A support structure for the inner circle of the end of the rotor winding of a phase modifier

Abstract

This utility model discloses a support structure for the inner circle of the coil winding end of a phase shifter rotor, belonging to the field of motor technology. It includes a positioning bushing, a tensioning bushing, and a constraint fixture. The positioning bushing is composed of multiple positioning blocks arranged sequentially along the circumference of the rotor shaft. The tensioning bushing is composed of multiple tensioning blocks arranged sequentially along the circumference of the positioning bushing. The constraint fixture is positioned between the positioning bushing, the tensioning bushing, and the rotor shaft. By setting up a positioning bushing composed of multiple positioning blocks and a tensioning bushing composed of multiple tensioning blocks, a two-layer assembly structure can form a detachable support system between the rotor shaft and the inner circle of the coil end. Compared with the traditional integral core mold, this structure no longer uses a one-piece molded support component, but instead utilizes multiple separate blocks to form a complete circumferential structure, fundamentally solving the technical problem that the integral fixture cannot be disassembled.

Description

Technical Field

[0001] This utility model belongs to the field of motor technology, specifically a support structure for the inner circle of the rotor winding end of a phase converter. Background Technology

[0002] During the manufacturing process of a synchronous condenser rotor, after the coil is wound and installed, the inner circle at the end of the coil is prone to irregular deformation, resulting in a large deviation in the concentricity of the inner circle and poor roundness. If the inner circle at the end of the coil is not properly shaped, it will not only increase the difficulty of subsequent retaining ring assembly, but may also lead to uneven rotor mass distribution, generating vibration and noise during high-speed rotation, thereby affecting the operational stability and service life of the synchronous condenser.

[0003] In existing technologies, the shaping of the inner circle at the end of a synchronous condenser rotor coil mainly employs two methods: manual hammering or shaping using an integral constraint fixture. Manual hammering relies on operators using specialized tools to locally correct the coil. This method is highly dependent on operator experience, and it's difficult to maintain consistent hammering force and position, easily leading to poor dimensional accuracy and concentricity of the shaped inner circle, failing to meet the manufacturing requirements of large, high-precision motors. Furthermore, during hammering, the tool directly contacts the coil surface, easily scratching the coil insulation layer, causing a decrease in insulation performance, and even triggering quality problems such as leakage and short circuits, affecting product yield.

[0004] The integral constraint tooling top-support shaping method typically involves pre-setting a constraint template during the rotor coil winding process. This template limits and supports the inner circle of the coil to achieve the shaping purpose. However, because the inner circle at the end of the synchronous condenser rotor coil often contains locally irregular cavity structures, the integral tooling is difficult to shrink, disassemble, or adjust in size after winding, making it difficult to detach smoothly from the coil. To achieve demolding, destructive dismantling of the tooling is often required, making it usable only once. This not only increases manufacturing costs but also wastes tooling resources and reduces production efficiency. Utility Model Content

[0005] The purpose of this utility model is to provide an inner circle support structure at the winding end of a camera rotor to solve the problems mentioned in the prior art.

[0006] A support structure for the inner circle of the winding end of a phase shifter rotor is provided, comprising: The positioning bushing is composed of multiple positioning blocks arranged sequentially along the circumference of the rotor shaft. The tensioning bushing is composed of multiple tensioning blocks arranged sequentially along the circumference of the positioning bushing. The constraint fixture is set between the positioning bushing, the tensioning bushing, and the rotor shaft.

[0007] As a further embodiment of this utility model: the constraint fixture includes a limiting ring and an adjusting bolt. The limiting ring is arranged along the annular end face of the positioning bushing and the tensioning bushing, and the adjusting bolt is set between the limiting ring and each positioning unit and between the limiting ring and each tensioning unit.

[0008] As a further embodiment of this utility model: the constraint fixture includes a stop part and an abutment part, the stop part is disposed in the annular groove of the rotor shaft, and the abutment part is disposed between the limiting ring and the stop part.

[0009] As a further embodiment of this utility model: the stop part is composed of multiple detachably connected splicing discs, and the abutment part is a screw threadedly connected to the stop part.

[0010] As a further embodiment of this utility model: a contact surface is formed between the positioning bushing and the tensioning bushing, and the diameter of the contact surface gradually decreases in the direction away from the constraint tooling.

[0011] As a further embodiment of this utility model: the tensioning block includes a first sub-tensioning block and several second sub-tensioning blocks. The first sub-tensioning block contacts the positioning block and extends along the length direction of the positioning block. Several second sub-tensioning blocks are disposed in the irregular cavity formed between the first sub-tensioning block and the coil.

