Coreless high-efficiency disc type generator coil stator capable of being used for batch production

Abstract

The utility model relates to the technical field of coreless disc generators, in particular to a coreless efficient disc generator coil stator capable of being used for batch production, which comprises a stator upper cover, a stator outer cover main body is arranged on one side of the stator upper cover in parallel, and a plurality of coil positioning blocks are fixedly connected to one end of the surface of the stator outer cover main body. A coil positioning block is arranged on the surface of the stator outer cover body, an upper end cover positioning protrusion is fixedly connected to the top of the coil positioning block, a plurality of penetrating upper end cover positioning holes are formed in the surface of the stator upper cover, and a stator body wire outlet is formed in one side of the surface of the stator outer cover body. The generator coil stator shell is processed in a 3D printing mode, the generator coil stator shell is made of glass fiber nylon and is provided with a plurality of supporting points and fixing points, the stability of stator forming can be enhanced, batch production can be achieved through the technology, and the power generation efficiency can be greatly improved by adding the first layer of coil and the second layer of coil.

Description

Technical Field

[0001] This utility model relates to the field of coreless disc generator technology, specifically to a coreless high-efficiency disc generator coil stator that can be mass-produced. Background Technology

[0002] The coreless disc generator is a lightweight and efficient generator. It consists of two main parts: a stator and a rotor. Taking wind turbine generators, steam turbine generator sets, and hydro turbine generator sets as examples, they all consist of two main parts: a stator and a rotor. The rotor rotates while the stator remains stationary. The rotor rotates within the stator to generate a magnetic field, which cuts magnetic lines of force to generate an electromotive force, thus converting mechanical energy into electrical energy and generating electricity. This method of power generation has been used to this day.

[0003] However, the technical difficulty of existing coreless disc generators lies in the fact that the generator stator coil cannot be mass-produced at present. This is because the generator stator coil is mostly made using epoxy resin injection molding, which is inefficient, and the stator molding is unstable and prone to deformation, thus affecting the collision and friction between the generator rotor and stator. In addition, only one layer of coil can be set inside the generator stator, and this structure has low efficiency in converting mechanical energy into electrical energy, resulting in low power generation efficiency of the generator. Therefore, a coreless high-efficiency disc generator coil stator that can be mass-produced is proposed.

[0004] Existing patent (publication number: CN214850853U) discloses a disc-type coreless generator, including a disc-shaped housing, a permanent magnet turntable, and two sets of stator winding assemblies. The permanent magnet turntable is built into the disc-shaped housing and is mounted on a rotating shaft, which is rotatably connected to the disc-shaped housing. The two sets of stator winding assemblies are symmetrically arranged at both ends of the permanent magnet turntable and are fixed to the inner wall of the disc-shaped housing. The permanent magnet turntable is equipped with a plurality of blades, which are evenly distributed on the circumference of the turntable. The disc-shaped housing is equipped with a plurality of air inlets and a plurality of air outlets. The air inlets are distributed on the two end faces of the disc-shaped housing, and the air outlets are distributed on the circumference of the disc-shaped housing. This invention can increase the air intake within the housing and improve cooling efficiency. In the process of realizing this utility model, the inventors discovered the following problems with the existing technology: 1. The existing epoxy resin injection method for making the stator makes the stator molding unstable and prone to deformation, which leads to friction and collision between the generator rotor and the stator. In addition, the injection efficiency is low and mass production is not possible; 2. The existing generator stator design can only set one layer of coil, resulting in low power generation efficiency. Utility Model Content

[0005] The purpose of this utility model is to provide a coreless high-efficiency disc generator coil stator that can be mass-produced, to solve the problems of instability in stator forming and the limitation of only one layer of coil mentioned in the background art. To achieve the above objective, this utility model provides the following technical solution: A coreless high-efficiency disc generator coil stator that can be mass-produced includes a stator top cover, a stator outer cover body parallel to one side of the stator top cover, a plurality of coil positioning blocks fixedly connected to one end of the surface of the stator outer cover body, an upper end cover positioning protrusion fixedly connected to the top of the coil positioning blocks, a plurality of through upper end cover positioning holes on the surface of the stator top cover, a stator body wire outlet on one side of the surface of the stator outer cover body, an upper end cover wire outlet on the edge of the surface of the stator top cover, a first layer of coil attached to one end of the surface of the stator outer cover body, and a second layer of coil attached to one end of the first layer of coil.

