Ignition coil of aviation range extender of unmanned aerial vehicle

Abstract

The ignition coil of the unmanned aerial vehicle aviation range extender comprises a shell, an iron core, a primary coil, a secondary coil and a plug, the iron core, the primary coil, the secondary coil and the plug are installed in the shell, and the periphery of the iron core is coated with a PBT plastic layer; the primary coil is wound outside the PBT plastic layer; and the secondary coil is wound outside the primary coil through the secondary framework. According to the invention, the PBT material shell and the composite structure coated by the iron core and the PBT plastic layer are adopted, no extra skeleton is arranged between the primary coil and the iron core, the structure is simplified, the weight is reduced, the overall weight is reduced by more than 15%, and meanwhile, the PBT plastic layer improves the structural redundancy and prevents the iron core from being damaged due to collision.

Description

Technical Field

[0001] This invention relates to the field of ignition coil technology, specifically to an ignition coil for a drone range extender. Background Technology

[0002] The ignition coil of the drone range extender is the core component that determines the ignition efficiency and operational stability of the range extender. It must simultaneously meet the stringent requirements of drones for lightweight design, resistance to high-frequency vibration, waterproofing and dustproofing, and resistance to electromagnetic interference.

[0003] However, existing UAV range extender ignition coils mostly use traditional metal shells and ordinary potting structures, which have the following drawbacks: First, the structural redundancy is low. The silicon steel sheet material combined with the heavy metal shell results in an excessively large overall weight, which does not meet the lightweight design requirements of UAVs. Second, the iron core is mostly fixed by clamps or adhesives, which are prone to loosening under the high-frequency vibration conditions of the range extender, leading to ignition energy attenuation and even causing the range extender to shut down. Third, the wiring terminals are mostly ordinary plugs with poor sealing, which can easily cause poor contact in high-altitude and high-humidity environments. Fourth, the high-voltage line lacks an effective shielding structure, and the electromagnetic radiation generated during operation can easily interfere with the UAV flight control system. At the same time, external electromagnetic signals can also affect the normal operation of the ignition coil.

[0004] Therefore, providing an ignition coil for an unmanned aerial vehicle range extender is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] In view of this, the present invention provides an ignition coil for an unmanned aerial vehicle range extender to at least solve one of the aforementioned technical problems.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: An ignition coil for an unmanned aerial vehicle (UAV) range extender includes a housing and an iron core, a primary coil, a secondary coil, and a plug installed inside the housing. The iron core is surrounded by a PBT plastic layer. The primary coil is wound around the outside of the PBT plastic layer. The secondary coil is wound around the outside of the primary coil via a secondary bobbin. Furthermore, the PBT plastic layer is 1mm thick; the outer shell is made of PBT material.

[0007] Furthermore, the outer casing is encapsulated as a single unit with the iron core, the primary coil, the secondary coil, and the plug located inside it.

[0008] Furthermore, the lead wire of the primary coil extends into and connects to the plug; the plug and the potting layer are integrally injection molded; and a sealing ring is fitted at the interface of the mating plug that is adapted to be inserted into the plug.

[0009] Furthermore, the iron core has symmetrically distributed threaded mounting holes at both ends, which are bolted together with the reserved mounting positions of the range extender engine cylinder block.

[0010] Furthermore, a spring washer is installed between the bolt and the threaded mounting hole.

[0011] Furthermore, the ignition coil of the UAV range extender also includes a high-voltage wire and a shielding tube. One end of the high-voltage wire is connected to the output end of the secondary coil, and the other end of the high-voltage wire is connected to a spark plug cap. The shielding tube is sleeved on the high-voltage wire, and one end of the shielding tube is locked to the threaded mounting hole through an OT wire terminal.

