets in the rotor assembly 31 is conducted to the air-cooled airflow through the copper spacer 40 and rotor disk 36; the heat of the stator coils is conducted to the side frame through the cover plate 28, and then carried away by the housing temperature control and air cooling.

[0175] IV. Electrical System Optimization Principles

[0176] Distributed filtering: Capacitor 27 and stator coil assembly 30 are connected in a one-to-one correspondence, and capacitor 35 and stator coil assembly 33 are connected in a one-to-one correspondence. This distributed arrangement greatly shortens the filter loop, reduces line inductance, and improves filtering efficiency, power factor compensation capability, and voltage waveform quality, making it particularly suitable for high-voltage, high-frequency output.

[0177] Winding optimization: The multi-layered, staggered stator coil assembly design optimizes the magnetic field waveform, which helps reduce torque ripple and electromagnetic noise.

[0178] V. Overall Collaborative Workflow

[0179] External power drives the linkage heat dissipation end assembly 1 → rotor shaft 24 and rotor assembly 31 to rotate at high speed (while the heat dissipation fan 12 starts) → the rotating magnetic field cuts the stator winding to generate high voltage electricity → the electrical control box 5 regulates and controls the electrical energy → at the same time, the forced airflow generated by the heat dissipation fan 12 cools the interior, and the spiral water channel of the water-cooled generator housing 2 provides the main cooling for the housing → the generated heat is carried out by the air and water dual systems in a coordinated manner → the entire system operates stably under the support of the mounting base 3.

[0180] In summary, the system employs a dual-system approach of "water-cooled main heat dissipation + air-cooled auxiliary heat dissipation." The spiral water-cooling channel has a large area and high efficiency; the linked air-cooling automatically starts with the rotor. The two systems work together to ensure continuous and efficient cooling of core components under compact high pressure, thereby improving operational reliability and lifespan.

[0181] Through deep integration, the cooling fan and power shaft are combined into one, and a distributed internal capacitor design is adopted, eliminating external accessories, significantly reducing the size, increasing power density, and adapting to occasions with limited installation space.

[0182] The modular stator frame and rotor with built-in multi-point support structure enhance overall rigidity, effectively suppress vibration and deformation at high speeds, and maintain a constant small air gap, thereby ensuring high power generation efficiency, low noise and stable operation.

[0183] By adopting a distributed layout of "one-to-one correspondence between coil and capacitor", the filter capacitor is placed close to the corresponding coil, which greatly shortens the filter circuit, improves the filtering effect and power factor compensation capability, optimizes the voltage waveform of high voltage output, and reduces harmonics.

[0184] Both the stator and rotor adopt a detachable modular structure. The stator is assembled from the side frame, and the rotor magnets are clamped into the prefabricated slot. This design facilitates production quality control and makes subsequent maintenance and component replacement easier, reducing maintenance costs.