[0006] More preferably, the number of positioning holes on the upper end cover is consistent with the number of positioning protrusions on the upper end cover, and the inner wall dimensions of the positioning holes on the upper end cover are consistent with the dimensions of the positioning protrusions on the upper end cover.

[0007] More preferably, the upper end cover positioning holes are evenly distributed on the surface of the stator upper cover, while the coil positioning blocks are evenly distributed on the surface of the stator outer cover body.

[0008] More preferably, the stator top cover and the stator outer cover are both made of fiberglass nylon, and the stator top cover forms an integral structure with the stator outer cover through the upper end cover positioning hole and the upper end cover positioning protrusion.

[0009] More preferably, the inner wall of the first layer coil is in contact with one side of the surface of the coil positioning block.

[0010] More preferably, the central axis of the first layer coil is aligned with the central axis of the second layer coil, and the fixed position of the first layer coil on the coil positioning block is not aligned with the fixed position of the second layer coil on the coil positioning block.

[0011] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0012] In this invention, the stator housing of the generator coil is processed by 3D printing. The stator housing is divided into two parts: a stator outer cover body and a top cover. The stator housing is made of fiberglass nylon. The stator housing has multiple support points and fixing points inside. The stator outer cover body and the top cover are bonded together by hot melt welding. This can effectively improve the instability of stator molding caused by epoxy resin injection molding, making the stator less prone to deformation after molding, reducing friction between the generator rotor and stator, and this technology can achieve mass production.

[0013] In this invention, by adding a first layer of coil and a second layer of coil, and by making the first layer of coil and the second layer of coil fixed at different positions on the coil positioning block, the two layers of coil can provide power generation function simultaneously during operation without affecting each other, thus greatly improving power generation efficiency. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the isometric structure of this utility model;

[0015] Figure 2 This is a schematic diagram of the exploded structure of this utility model;

[0016] Figure 3 This is a partially enlarged structural diagram of part A of this utility model.

[0017] In the diagram: 1. Stator top cover; 2. Stator outer cover body; 3. Coil positioning block; 4. Top cover positioning protrusion; 5. Top cover positioning hole; 6. Stator body wire outlet; 7. Top cover wire outlet; 8. First layer coil; 9. Second layer coil. Detailed Implementation

[0018] 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 skilled in the art without creative effort are within the protection scope of the present utility model.

[0019] Please see Figures 1 to 3 This utility model provides a technical solution: a coreless high-efficiency disc generator coil stator that can be mass-produced, including a stator top cover 1, a stator outer cover body 2 parallel to one side of the stator top cover 1, a plurality of coil positioning blocks 3 fixedly connected to one end of the surface of the stator outer cover body 2, an upper end cover positioning protrusion 4 fixedly connected to the top of the coil positioning blocks 3, a plurality of through upper end cover positioning holes 5 on the surface of the stator top cover 1, a stator body wire outlet 6 on one side of the surface of the stator outer cover body 2, an upper end cover wire outlet 7 on the edge of the surface of the stator top cover 1, a first layer of coil 8 attached to one end of the surface of the stator outer cover body 2, and a second layer of coil 9 attached to one end of the first layer of coil 8.

[0020] In this embodiment, as Figure 1As shown, the number of upper cover positioning holes 5 is consistent with the number of upper cover positioning protrusions 4, and the inner wall size of the upper cover positioning holes 5 is consistent with the size of the upper cover positioning protrusions 4. This structure facilitates the formation of a sleeve structure between the upper cover positioning holes 5 and the upper cover positioning protrusions 4, and facilitates the formation of an integrated structure between the upper cover positioning holes 5 and the coil positioning block 3 through the upper cover positioning protrusions 4.

[0021] In this embodiment, as Figure 1 As shown, the upper cover positioning holes 5 are evenly distributed on the surface of the stator upper cover 1, while the coil positioning blocks 3 are evenly distributed on the surface of the stator outer cover body 2. This structure can form multiple support points and fixing points inside the stator outer cover body 2, so that the stator forming can maintain a stable structure.

[0022] In this embodiment, as Figure 1 As shown, both the stator upper cover 1 and the stator outer cover body 2 are made of glass fiber nylon. The stator upper cover 1 and the stator outer cover body 2 are integrated through the upper cover positioning hole 5 and the upper cover positioning protrusion 4. This structure can fix the stator upper cover 1 and the stator outer cover body 2 together and form a complete stator, which enhances the stability of the stator after molding.