[0012] Furthermore, the high-voltage line is a high-voltage damping line; the shielding tube is a tin-plated metal braided shielding tube. Therefore, the present invention provides an ignition coil for an unmanned aerial vehicle (UAV) range extender, and compared with the prior art, the present invention has the following beneficial effects: 1) Significant weight reduction: The PBT material shell and the composite structure of iron core + PBT plastic layer are used. Compared with the traditional silicon steel core + metal shell ignition coil, the overall weight is reduced by more than 15%. At the same time, the PBT plastic layer increases the structural redundancy and avoids damage to the iron core due to collision. 2) Excellent vibration resistance: The threaded mounting holes at both ends of the iron core allow for direct bolt fastening to the engine block. With the help of spring anti-loosening washers, the iron core displacement is ≤0.01mm under high-frequency vibration conditions of 200Hz, and the ignition energy fluctuation is ≤3% after 100h bench test, completely solving the problem of iron core loosening. 3) High waterproof reliability: The plug and potting layer are integrally injection molded and equipped with a mating plug sealing ring, with a protection level of IP67. It can work stably for a long time in high-altitude and high-humidity environments without poor contact. 4) Strong resistance to EMC interference: The high-voltage line adopts high-voltage damping wire, and the tin-plated metal braided shielding tube outside the high-voltage line is locked with the grounding nut of the iron core to form a fully enclosed shielding channel. The electromagnetic radiation attenuation rate is ≥70%, which not only avoids interference with the UAV flight control system, but also resists the influence of external electromagnetic signals. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0014] Figure 1The attached figure is a front view of an ignition coil for an unmanned aerial vehicle (UAV) range extender provided by the present invention. Figure 2 The attached image is... Figure 1 Sectional view of AA; Figure 3 The attached image is... Figure 1 BB section view; Figure 4 The attached image is... Figure 1 CC section view; Figure 5 The attached figure is a side view of an ignition coil for an unmanned aerial vehicle range extender provided by the present invention; Figure 6 The attached figure is a cross-sectional view of the plug portion provided by the present invention; Figure 7 The attached figure is a front view of the relationship between the iron core and the engine provided by the present invention. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] like Figure 1-7 As shown, this embodiment of the invention discloses an ignition coil for an unmanned aerial vehicle (UAV) range extender, including a housing 1 and an iron core 2, a primary coil 3, a secondary coil 4, and a plug 5 installed inside the housing 1. In this embodiment, the housing 1 is made of PBT material, and the iron core 2 is a type I silicon steel sheet laminated core, made of silicon steel sheets with a thickness of 0.5mm. The iron core 2 is surrounded by a PBT plastic layer 6, which has a thickness of 1mm in this embodiment. The primary coil 3 is wound around the PBT plastic layer 6. In this embodiment, the primary coil 3 is made of 0.44mm polyimide enameled copper wire with 128 turns. The secondary coil 4 is wound around the primary coil 3 through a secondary frame 7. In this embodiment, the secondary coil 4 is made of 0.05mm polyimide enameled copper wire with 11,500 turns. During the winding process, the tension is controlled at 20-22g to avoid damage to the enameled wire. The present invention adopts a composite structure consisting of a PBT material outer shell 1 and an iron core 2 covered by a PBT plastic layer 6. There is no extra skeleton between the primary coil 3 and the iron core 2, which simplifies the structure and reduces weight. The overall weight is reduced by more than 15%. At the same time, the PBT plastic layer 6 increases the structural redundancy and prevents the iron core from being damaged by collision. To further optimize the technical solution of this invention, the outer shell 1 is encapsulated together with the iron core 2, primary coil 3, secondary coil 4, and plug 5 located inside it to form an encapsulation layer 8. The specific encapsulation steps are as follows: the iron core 2, primary coil 3, secondary coil 4, and plug 5 connection parts are assembled into the outer shell 1, and a Kyocera TCG1698K2A / B high-temperature resistant epoxy resin potting compound is injected using a vacuum potting machine (vacuum 1-2MPa). The epoxy resin needs to be degassed in advance (vacuum value 0.2-1MPa, time 3h). After the encapsulation is completed, the assembly is placed in an oven and cured in stages at 75°C for 2h, 90°C for 3h, and 130°C for 3h to form an integrated structure.

