Lead connector

Abstract

The utility model discloses a lead connector, which relates to the technical field of generators, is used for connecting a stator winding outgoing line and an external cable, and comprises a sealing plug, a connecting part, and a welding head and a crimping head which are respectively arranged at two ends of the connecting part, the welding head is used for being welded with a stator winding outgoing line, a crimping cavity is formed in the crimping head, and an external cable extends into the crimping cavity to be connected with the crimping head; and the sealing plug is movably mounted in the crimping cavity and is used for blocking the crimping cavity when the stator winding outgoing line is dipped in paint. Through the arrangement, an insulating layer on the surface of the stator winding outgoing line does not need to be polished and then connected with an external cable, so that the polishing process is avoided, the actual input working hours of the working procedure are reduced, and the production efficiency of the working procedure is further improved.

Description

Technical Field

[0001] This utility model relates to the field of generator technology, and in particular to a lead connector. Background Technology

[0002] The stator windings in a wind turbine need to be led out and connected to external cables to transmit electrical energy to the power grid. In the stator winding lead-out process during wind turbine manufacturing, the stator windings first undergo vacuum pressure impregnation (VPI), then the insulating varnish on the surface of the impregnated stator winding leads is sanded clean, and finally connected to external cables via connectors. This process requires careful sanding of the VPI leads to completely remove the insulating varnish before the connectors can be installed. This sanding process is time-consuming and labor-intensive, and requires strict quality control, thus significantly increasing the actual man-hours required for the stator winding lead-out process and resulting in low production efficiency for this step.

[0003] Therefore, it is necessary to provide a lead connector to solve or at least alleviate the above-mentioned technical problems. Utility Model Content

[0004] The main purpose of this invention is to propose a lead wire connector, which aims to solve the technical problem of low production efficiency in the stator winding lead-out process.

[0005] To achieve the above objectives, this utility model proposes a lead wire connector for connecting stator winding leads and external cables, comprising: a sealing plug and a connecting part, and welding heads and crimping heads respectively disposed at both ends of the connecting part;

[0006] The welding head is used to weld to the stator winding lead wire, and the crimping head is provided with a crimping cavity inside. The external cable extends into the crimping cavity and connects to the crimping head.

[0007] The sealing plug is movably installed in the crimping cavity, and the sealing plug is used to seal the crimping cavity when the stator winding leads are impregnated with varnish.

[0008] In one embodiment, the welding head includes an overlap platform, the overlap platform having two contact surfaces arranged opposite to each other, the stator winding lead overlapping at least one of the contact surfaces and being welded to the contact surfaces.

[0009] In one embodiment, the connecting part is a connecting rod, and the two ends of the connecting rod are respectively provided with the welding head and the crimping head.

[0010] In one embodiment, the connecting rod is a bent component, and the connecting rod includes an arc-shaped segment;

[0011] Definition: The central angle of the arc segment is α;

[0012] The α satisfies: 0°≤α≤90°.

[0013] In one embodiment, the connecting part includes a first material segment and a second material segment, the welding head is connected to the first material segment, the crimping head is connected to the second material segment, the welding head and the first material segment are made of a first material, and the crimping head and the second material segment are made of a second material, wherein the material of the first material and the material of the second material are different.

[0014] In one embodiment, the welding head, the connecting part, and the crimping head are integrally molded parts made of the same material.

[0015] In one embodiment, the crimping cavity is cylindrical in shape.

[0016] In one embodiment, at least a portion of the inner surface of the crimping cavity is provided with crimping teeth.

[0017] According to the technical solution provided by this utility model, a lead connector is used to connect stator winding leads and external cables. It includes a sealing plug and a connecting part, as well as a welding head and a crimping head respectively disposed at both ends of the connecting part. The welding head is used to weld with the stator winding leads. The crimping head has a crimping cavity inside, into which the external cable extends and connects with the crimping head. The sealing plug is movably installed in the crimping cavity and is used to seal the crimping cavity during stator winding lead impregnation. With this configuration, in the stator winding lead-out process of a wind turbine generator, before VPI (Ventilation Impregnation) of the stator winding, the stator winding leads are first welded to the welding head, and the crimping cavity is sealed with the sealing plug. Then, the stator winding undergoes VPI impregnation. After VPI is completed, the sealing plug is removed, and the external cable is inserted into the crimping cavity. Finally, the crimping head is crimped with the external cable to complete the stator winding lead-out. This process eliminates the need to grind the insulation layer on the surface of the stator winding leads before connecting them to external cables, thus avoiding the grinding process, reducing the actual working hours invested in this step, and thereby improving the production efficiency of this step. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model 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 some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0019] Figure 1 A schematic diagram of an embodiment of the stator lead-out structure provided by this utility model;