[0012] As a further embodiment of this utility model: the tensioning single-piece block is covered with a thin film.

[0013] As a further aspect of this invention, the film is made of polyimide.

[0014] As a further embodiment of this invention, a padding layer is provided between the tensioning bushing and the coil.

[0015] As a further embodiment of this utility model, the material of the padding layer is epoxy glass cloth board.

[0016] Compared with the prior art, the beneficial effects of this utility model are as follows: By setting up a positioning bushing composed of multiple positioning blocks and a tensioning bushing composed of multiple tensioning blocks, the two-layer assembly structure can form a detachable support system between the rotor shaft and the inner circle of the coil end. Compared with the traditional integral core mold, this structure no longer uses a one-piece molded support component, but uses multiple split blocks to form a complete circumferential structure, fundamentally solving the technical problem that the integral tooling cannot be disassembled. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this drawing 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 drawing. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall structure of the inner circular support structure. Figure 2 The structural layout diagram of the positioning single block and the tensioning single block provided by this utility model; Figure 3 This is one of the working state diagrams during the disassembly of the inner circular support structure; Figure 4 This is the second working state diagram during the disassembly of the inner circular support structure; Figure 5 This is the third diagram showing the working state of the inner circular support structure during disassembly. Figure 6 The fourth diagram shows the working state of the inner circular support structure during disassembly. Figure 7 This is a schematic diagram of the structure of the stop provided by this utility model.

[0019] In the diagram: 1. Positioning unit; 2. Tensioning unit; 21. First sub-tensioning unit; 22. Second sub-tensioning unit; 3. Constraint fixture; 31. Limiting ring; 32. Adjusting bolt; 33. Stop; 331. Splicing plate; 34. Abutment; 4. Rotor shaft; 41. Ring groove; 5. Coil; 51. Irregular cavity; 6. Pad layer. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this application clearer, the application is described and illustrated below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application. All other embodiments obtained by those skilled in the art based on the embodiments provided in this application without inventive effort are within the scope of protection of this application.

[0021] Obviously, the accompanying drawings described below are merely some examples or embodiments of this application. Those skilled in the art can apply this application to other similar scenarios based on these drawings without any inventive effort. Furthermore, it is understood that although the efforts made in this development process may be complex and lengthy, for those skilled in the art related to the content disclosed in this application, any changes to design, manufacturing, or production based on the technical content disclosed in this application are merely conventional technical means and should not be construed as insufficient disclosure of the content of this application.

[0022] However, there may be instances where unnecessary detailed descriptions are omitted. For example, detailed descriptions of well-known matters or repetitive descriptions of essentially the same structures may be omitted. This is to avoid unnecessarily lengthy descriptions and to facilitate understanding by those skilled in the art. Furthermore, the accompanying drawings and the following description are provided to enable those skilled in the art to fully understand this application and are not intended to limit the subject matter of the claims.

[0023] Please see Figures 1-2 As shown in the embodiment of this utility model, a supporting structure for the inner circle of the winding end of a phase shifter rotor includes a positioning bushing, a tensioning bushing, and a constraint fixture 3. The positioning bushing is composed of multiple positioning single blocks 1 arranged sequentially along the circumference of the rotor shaft 4. The tensioning bushing is composed of multiple tensioning single blocks 2 arranged sequentially along the circumference of the positioning bushing. The constraint fixture 3 is disposed between the positioning bushing, the tensioning bushing, and the rotor shaft 4.

[0024] In a typical embodiment, multiple positioning blocks 1 are placed one by one around the rotor shaft 4. The positioning blocks 1 are arranged circumferentially around the shaft to form a positioning sleeve, providing the entire support structure with an installation reference and establishing a coaxial positioning relationship with the rotor shaft 4. The positioning sleeve is then maintained in an enclosed state by a constraint fixture 3.

[0025] Subsequently, multiple tensioning single-piece blocks 2 are installed sequentially around the positioning bushing. Each tensioning single-piece block 2 also adopts a split structure, which can be assembled piece by piece within a limited space, and finally form a complete tensioning bushing around the positioning bushing. The tensioning bushing is located between the inner circle of the end of the coil 5 and the positioning bushing, preparing for subsequent radial support. After the two-layer assembly structure is installed, the closed state of the tensioning bushing is maintained by the constraint fixture 3.

[0026] During coil 5 installation, the constraint fixture 3 provides the force required to support the structure. After the coil 5 is subjected to the supporting force, the resulting localized deformation area begins to recover towards the designed arc contour. Since the tensioning bushing is continuously distributed along the entire circumference, the supporting force can cover the entire inner circular area, allowing all positions of the coil 5 to be simultaneously corrected, thereby improving the roundness and concentricity of the inner circle at the end of the coil 5.