[0185] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A compact high-voltage generator with excellent heat dissipation performance, comprising a water-cooled generator housing (2), characterized in that, The water-cooled generator housing (2) has a rear end cover (4) at its rear end and a linkage heat dissipation end assembly (1) at its front end. A stator assembly (6) is located between the rear end cover (4) and the linkage heat dissipation end assembly (1). The stator assembly (6) is located inside the water-cooled generator housing (2). A rotor shaft (24) is rotatably mounted inside the stator assembly (6). Both ends of the rotor shaft (24) are rotatably mounted between the rear end cover (4) and the linkage heat dissipation end assembly (1). Several rotor assemblies (31) are mounted on the rotor shaft (24). Several rotor assemblies (31) are distributed inside the stator assembly (6). An electrical control box (5) is located above the water-cooled generator housing (2), and a mounting base is located below the water-cooled generator housing (2). (3); The water-cooled generator housing (2) includes a generator housing body (21), with mounting flanges at both the front and rear ends of the generator housing body (21). The inner layer of the generator housing body (21) is provided with a spiral cooling channel (22) arranged in a spiral pattern. The generator housing body (21) is provided with a water inlet connector (20) and a water outlet connector (23), which are respectively connected to the two ends of the cooling spiral channel (22). The linkage heat dissipation end assembly (1) includes an end heat dissipation main cover (7), an end heat dissipation side cover (8) is provided on the rear side of the end heat dissipation main cover (7), and an air guide frame (11) is provided inside the end heat dissipation side cover (8). A heat dissipation fan wheel (12) is rotatably provided in the middle of the air guide frame (11). (12) Located inside the end heat dissipation main cover (7), the rear end of the main shaft of the heat dissipation fan (12) is fixedly connected to the front end of the rotor shaft (24); the rear end cover (4) includes a rear end cover body (15), and the front side of the rear end cover body (15) is provided with a rear end stator mounting protrusion (17); the rear side of the end heat dissipation side cover (8) is provided with an end flange (9), and the rear side of the end flange (9) is provided with a front end stator mounting protrusion (10); the stator assembly (6) includes, from front to back, an end seat (25), a stator side frame one (26), a stator side frame two (29), a stator side frame three (32), a cage-type double side frame (34), a stator side frame two (29), a stator side frame three (32), a cage-type double side frame (34), and a stator side frame three (26). 32) Stator side frame 2 (29), stator side frame 1 (26) and end seat (25), end seat (25) is detachably connected to the outside of stator side frame 1 (26) on the same side, stator side frame 1 (26) and stator side frame 2 (29) are detachably connected, stator side frame 2 (29) and stator side frame 3 (32) are detachably connected, and stator side frame 2 (29) and stator side frame 3 (32) form a rotor mounting frame, and both sides of the rotor mounting frame are detachably provided with cover plates (28), and the cage-type double side frame (34) is detachably connected to stator side frame 2 (29) and stator side frame 3 (32) on both sides respectively, and stator side frame 1 (26) at both ends is fixed on the rear stator mounting protrusion (17) and the front stator mounting protrusion (10) respectively;The stator side frame 1 (26) is provided with several circumferentially distributed capacitors 1 (27) inside. The cage-type double-sided frame (34) is provided with a set of several circumferentially distributed capacitors 2 (35) on both sides inside. The stator side frame 2 (29) is provided with several circumferentially distributed stator coil assemblies 1 (30) inside. The stator side frame 3 (32) is provided with several circumferentially distributed stator coil assemblies 2 (33) inside. The number of stator coil assemblies 1 (30) and stator coil assemblies 2 (33) are the same and they are directly opposite each other. There are several circumferentially distributed stator coil assemblies 3 between the stator side frame 2 (29) and the stator side frame 3 (32). The stator coil assemblies 3 are located on the periphery of the stator coil assemblies 1 (30) and are staggered with the stator coil assemblies 1 (30). The capacitors 1 (27) and stator coil assemblies 1 (30) are electrically connected in a one-to-one correspondence. The second stator (35) is electrically connected to the second stator coil assembly (33) in a one-to-one correspondence; the cover plate (28) abuts against the outer side of the first stator coil assembly (30) and the second stator coil assembly (33) respectively; the end seat (25) is provided with a first bearing for rotation; the rotor shaft (24) is fixed inside the inner ring of the first bearing; the rotor shaft (24) passes through the end seat (25), the first stator side frame (26), the cover plate (28), the second stator side frame (29), the third stator side frame (32), the cover plate (28), the cage double side frame (34), the cover plate (28), the second stator side frame (29), the third stator side frame (32), the cover plate (28), the cage double side frame (34), the cover plate (28), the third stator side frame (32), the second stator side frame (29), the cover plate (28), the first stator side frame (26) and the end seat (25) in sequence;The rotor assembly (31) includes a rotor disk (36) and a bushing (46). The bushing (46) is fitted onto the rotor shaft (24), and the bushing (46) is provided with two mounting screws (41) that perpendicularly penetrate the bushing (46) and the rotor shaft (24). The rotor disk (36) is provided with a mounting seat (47) in the middle, and the mounting seat (47) has two mounting through holes. The mounting seat (47) is fitted onto the bushing (46), and the mounting screws (41) penetrate the two holes respectively. The bushing (46) has a through hole, and rotor bearings (45) are fixed at both ends. The two rotor bearings (45) are respectively fixed on the stator side brackets 2 (29) and 3 (32) of the rotor mounting bracket at the corresponding positions. Locking nuts 1 (43) and 2 (44) are screwed to both ends of the bushing (46). The two rotor bearings (45) are located between the locking nuts 1 (43) and 2 (44) on the same side. The rotor disc (36) has two... Each side is provided with a copper spacer (40), and each outer side of the copper spacer (40) is provided with a limiting plate (42). Each side of the rotor disk (36) is provided with a group of several circumferentially distributed positive magnets (38) and a group of several circumferentially distributed negative magnets (39). The positive magnets (38) and negative magnets (39) are alternately distributed. The positive magnets (38) and negative magnets (39) abut against the outer end face of the copper spacer (40), and the positive magnets (38) and negative magnets (39) abut against each other. The rotor disk (36) is contacted on the outer arc surface of the limiting plate (42); both sides of the rotor disk (36) are provided with integrally formed rotor disk side ring covers (37), and several circumferentially distributed partition plates (48) are provided between the rotor disk side ring covers (37) and the rotor disk (36), forming a magnet placement area between the rotor disk side ring covers (37), the rotor disk (36), and two adjacent partition plates (48), with the positive magnet (38) and the negative magnet (39) engaging and placed inside the corresponding magnet placement area.

2. The compact high-voltage generator with excellent heat dissipation performance according to claim 1, characterized in that, The rear end cover body (15) is provided with several circumferentially distributed rear end cover fixing through holes (16). The rear end cover body (15) is detachably mounted on the mounting flange located at the rear end of the generator housing body (21) through several rear end cover fixing through holes (16). The rear end stator mounting protrusion (17) is provided with an air inlet hole (18). A filter screen is provided on the rear side of the air inlet hole (18). The middle part of the rear end stator mounting protrusion (17) is provided with a bearing mounting hole (19). The rear end of the rotor shaft (24) is fixed with a mounting bearing, which is located inside the bearing mounting hole (19).

3. A compact high-voltage generator with excellent heat dissipation performance according to claim 2, characterized in that, The end flange (9) is detachably mounted on the mounting flange located at the front end of the generator housing body (21). The ventilation holes of the end heat dissipation main cover (7) and the end heat dissipation side cover (8) are provided with filter screens. The front end of the main shaft of the heat dissipation fan (12) is fixed with a linkage shaft (14), and the end of the linkage shaft (14) is fixed with a linkage flange (13).

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