Arc-shaped rectifying rotary module and installation method

Abstract

The application discloses an arc-shaped rectification rotating module and a mounting method, and belongs to the technical field of power electronic devices, which comprises an arc-shaped shell, a plurality of rectification chips, a sealing fixing part and a copper electrode column, the outer surface of the arc-shaped shell is an arc-shaped curved surface suitable for an arc-shaped mounting space, the inner surface is processed with a plurality of chip mounting planes which are located on the same reference cylindrical surface chord surface and are symmetrically distributed with the module central axis as the reference center; the one end of the copper electrode column is covered with an insulating part as an external port, and the other end is fixedly connected with the upper surface of the rectification chip through the intermediate electrode, and the adjacent rectification chips are electrically connected through the electrode connecting sheet. The application also provides a standardized mounting method of the module. The application can be directly attached and mounted without an adapter, has excellent heat dissipation performance, uniform stress of the symmetrical structure, stable and reliable high-precision electrical connection, good sealing protection of the epoxy resin pouring and sealing, and is suitable for the arc-shaped mounting scene of wind driven generators and synchronous motor rotating equipment.

Description

Technical Field

[0001] This invention relates to the field of power electronic device technology, and in particular to an arc-shaped rectifier rotating module and its installation method. Background Technology

[0002] Rectifier modules are core components in power electronic systems that convert alternating current (AC) to direct current (DC). They are widely used in power generation, transmission, distribution, and various electrical equipment. Traditional rectifier modules often adopt a square or rectangular planar structure, designed to be suitable for planar installation scenarios.

[0003] However, in special applications such as rotating electric machines (e.g., generator rotors, exciters), the installation space is often an arc-shaped curved surface. Traditional planar rectifier modules cannot fit tightly against arc-shaped mounting surfaces, resulting in the following significant drawbacks: poor heat dissipation performance, with air gaps between the module and the mounting surface, significantly increasing thermal resistance, leading to excessively high operating temperatures of the rectifier chip, shortened lifespan, and even thermal runaway failures; insufficient structural stability, requiring additional adapters for fixing planar modules on arc-shaped surfaces, increasing system complexity and weight, and prone to loosening and detachment under the centrifugal force generated by high-speed rotation; low electrical reliability, with insufficient machining precision and large symmetry deviations in the chip mounting planes of some existing arc-shaped rectifier modules, resulting in additional stress during electrode connections, which can easily lead to poor contact and electrode breakage after long-term operation; and insufficient sealing protection, as traditional sealing methods are difficult to adapt to the sealing requirements of arc-shaped structures, easily leading to sealing failure, allowing moisture and dust to enter the module, affecting insulation performance and electrical safety.

[0004] Therefore, developing an arc-shaped rectifier rotating module that can perfectly adapt to arc-shaped installation spaces, has a symmetrical and stable structure, high precision, good heat dissipation, and high reliability, as well as its standardized installation method, has become a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0005] The purpose of this invention is to provide an arc-shaped rectifier rotary module and its installation method, which solves the technical problems of traditional rectifier modules being unable to adapt to arc-shaped installation spaces, having poor heat dissipation, low precision, and insufficient reliability.

[0006] To achieve the above objectives, the present invention provides an arc-shaped rectifier rotating module, comprising an arc-shaped shell, multiple rectifier chips, a sealing fastener, and multiple copper electrode posts; the outer surface of the arc-shaped shell is an arc-shaped curved surface adapted to the arc-shaped mounting space, and multiple chip mounting planes are machined on the inner surface of the arc-shaped shell; the multiple chip mounting planes are all located on the tangential plane of the same reference cylindrical surface, and are centrally symmetrically distributed with the central axis of the arc-shaped rectifier rotating module as the reference; one end of each copper electrode post is covered with an insulating component, serving as the external electrical connection port of the module, and the other end is vertically fixedly connected to the upper surface of the rectifier chip through an intermediate electrode; adjacent rectifier chips are electrically connected through electrode connecting pieces; among the multiple copper electrode posts, the copper electrode post located at one end of the module is the output electrode, and the remaining copper electrode posts are the input electrodes.

[0007] Preferably, the arc of the outer surface of the arc-shaped shell is 60°, and the transition connection between the chip mounting plane and the inner surface of the arc-shaped shell is provided with an R3 chamfer.