[0020] Figure 2for Figure 1 A structural diagram from another perspective;

[0021] Figure 3 for Figure 1 Another structural diagram from a different perspective;

[0022] Figure 4 A schematic diagram of another embodiment of the stator lead-out structure provided by this utility model;

[0023] Figure 5 for Figure 4 A structural diagram from another perspective;

[0024] Figure 6 A schematic diagram of another embodiment of the stator lead-out structure provided by this utility model;

[0025] Figure 7 for Figure 6 A structural diagram from another perspective.

[0026] Explanation of icon numbers:

[0027] 1. Welding head; 1a. Overlapping platform; 2. Connecting part; 2a. Connecting rod; 21. First material section; 22. Second material section; 23. Arc-shaped section; 3. Crimping joint; 31. Crimping cavity; 4. Stator winding lead wire; 5. External cable; 51. Wire core; 52. Outer sheath.

[0028] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0030] It should be noted that if the embodiments of this utility model involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0031] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0032] A wind turbine is a device that converts wind energy into electrical energy, and one of its core components is the stator winding. The stator winding's function is to convert mechanical energy into electrical energy and transmit it to the power grid via leads. The stator winding lead-out process is a crucial step in the manufacturing of a wind turbine. First, the stator winding needs to undergo vacuum pressure impregnation (VPI). VPI is an insulation treatment process that effectively improves the insulation performance and mechanical strength of the stator winding by impregnating it with varnish and pressure curing it under vacuum conditions. After VPI treatment, an insulating varnish layer forms on the surface of the stator winding leads. This insulating varnish layer needs to be removed during subsequent connection processes to connect the leads to external cables and ensure smooth power transmission. Therefore, after VPI treatment, the stator winding leads need to be polished to remove the insulating varnish layer, preparing them for subsequent terminal installation.

[0033] According to the applicant's research, while vacuum pressure impregnation (VPI) treatment can significantly improve the insulation performance of wind turbine stator windings, it also introduces certain production and quality issues. Firstly, a hard and strongly adhering insulating varnish layer forms on the surface of the leads after VPI treatment, requiring significant time and effort in subsequent polishing. Polishing is not only time-consuming and labor-intensive but also demands a high level of operator skill. Damage to the leads or incomplete removal of the insulating varnish layer during polishing can easily affect the installation quality of the connection terminals and the efficiency of power transmission. Furthermore, quality control during polishing is stringent, requiring careful inspection of each lead to ensure complete removal of the insulating varnish layer. This stringent quality control requirement further increases the time invested in the production process, resulting in low production efficiency for the stator winding lead-out process.

[0034] In view of this, the present invention proposes a lead wire connector to solve the above-mentioned technical problems.

[0035] Please see Figures 1 to 6 This utility model provides three embodiments. In the above three embodiments, the lead connector is used to connect the stator winding lead 4 and the external cable 5. It includes a sealing plug and a connecting part 2, as well as a welding head 1 and a crimping head 3 respectively disposed at both ends of the connecting part 2. The welding head 1 is used to weld with the stator winding lead 4. The crimping head 3 is provided with a crimping cavity 31 inside. The external cable 5 extends into the crimping cavity 31 and connects with the crimping head 3. The sealing plug is movably installed in the crimping cavity 31. The sealing plug is used to seal the crimping cavity 31 when the stator winding lead 4 is impregnated with varnish.

[0036] The steps for using the lead connector in the stator winding lead-out process are as follows: (1) Weld the welding head 1 to the stator winding lead wire 4 using a welding process. The welding method can be brazing or flash welding. (2) Insert the sealing plug into the crimping cavity 31 to seal the crimping cavity 31. (3) Perform VPI process on the stator winding and the lead connector as a whole. (4) After VPI is completed, pull out the sealing plug. (5) Peel off the outer sheath 52 of the end of the external cable 5, expose the wire core 51, and insert it into the crimping cavity 31 to squeeze the crimping head 3 and complete the crimping of the crimping head 3 and the external cable 5.