[0023] In this embodiment, as Figure 1 As shown, the inner wall of the first layer coil 8 is attached to one side of the surface of the coil positioning block 3. This structure can fix the position of the first layer coil 8 through the coil positioning block 3 so that it will not shake during operation.

[0024] In this embodiment, as Figure 1 As shown, the central axis of the first layer coil 8 is aligned with the central axis of the second layer coil 9, and the fixed position of the first layer coil 8 on the coil positioning block 3 is not the same as the fixed position of the second layer coil 9 on the coil positioning block 3. This structure enables the two layers of coils to work without affecting each other and generate electricity at the same time, greatly improving the power generation efficiency.

[0025] The usage and advantages of this utility model: This coreless high-efficiency disc generator coil stator, which can be used for mass production, operates as follows:

[0026] like Figure 1 , Figure 2 and Figure 3As shown, the generator coil stator shell is first processed using 3D printing. The shell is divided into two parts: the stator outer cover body 2 and the stator upper cover 1. Both the stator outer cover body 2 and the stator upper cover 1 are made of fiberglass nylon. The coil positioning blocks 3 are uniformly distributed throughout the structure, meaning that multiple support points and fixing points are provided inside the stator outer cover body 2. The stator outer cover body 2 and the stator upper cover 1 are then bonded together as a single unit using a hot melt welding method. This simple and efficient structural principle enables the mass production of the generator coil stator in the disc generator and ensures its stability after molding, preventing easy deformation. This reduces friction between the generator stator and rotor, improves generator efficiency, and reduces generator failure rate. Furthermore, a double-layer coil structure with a first layer coil 8 and a second layer coil 9 is adopted, and the positioning positions of the first layer coil 8 and the second layer coil 9 on the coil positioning block 3 are staggered. This ensures that the two layers of coils do not interfere with each other during operation, while simultaneously generating electricity, greatly improving power generation efficiency.

[0027] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A coreless high-efficiency disc generator coil stator suitable for mass production, comprising a stator cover (1), characterized in that: The stator cover (1) has a stator outer cover body (2) parallel to one side. A plurality of coil positioning blocks (3) are fixedly connected to one end of the surface of the stator outer cover body (2). An upper cover positioning protrusion (4) is fixedly connected to the top of the coil positioning block (3). A plurality of through upper cover positioning holes (5) are provided on the surface of the stator cover (1). A stator body wire outlet (6) is provided on one side of the surface of the stator outer cover body (2). An upper cover wire outlet (7) is provided on the edge of the surface of the stator cover (1). A first layer coil (8) is attached to one end of the surface of the stator outer cover body (2). A second layer coil (9) is attached to one end of the first layer coil (8).

2. The coreless high-efficiency disc generator coil stator that can be mass-produced according to claim 1, characterized in that: The number of positioning holes (5) on the upper end cover is consistent with the number of positioning protrusions (4) on the upper end cover, and the inner wall size of the positioning holes (5) on the upper end cover is consistent with the size of the positioning protrusions (4) on the upper end cover.

3. The coreless high-efficiency disc generator coil stator that can be mass-produced according to claim 1, characterized in that: The upper end cover positioning holes (5) are evenly distributed on the surface of the stator upper cover (1), while the coil positioning blocks (3) are evenly distributed on the surface of the stator outer cover body (2).

4. The coreless high-efficiency disc generator coil stator that can be mass-produced according to claim 1, characterized in that: The stator top cover (1) and the stator outer cover body (2) are both made of glass fiber nylon, and the stator top cover (1) forms an integral structure with the stator outer cover body (2) through the upper end cover positioning hole (5) and the upper end cover positioning protrusion (4).

5. The coreless high-efficiency disc generator coil stator that can be mass-produced according to claim 1, characterized in that: The inner wall of the first layer coil (8) is in contact with one side of the surface of the coil positioning block (3).

6. The coreless high-efficiency disc generator coil stator that can be mass-produced according to claim 1, characterized in that: The central axis of the first layer coil (8) is aligned with the central axis of the second layer coil (9), and the fixed position of the first layer coil (8) on the coil positioning block (3) is not aligned with the fixed position of the second layer coil (9) on the coil positioning block (3).

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