[0008] Preferably, the symmetry error of the plurality of chip mounting planes relative to the central axis does not exceed ±0.5mm.

[0009] Preferably, the perpendicularity error between the copper electrode post and the central axis does not exceed ±0.2mm.

[0010] Preferably, the sealing fastener is epoxy resin adhesive, used to seal and fix the rectifier chip, copper electrode post and electrode connecting piece inside the arc-shaped housing.

[0011] This invention also discloses an installation method for an arc-shaped rectifier rotating module, comprising the following steps: S1. Prepare an arc-shaped shell: process an arc-shaped shell with an outer surface that is an arc-shaped curved surface, and process multiple chip mounting planes on its inner surface, so that the multiple chip mounting planes are all located on the tangential surface of the same reference cylindrical surface and are centrally symmetrically distributed with the central axis of the module as the reference. S2. Chip mounting: The rectifier chip is attached and fixed to the corresponding chip mounting surface using a sealing fastener; S3. Electrode assembly connection: The copper electrode post is vertically and fixedly connected to the upper surface of the rectifier chip through the intermediate electrode. The outer end of the copper electrode post is covered with an insulating material, and then the adjacent rectifier chips are electrically connected through the electrode connecting piece to form a complete electrical conduction path. S4. Sealing and Curing: The connections between the various components inside the module are sealed using sealing fasteners and then cured. S5. Precision Inspection: Inspect the symmetry of the chip mounting plane relative to the central axis and the perpendicularity of the copper electrode posts to the central axis to ensure that they meet the preset precision requirements.

[0012] Preferably, in step S1, after the chip mounting plane is processed, an R3 chamfer is applied to the transition connection between the chip mounting plane and the inner surface of the arc-shaped outer shell to remove structural edges and eliminate stress concentration.

[0013] Preferably, in step S2, the rectifier chips are aligned with the central axis of the module during installation to ensure that all rectifier chips are symmetrically distributed along the central axis.

[0014] Preferably, in step S3, the intermediate electrode and the copper electrode post are fixedly connected by soldering or resistance welding, and the electrode connecting piece is connected to the electrode of the rectifier chip by ultrasonic pressing.

[0015] Preferably, in step S5, a coordinate measuring machine is used for accuracy testing, and the qualified standards are: the symmetry error of the chip mounting plane ≤ ±0.5mm, and the perpendicularity error between the copper electrode post and the central axis ≤ ±0.2mm.

[0016] Therefore, the present invention, by employing the above-mentioned arc-shaped rectifier rotating module and installation method, has the following technical advantages: (1) The present invention adopts a 60° arc-shaped shell design that is perfectly matched with the arc-shaped mounting surface of the rotating equipment. It can be directly fitted and installed without the need for adapters, which greatly reduces thermal resistance, significantly improves heat dissipation performance, reduces system weight, and improves structural stability under high-speed rotation.

[0017] (2) The chip mounting plane of the present invention is centrally symmetrically distributed with the central axis of the module as the reference, and the symmetry error is controlled within ±0.5mm, which ensures that each rectifier chip is subjected to uniform force, effectively avoids the problem of stress concentration in electrode connection caused by uneven force, and extends the service life of the module.

[0018] (3) The perpendicularity error between the copper electrode post and the central axis of the module is controlled within ±0.2mm, which ensures the coaxiality of the electrode connection, reduces the contact resistance, and improves the reliability and stability of the electrical connection.

[0019] (4) The present invention uses epoxy resin to completely encapsulate and seal the rectifier chip and electrode assembly, which has good insulation, waterproof, dustproof and corrosion-resistant properties and can adapt to complex and harsh working environments.

[0020] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of an arc-shaped rectifier rotating module according to the present invention; Figure 2 This is a front view of an arc-shaped rectifier rotating module according to the present invention; Figure 3This is a schematic diagram of the internal structure of the arc-shaped outer shell in an arc-shaped rectifier rotary module of the present invention; Figure 4 This is an overall cross-sectional view of an arc-shaped rectifier rotating module of the present invention.