[0027] After the shaping is completed and the predetermined dimensional requirements are met, the force applied by the constraint fixture 3 is released, allowing the tensioning bushing to return to a state that facilitates disassembly. Subsequently, the positioning single-piece assembly 1 and the tensioning single-piece assembly 2 are removed in sequence. Since each component is a separate structure, it can be removed piece by piece from between the rotor shaft 4 and the coil 5 without destructive disassembly of the fixture.

[0028] Throughout the process, the positioning bushing is responsible for establishing a coaxial positioning reference and providing an internal support foundation, the tensioning bushing is responsible for applying radial shaping force to coil 5, and the constraint fixture 3 is responsible for generating and maintaining the support force. The three work together to form an assemblable, tensionable, and detachable support system. Through this process, precise shaping of the inner circle at the end of the synchronous condenser rotor coil 5 can be achieved, while avoiding the problem of traditional integral fixtures being unable to be demolded. At the same time, the fixture can be reused, improving shaping efficiency and reducing manufacturing costs.

[0029] Specifically, the constraint fixture 3 includes a limiting ring 31 and an adjusting bolt 32. The limiting ring 31 is arranged along the annular end face of the positioning bushing and the tensioning bushing. The adjusting bolt 32 is located between the limiting ring 31 and each positioning single block 1 and between the limiting ring 31 and each tensioning single block 2.

[0030] The limiting ring 31 is located at the end face of the positioning bushing and the tensioning bushing, serving as the axial constraint foundation for the entire assembly structure. After multiple blocks are circumferentially assembled, the limiting ring 31 can connect the blocks into a whole, preventing the blocks from axially shifting or separating during the stress process.

[0031] Adjusting bolts 32 are connected between the limiting ring 31 and the positioning block 1 and the tensioning block 2, respectively. By adjusting the bolts 32 in or out, the relative position between each block and the limiting ring 31 can be controlled.

[0032] In one specific embodiment, the adjusting bolt 32 is threadedly connected to the limiting ring 31, and the adjusting bolt 32 abuts against the positioning single block 1 and the tensioning single block 2. The threaded movement between the adjusting bolt 32 and the limiting ring 31 generates an axial force applied to the positioning single block 1 and the tensioning single block 2.

[0033] Furthermore, the constraint fixture 3 includes a stop part 33 and an abutment part 34. The stop part 33 is disposed in the annular groove 41 of the rotor shaft 4, and the abutment part 34 is disposed between the limiting ring 31 and the stop part 33.

[0034] When the constraint fixture 3 is installed on the rotor shaft 4, the stop part 33 is embedded inside the annular groove 41 to form a fixed support point. Since the annular groove 41 is an inherent structure of the rotor shaft 4, the stop part 33 can reliably withstand the axial load generated by the limiting ring 31 and the support structure.

[0035] The abutment portion 34 is located between the stop portion 33 and the limiting ring 31. The function of the abutment portion 34 is to transmit the axial reaction force generated by the stop portion 33 to the limiting ring 31. When the limiting ring 31 is subjected to the action of the adjusting bolt 32 and generates an axial load, the abutment portion 34 can transmit the load to the rotor shaft 4, thereby forming a complete force closed loop.

[0036] Furthermore, please refer to Figure 1 and Figure 7 As shown, the stop part 33 is composed of multiple detachably connected splicing plates 331, and the abutment part 34 is a screw that is threadedly connected to the stop part 33.

[0037] Since the outer diameter of the annular groove 41 region is smaller than the outer diameter of other regions of the rotor shaft 4, it would be impossible to install it into the annular groove 41 position if an integral disc structure were used. However, by using multiple splicing discs 331, each segment can be placed into the annular groove 41 position in sequence, and then assembled to form a complete stop structure, thereby improving the ease of assembly.

[0038] The abutment portion 34 adopts a screw structure that is threadedly connected to the stop portion 33. By rotating the screw, the extension length of the screw can be changed, thereby adjusting the distance between the limit ring 31 and the stop portion 33.

[0039] During installation, workers can axially pre-tighten the limiting ring 31 by rotating the screw, ensuring the stability of the entire assembly support system. During disassembly, the pre-tightening force can be released by rotating the screw in the opposite direction, facilitating quick disassembly of the tooling.

[0040] In some embodiments, a contact surface is formed between the positioning bushing and the tensioning bushing, and the diameter of the contact surface gradually decreases in the direction away from the constraint fixture 3.