[0037] Through the above steps, in the stator winding lead-out process of the wind turbine generator, before VPI (Ventilation Impregnation) of the stator winding, the stator winding lead-out wire 4 is first welded to the welding head 1, and the crimping cavity 31 is sealed with a sealing plug. Then, the stator winding is VPI impregnated. After VPI is completed, the sealing plug is removed, and the external cable 5 is inserted into the crimping cavity 31. Finally, the crimping head 3 is crimped with the external cable 5 to complete the stator winding lead-out. This process eliminates the need to grind the insulation layer on the surface of the stator winding lead-out wire 4 before connecting it to the external cable 5, thus avoiding the grinding process, reducing the actual working time of this process, and thereby improving the production efficiency of this process.

[0038] Further, please refer to Figure 3 In one embodiment of this utility model, the welding head 1 includes a lap joint 1a, which includes two relatively parallel contact surfaces. The stator winding lead 4 overlaps with at least one contact surface and is welded to the contact surface. By providing two opposing contact surfaces, the stator winding lead 4 can overlap with the lap joint 1a, increasing the contact area between the stator winding lead 4 and the lap joint 1a. This helps to reduce contact resistance and improve the welding strength between the stator winding lead 4 and the lap joint 1a, thereby improving the reliability of the generator during operation.

[0039] In one embodiment of this utility model, the connecting part 2 is a connecting rod 2a, and a welding head 1 and a crimping head 3 are respectively provided at both ends of the connecting rod 2a. There are various implementations of the connecting rod 2a; in this embodiment, please refer to... Figure 1 The connecting rod 2a is a bent part. When the stator winding lead 4 cannot be bent to the required angle, the bent connecting rod 2a can smoothly connect the stator winding lead 4 to the external cable 5.

[0040] In another embodiment, please refer to Figure 4 When the connecting rod 2a is a straight rod, and the stator winding lead 4 and the external cable 5 are at a right angle or a flat angle, a lead connector with a straight connecting rod 2a can be used to connect the two. When the connecting rod 2a is a straight rod, the manufacturing and installation process of the lead connector is simpler, which helps to reduce production costs.

[0041] Furthermore, the connecting rod 2a is a bent component, including an arc segment 23; the central angle of the arc segment 23 is defined as α, and α satisfies: 0°≤α≤90°. By changing the angle value of α during production, the lead connector can solve the problem that the stator winding lead 4 cannot be bent or the bending angle after bending cannot meet the bending angle required for connection with the external cable 5. When α is 0°, the connecting rod 2a is a straight rod, and the lead connector is... Figure 4 The configuration shown in the embodiment; when α is 90°, the angle between the central axes of the welding heads 1 and the crimping heads 3 at both ends of the connecting rod 2a is 90°, and at this time the lead connector is Figure 1 The configuration shown in the embodiment is as described above. In actual production, those skilled in the art can select the angle α according to their needs; for example, α can be 30°, 60°, or 70°.

[0042] Please see Figure 6 and Figure 7In one embodiment of this utility model, the connecting part 2 includes a first material segment 21 and a second material segment 22. The welding head 1 is connected to the first material segment 21, and the crimping head 3 is connected to the second material segment 22. The welding head 1 and the first material segment 21 are made of a first material, while the crimping head 3 and the second material segment 22 are made of a second material. The materials of the first and second materials are different. Specifically, the first material is the same as the material used to manufacture the stator winding lead wire 4, and the second material is the same as the material used to manufacture the core 51 of the external cable 5. In this embodiment, the stator winding lead wire 4 is made of aluminum, and the core 51 of the external cable 5 is made of copper; therefore, the first material is aluminum, and the second material is copper. Since the stator winding lead wire 4 is made of aluminum and the core 51 of the external cable 5 is made of copper wire, for corrosion prevention, the welding head 1 is made of aluminum, and the crimping head 3 is made of copper to prevent corrosion at the connection between the welding head 1 and the stator winding lead wire 4, and also to prevent corrosion at the connection between the core 51 and the crimping head 3. Furthermore, aluminum has a lower density and its conductivity is slightly lower than that of copper. By rationally designing the length of the first material segment 21, it is beneficial to reduce the overall weight of the lead connector while ensuring its overall conductivity. It should be noted that the first and second materials are not limited to aluminum and copper. Depending on the different usage environments, the first and second materials can also be copper alloys, aluminum alloys, or even materials with good conductivity such as gold and silver.

[0043] In one embodiment of this utility model, the welding head 1, the connecting part 2, and the crimping head 3 are integrally molded parts made of the same material, and the sealing plug is detachably disposed in the crimping cavity 31. The integral molding process avoids seams between the welding head 1, the connecting part 2, and the crimping head 3, making the quality of the lead connector more stable and reliable. In this embodiment, the integrally molded welding head 1, the connecting part 2, and the crimping head 3 are made of the same material, including copper, aluminum, and copper alloys.