[0022] Figure Labels 1. Arc-shaped outer shell; 2. Rectifier chip; 3. Sealing and fixing component; 4. Copper electrode post; 5. Insulating component; 6. Intermediate electrode; 7. Electrode connecting piece; 8. Chip mounting plane. Detailed Implementation

[0023] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0024] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0025] like Figures 1 to 4 As shown, an arc-shaped rectifier rotating module includes an arc-shaped shell 1, four rectifier chips 2, a sealing fastener 3, and four copper electrode posts 4.

[0026] The arc-shaped outer shell 1 is die-cast from aluminum alloy, possessing excellent thermal conductivity and mechanical strength. Its outer surface is a 60° arc-shaped curved surface, allowing it to perfectly fit the arc-shaped mounting surface of rotating equipment. Four chip mounting planes 8 are machined on the inner surface of the arc-shaped outer shell 1. These four chip mounting planes 8 are all located on the tangential surface of the same reference cylindrical surface and are centrally symmetrically distributed with respect to the module's central axis.

[0027] Each chip mounting plane 8 has an R3 chamfer at the transition point between its mounting surface 8 and the inner surface of the curved housing 1 to remove burrs and sharp edges, and to eliminate stress concentration. The symmetry error of the four chip mounting planes 8 relative to the central axis is controlled within ±0.3mm.

[0028] The rectifier chip 2 is bonded and fixed to the chip mounting plane 8 by a sealing fastener 3 (epoxy resin adhesive). The upper surface of each rectifier chip 2 is vertically fixed to a copper electrode post 4 via an intermediate electrode 6 (molybdenum-copper composite sheet). The copper electrode post 4 is made of copper, which has excellent conductivity, and its perpendicularity error with the central axis is controlled within ±0.15mm.

[0029] The upper (outer) end of the copper electrode post 4 is covered with an insulating component 5 (high-temperature resistant plastic), serving as the external electrical connection port of the module. Adjacent rectifier chips 2 are electrically connected via electrode connecting pieces 7 (thin copper sheets). Of the four copper electrode posts 4, the one located at the right end of the module is the output electrode, and the three located at the left end of the module are the input electrodes.

[0030] An installation method for an arc-shaped rectifier rotary module specifically includes the following steps: S1. Prepare the arc-shaped outer shell. Use a CNC milling machine to machine the aluminum alloy blank. First, machine an arc surface with a curvature of 60° on the outer surface. Then, using the reference cylindrical surface of the inner surface as a reference, machine four evenly distributed chip mounting planes 8, ensuring that all chip mounting planes 8 are located on the tangential surface of the same reference cylindrical surface and are symmetrical about the central axis. After machining, use a chamfering tool to perform an R3 chamfer at the transition connection between the chip mounting planes 8 and the inner surface of the arc-shaped outer shell 1 to remove burrs and sharp edges.

[0031] S2. Chip installation: Apply epoxy resin evenly to the chip mounting surface 8, and then use a high-precision positioning fixture to precisely align and fix the four rectifier chips 2 onto the corresponding chip mounting surface 8 with the central axis as the reference, ensuring that all rectifier chips 2 are symmetrically distributed along the central axis.

[0032] S3. Electrode assembly connection: Place the intermediate electrode 6 on the upper surface electrode of the rectifier chip 2, then vertically place the copper electrode post 4 on the intermediate electrode 6, and firmly weld the copper electrode post 4 to the intermediate electrode 6 using resistance welding. An insulating piece 5 is fitted onto the upper end of the copper electrode post 4. Then, use an ultrasonic crimping machine to crimp the electrode connecting pieces 7 onto the electrodes of two adjacent rectifier chips 2, forming a complete three-phase bridge rectifier electrical path.

[0033] S4. Sealing and Curing: Place the assembled arc-shaped shell 1 with the electrode assembly into the potting mold. Use a vacuum potting machine to inject epoxy resin into the interior of the arc-shaped shell 1, ensuring that the epoxy resin completely fills all gaps and wraps the rectifier chip 2, copper electrode post 4, and electrode connecting piece 7. After potting, place the module in an oven and cure at 80°C for 4 hours to allow the epoxy resin to fully cure.

[0034] S5. Precision Inspection: A coordinate measuring machine (CMM) was used to inspect the precision of the cured module. The symmetry of the four chip mounting planes 8 relative to the central axis and the perpendicularity of the four copper electrode posts 4 to the central axis were measured. The results showed that the symmetry error of the chip mounting planes 8 was ±0.25mm, and the perpendicularity error of the copper electrode posts 4 was ±0.12mm, both meeting the acceptable standards. A module that passes the inspection is considered a finished product.