[0041] After the shaping is completed, the support structure needs to be removed from inside the coil 5. Because the positioning bushing and the tensioning bushing use a wedge-shaped fit, the outer diameter of the positioning unit 1 near the limiting ring 31 is larger, while the outer diameter of the end away from the limiting ring 31 is smaller. Therefore, the positioning unit 1 itself forms a structure with a draft angle. During disassembly, the positioning unit 1 can be preferentially pulled outwards along the axial direction, unlike traditional straight-wall structures which can be stuck inside the coil 5 due to radial interference or excessive friction.

[0042] As the positioning unit 1 is gradually removed, the internal space originally occupied by the positioning bushing is released, and the inner side of the tensioning unit 2 loses its supporting foundation, thus releasing the radial constraint condition of the tensioning unit 2. At this time, the tensioning unit 2 can contract inward, creating a disassembly gap between the tensioning unit 2 and the coil 5.

[0043] In particular, for the tensioning single-piece block 2 inside the irregular cavity 51 embedded in the coil 5, since the irregular cavity 51 usually has a reverse envelope structure or a locally narrowed area, it is difficult to remove it directly without sufficient clearance. The cavity formed after the positioning single-piece block 1 is removed provides the necessary clearance for the tensioning single-piece block 2 to move inward and exit the irregular cavity 51, so that the tensioning single-piece block 2 can be separated from the irregular cavity 51 area piece by piece and removed smoothly.

[0044] In some embodiments, please refer to Figures 1-6 As shown, the tensioning block 2 includes a first sub-tensioning block 21 and several second sub-tensioning blocks 22. The first sub-tensioning block 21 contacts the positioning block 1 and extends along the length direction of the positioning block 1. Several second sub-tensioning blocks 22 are disposed in the irregular cavity 51 formed between the first sub-tensioning block 21 and the coil 5.

[0045] The first sub-tensioning block 21 is in direct contact with the positioning block 1 and extends axially to form the main support part. However, since the end of the synchronous condenser rotor coil 5 is usually not a standard circle, but has irregular cavity structures such as local grooves and clearance areas 51, it is difficult to achieve uniform support around the entire circumference by relying solely on the main tensioning block. Therefore, several second sub-tensioning blocks 22 are further set inside the irregular cavity 51.

[0046] The second sub-tensioning block 22 can fill the irregular cavity 51 according to its actual shape, providing support to areas that were previously inaccessible. This not only eliminates the risk of localized deformation in irregular areas but also ensures more uniform stress distribution on the inner circle of the entire coil 5 end, improving the shaping effect. Furthermore, the second sub-tensioning block 22 is an independent component and can be added or removed according to different rotor models, improving the tooling versatility.

[0047] Furthermore, the tensioning unit 2 is covered with a thin film. Before the coil 5 is shaped, the first sub-tensioning unit 21 and multiple second sub-tensioning units 22 need to be assembled together at the end of the coil 5. Since the second sub-tensioning unit 22 is an independent part and the internal space of the irregular cavity 51 is complex, it is easy to loosen, shift, or even fall off during installation and shaping. By covering the tensioning unit 2 with a thin film, the first sub-tensioning unit 21 and multiple second sub-tensioning units 22 can be bound together as a whole, so that the originally scattered parts form a relatively complete assembly.

[0048] After the shaping is completed, the support structure needs to be removed from inside coil 5. At this point, the function of the membrane changes from overall constraint to controlled release. After the workers cut or puncture the membrane, the overall connection between the first sub-tension block 21 and the second sub-tension block 22 is lost, and each sub-block returns to its independent state.

[0049] Furthermore, since the rotor shaft 4 is usually provided with a rounded chamfer at its end, this chamfer is beneficial for the transition of the shaft structure and stress release. However, during disassembly, the chamfered area may form a local obstruction. When the size of the second sub-tensioning block 22 is large, the disassembly path is easily interfered with by the chamfer, making it impossible to directly remove it radially or axially.

[0050] Therefore, the second sub-tensioning block 22 is further divided into at least two independent modules. Multiple second sub-tensioning blocks 22 are assembled together during installation to form a complete filling structure, providing overall support during the shaping stage. During disassembly, they can be separated piece by piece after the membrane is released from its constraints. Please refer to the following for the step-by-step disassembly process of the inner circular support structure. Figures 3-6 As shown, since the size of each sub-block is significantly reduced, it is able to avoid the interference area formed by the rounded chamfer of the rotor shaft 4, and move into the empty internal space and be taken out in sequence.

[0051] In one specific embodiment, the film mainly serves the functions of covering and restraining, insulating and protecting, and facilitating removal. The film can be polyimide film, polyester film, polytetrafluoroethylene film, polyethylene film, polypropylene film, aramid paper film, heat shrink sleeve film, etc.