[0044] In one embodiment of this utility model, the crimping cavity 31 is cylindrical. The core 51 of the external cable 5 used in this embodiment is cylindrical; therefore, the crimping cavity 31 is set as a cylindrical cavity, and the diameter of the crimping cavity 31 is slightly larger than the diameter of the core 51. This arrangement facilitates the core 51 extending into the crimping cavity 31, and after crimping, the core 51 can fill the crimping cavity 31, which is beneficial for a stable connection between the crimp connector 3 and the external cable 5. It should be noted that, depending on the shape of the core 51, the crimping cavity 31 can be set as a cylindrical cavity or a cavity of other shapes; those skilled in the art can make substitutions according to their needs.

[0045] Furthermore, in one embodiment of this invention, at least a portion of the inner surface of the crimping cavity 31 is provided with crimping teeth. The crimping teeth protrude from the inner wall surface of the crimping cavity 31, and through their toothed structure, they can penetrate deep between the metal wires of the wire core 51 during the crimping process, forming a mechanical lock and making the connection between the wire core 51 and the crimp connector 3 more secure. This locking effect can effectively prevent the external cable 5 from loosening under vibration or tension, improving the mechanical stability of the connection.

[0046] This utility model also proposes a stator lead-out structure, which includes a lead connector, stator winding lead-out wires 4, and external cables 5. The lead connector includes a connecting part 2 and a welding head 1 and a crimping head 3 respectively disposed at both ends of the connecting part; the stator winding lead-out wires 4 are welded to the welding head 1, and the external cables 5 extend into the crimping cavity 31 and are crimped with the crimping head 3.

[0047] The stator winding lead 4 and the welding head 1 are welded together to form a weld. The stator lead structure also includes an insulating layer, which covers the surfaces of the stator winding lead 4, the welding head 1, the weld, and the connecting part 2. The insulating layer also covers the parts of the crimp connector 3 except for the crimp cavity 31. After the stator winding is VPI-processed and cured, an insulating layer is formed in the stator winding, the stator winding lead 4, and the lead connector except for the crimp cavity 31. Since the lead connector is first welded to the stator winding lead 4 and then VPI-processed together with the stator winding, the weld between the stator winding lead 4 and the welding head 1 is also covered by the insulating layer. This arrangement can further improve the connection stability between the welding head 1 and the stator winding lead 4, while preventing the weld from being exposed to the outside, thus improving the rust resistance of the weld.

[0048] The above description is merely an exemplary embodiment of the present utility model and does not limit the patent scope of the present utility model. Any equivalent structural transformations made based on the technical concept of the present utility model and the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present utility model.

Claims

1. A lead connector for connecting stator winding leads and external cables, characterized in that, include: A sealing plug and a connecting part, and a welding head and a crimping head respectively disposed at both ends of the connecting part; The welding head is used to weld to the stator winding lead wire, and the crimping head is provided with a crimping cavity inside. The external cable extends into the crimping cavity and connects to the crimping head. The sealing plug is movably installed in the crimping cavity, and the sealing plug is used to seal the crimping cavity when the stator winding leads are impregnated with varnish.

2. The lead connector as described in claim 1, characterized in that, The welding head includes an overlap platform, which includes two contact surfaces arranged in parallel with each other. The stator winding lead wire overlaps with at least one of the contact surfaces and is welded to the contact surfaces.

3. The lead connector as described in claim 1, characterized in that, The connecting part is a connecting rod, and the two ends of the connecting rod are respectively provided with the welding head and the crimping head.

4. The lead connector as described in claim 3, characterized in that, The connecting rod is a bent component, and the connecting rod includes an arc-shaped segment; Definition: The central angle of the arc segment is α; The α satisfies: 0°≤α≤90°.

5. The lead connector as described in claim 1, characterized in that, The connecting part includes a first material segment and a second material segment. The welding head is connected to the first material segment, and the crimping head is connected to the second material segment. The welding head and the first material segment are made of a first material, and the crimping head and the second material segment are made of a second material. The materials of the first material and the second material are different.

6. The lead connector as claimed in claim 1, characterized in that, The welding head, the connecting part, and the crimping head are all integrally molded parts made of the same material.

7. The lead connector as claimed in claim 1, characterized in that, The crimping cavity is cylindrical in shape.

8. The lead connector as claimed in claim 1, characterized in that, At least a portion of the inner surface of the crimping cavity is provided with crimping teeth.

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