[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. An arc-shaped rectifier rotary module, characterized in that: The module includes an arc-shaped outer shell, multiple rectifier chips, a sealing fastener, and multiple copper electrode posts. The outer surface of the arc-shaped outer shell is an arc-shaped curved surface adapted to the arc-shaped mounting space, and multiple chip mounting planes are machined on the inner surface of the arc-shaped outer shell. The multiple chip mounting planes are all located on the tangential surface of the same reference cylindrical surface and are centrally symmetrically distributed with the central axis of the arc-shaped rectifier rotating module as the reference. One end of each copper electrode post is covered with an insulating component, serving as the external electrical connection port of the module, and the other end is vertically fixedly connected to the upper surface of the rectifier chip through an intermediate electrode. Adjacent rectifier chips are electrically connected through electrode connecting pieces. Among the multiple copper electrode posts, the copper electrode post located at one end of the module is the output electrode, and the remaining copper electrode posts are the input electrodes.

2. The arc-shaped rectifier rotating module according to claim 1, characterized in that: The arc of the outer surface of the arc-shaped shell is 60°, and the transition connection between the chip mounting plane and the inner surface of the arc-shaped shell is provided with an R3 chamfer.

3. The arc-shaped rectifier rotary module according to claim 1, characterized in that: The symmetry error of the multiple chip mounting planes relative to the central axis does not exceed ±0.5mm.

4. The arc-shaped rectifier rotary module according to claim 1, characterized in that: The perpendicularity error between the copper electrode post and the central axis shall not exceed ±0.2mm.

5. The arc-shaped rectifier rotary module according to claim 1, characterized in that: The sealing and fixing component is epoxy resin adhesive, which is used to seal and fix the rectifier chip, copper electrode post and electrode connecting piece inside the arc-shaped shell.

6. A method for installing an arc-shaped rectifier rotary module, based on the arc-shaped rectifier rotary module according to any one of claims 1-5, characterized in that, Includes the following steps: S1. Prepare an arc-shaped shell: process an arc-shaped shell with an outer surface that is an arc-shaped curved surface, and process multiple chip mounting planes on its inner surface, so that the multiple chip mounting planes are all located on the tangential surface of the same reference cylindrical surface and are centrally symmetrically distributed with the central axis of the module as the reference. S2. Chip mounting: The rectifier chip is attached and fixed to the corresponding chip mounting surface using a sealing fastener; S3. Electrode assembly connection: The copper electrode post is vertically and fixedly connected to the upper surface of the rectifier chip through the intermediate electrode. The outer end of the copper electrode post is covered with an insulating material, and then the adjacent rectifier chips are electrically connected through the electrode connecting piece to form a complete electrical conduction path. S4. Sealing and Curing: The connections between the various components inside the module are sealed using sealing fasteners and then cured. S5. Precision Inspection: Inspect the symmetry of the chip mounting plane relative to the central axis and the perpendicularity of the copper electrode posts to the central axis to ensure that they meet the preset precision requirements.

7. The installation method of an arc-shaped rectifier rotating module according to claim 6, characterized in that: In step S1, after the chip mounting plane is processed, an R3 chamfer is applied to the transition connection between the chip mounting plane and the inner surface of the arc-shaped shell to remove structural edges and eliminate stress concentration.

8. The installation method of an arc-shaped rectifier rotating module according to claim 6, characterized in that: In step S2, the rectifier chips are aligned with the central axis of the module during installation to ensure that all rectifier chips are symmetrically distributed along the central axis.

9. The installation method of an arc-shaped rectifier rotating module according to claim 6, characterized in that: In step S3, the intermediate electrode and the copper electrode post are fixedly connected by soldering or resistance welding, and the electrode connecting piece is connected to the electrode of the rectifier chip by ultrasonic pressing.

10. The installation method of an arc-shaped rectifier rotary module according to claim 6, characterized in that: In step S5, a coordinate measuring machine is used for accuracy testing. The qualified standards are: the symmetry error of the chip mounting plane is ≤ ±0.5mm, and the perpendicularity error between the copper electrode post and the central axis is ≤ ±0.2mm.

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