[0017] To further optimize the technical solution of the present invention, the lead wire of the primary coil 3 extends into the plug 5 and is connected thereto; the plug 5 and the potting layer 8 are integrally injection molded; a sealing ring 10 is fitted and installed at the interface of the mating plug 9 that is adapted to be plugged into the plug 5. In this embodiment, the sealing ring 10 is a fluororubber sealing ring with a Shore hardness of 70 degrees, achieving an IP67 protection level.

[0018] To further optimize the technical solution of the present invention, the two ends of the iron core 2 are provided with symmetrically distributed threaded mounting holes 21, which are connected to the reserved mounting positions of the range extender engine cylinder block 11 by bolts 12, and spring washers are installed between the bolts 12 and the threaded mounting holes 21 to eliminate vibration gaps.

[0019] To further optimize the technical solution of the present invention, an ignition coil for an unmanned aerial vehicle range extender also includes a high-voltage wire 13 and a shielding tube 14. In this embodiment, the high-voltage wire 13 is a high-voltage damping wire (containing nickel-chromium wire wound in a 7kΩ resistance type, high-temperature and wear-resistant EPDM high-voltage wire), and the shielding tube 14 is a tin-plated brass brass shielding tube (with an inner diameter of 7mm and a metal wire wall thickness of 0.05mm). One end of the high-voltage wire 13 is connected to the output end of the secondary coil 4, and the other end of the high-voltage wire 13 is connected to a spark plug cap 15. The shielding tube 14 is sleeved on the high-voltage wire 13, and one end of the shielding tube 14 is locked to the threaded mounting hole 21 through the OT wire terminal 16. In this embodiment, locking can be achieved by metal bolts and nuts, so that the shielding tube 14 is grounded and a closed electromagnetic shielding channel is formed.

[0020] Comprehensive performance tests were conducted on the ignition coil: its overall weight is 195g, 10% lighter than traditional structures; it operated continuously for 100 hours under 200Hz high-frequency vibration conditions without core loosening, and the ignition energy fluctuation was 1.5%; after immersion in 1m water for 30 minutes, it functioned normally upon removal; electromagnetic radiation tests showed a radiation attenuation rate of 85%, with no interference to the UAV flight control system. It combines lightweight, vibration resistance, waterproofing, and electromagnetic interference resistance.

[0021] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0022] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An ignition coil for an unmanned aerial vehicle (UAV) range extender, comprising a housing and an iron core, a primary coil, a secondary coil, and a plug installed within the housing, characterized in that, The core is covered with a PBT plastic layer; the primary coil is wound around the PBT plastic layer; and the secondary coil is wound around the primary coil via a secondary bobbin.

2. The ignition coil for a UAV range extender according to claim 1, characterized in that, The thickness of the PBT plastic layer is 1mm; the outer shell is made of PBT material.

3. The ignition coil for a UAV range extender according to claim 1, characterized in that, The outer casing is encapsulated as a single unit with the iron core, the primary coil, the secondary coil, and the plug located inside it.

4. The ignition coil for a UAV range extender according to claim 3, characterized in that, The lead wire of the primary coil extends into and connects to the plug; the plug and the potting layer are integrally injection molded; a sealing ring is fitted at the interface of the mating plug that is adapted to be inserted into the plug.

5. The ignition coil for a UAV range extender according to claim 1, characterized in that, The iron core has symmetrically distributed threaded mounting holes at both ends, which are bolted together with the reserved mounting positions of the range extender engine cylinder block.

6. The ignition coil for a UAV range extender according to claim 5, characterized in that, A spring washer is installed between the bolt and the threaded mounting hole.

7. The ignition coil for a UAV range extender according to claim 5, characterized in that, The ignition coil for the UAV range extender also includes a high-voltage wire and a shielding tube. One end of the high-voltage wire is connected to the output end of the secondary coil, and the other end of the high-voltage wire is connected to a spark plug cap. The shielding tube is sleeved on the high-voltage wire, and one end of the shielding tube is locked to the threaded mounting hole through an OT wire terminal.

8. The ignition coil for a UAV range extender according to claim 7, characterized in that, The high-voltage line is a high-voltage damping line; the shielding tube is a tin-plated metal braided shielding tube.

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