[0052] Preferably, the film is made of polyimide. Polyimide has excellent insulation properties, wear resistance, and high temperature resistance. During the coil 5 shaping process, even if the tensioning block 2 comes into contact with and rubs against the coil 5, the polyimide film can still maintain a stable structure and is not easily damaged, thus continuously protecting the insulation layer of the coil 5.

[0053] In some embodiments, a padding layer 6 is provided between the tensioning bushing and the coil 5. The padding layer 6 is located between the rigid support structure and the coil 5, acting as a buffer transition layer. When the tensioning bushing applies a supporting force outward, the padding layer 6 can first undergo slight deformation, spreading the localized concentrated load to a larger contact area. At the same time, the transition structure can effectively avoid the risk of the coil 5's insulation layer being scratched by the rigid structure.

[0054] In one specific embodiment, the padding layer 6 is made of epoxy glass cloth board, aramid insulation board, laminated wood, glass fiber reinforced polyester board, polyimide laminate, phenolic laminate, etc.

[0055] Preferably, the material of the padding layer 6 is an epoxy glass cloth board. Epoxy glass cloth board has high mechanical strength, good insulation properties, and small compressive deformation. When the tensioning bushing applies pressure outward, the epoxy glass cloth board can withstand a large compressive load without undergoing significant plastic deformation due to long-term stress, thus ensuring the dimensional stability of the inner circle after shaping.

[0056] It should be noted that this application is not limited to the above-described embodiments. The above embodiments are merely examples, and any embodiments with the same structure and effect as the technical concept within the scope of this application are included in the technical scope of this application. Furthermore, various modifications that can be conceived by those skilled in the art to the embodiments, and other ways of constructing by combining some of the constituent elements of the embodiments, without departing from the spirit of this application, are also included in the scope of this application.

Claims

1. A support structure for the inner circle of the winding end of a phase shifter rotor, characterized in that, include: The positioning bushing is composed of multiple positioning single blocks (1) arranged sequentially along the circumference of the rotor shaft (4); The tensioning bushing is composed of multiple tensioning single blocks (2) arranged sequentially along the circumferential periphery of the positioning bushing; The constraint fixture (3) is set between the positioning bushing, the tensioning bushing and the rotor shaft (4).

2. The inner circle support structure at the end of the rotor of a phase shifter according to claim 1, characterized in that, The constraint fixture (3) includes a limiting ring (31) and an adjusting bolt (32). The limiting ring (31) is arranged along the annular end face of the positioning bushing and the tensioning bushing. The adjusting bolt (32) is located between the limiting ring (31) and each positioning single block (1) and between the limiting ring (31) and each tensioning single block (2).

3. The inner circle support structure at the end of the rotor of a condenser according to claim 2, characterized in that, The constraint fixture (3) includes a stop (33) and an abutment (34). The stop (33) is disposed in the annular groove (41) of the rotor shaft (4), and the abutment (34) is disposed between the limiting ring (31) and the stop (33).

4. The inner circle support structure at the end of the rotor of a condenser according to claim 3, characterized in that, The stop part (33) is composed of multiple detachably connected splicing plates (331), and the abutment part (34) is a screw threadedly connected to the stop part (33).

5. The inner circle support structure at the end of the rotor of a phase shifter according to claim 1, characterized in that, A contact surface is formed between the positioning bushing and the tensioning bushing, and the diameter of the contact surface gradually decreases in the direction away from the constraint fixture (3).

6. The inner circle support structure at the end of the rotor of a phase shifter according to claim 1, characterized in that, The tensioning block (2) includes a first sub-tensioning block (21) and several second sub-tensioning blocks (22). The first sub-tensioning block (21) contacts the positioning block (1) and extends along the length direction of the positioning block (1). Several second sub-tensioning blocks (22) are disposed in the irregular cavity (51) formed between the first sub-tensioning block (21) and the coil (5).

7. The inner circle support structure at the end of the rotor of a condenser according to claim 6, characterized in that, The tensioned single-piece block (2) is covered with a thin film on the outside.

8. The inner circle support structure at the end of the rotor of a phase shifter according to claim 7, characterized in that, The film is made of polyimide.

9. The inner circle support structure at the end of the rotor of a phase shifter according to claim 1, characterized in that, A pad (6) is provided between the tensioning bushing and the coil (5).

10. The inner circle support structure at the end of the rotor of a phase shifter according to claim 9, characterized in that, The material of the padding layer (6) is epoxy glass cloth board.

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