Generator rotor end insulation
By introducing detection and locking mechanisms into the end insulation structure of the generator stator and rotor, full-circumference automated scanning of the weld and optimization of contact resistance are achieved, solving the problem of weak points in the weld and improving the safety and reliability of the generator.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- XUCHANG LONGGANG POWER GENERATION
- Filing Date
- 2025-09-12
- Publication Date
- 2026-07-31
AI Technical Summary
In the existing generator stator and rotor end insulation structure, the mechanical strength and electrical safety of the welds are weak, and 360° full-circumference inspection cannot be carried out, resulting in potential defects going undetected, leading to mechanical failure and deterioration of insulation performance, which may cause operational accidents.
The design combines a detection mechanism and a locking mechanism, and uses a servo motor and an ultrasonic detection head to achieve 360° full-circumference automated scanning of the weld. Flexible connecting pieces and silver-plated conductive surfaces reduce Joule heat loss and contact resistance fluctuations.
It enables full-circumference, blind-angle inspection of welds, reducing the risk of mechanical failure and insulation performance deterioration, and improving the safety and reliability of generators.
Smart Images
Figure CN224583047U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of power equipment manufacturing and electrical engineering, and more specifically, to an insulation structure at the ends of a generator stator and rotor. Background Technology
[0002] The generator stator and rotor end insulation structure is an insulation protection system for the ends of the generator stator and rotor coils (exposed parts away from the iron core). Its core function is to isolate conductive components (such as coils, leads, and metal components) with different potentials, prevent short circuits, leakage, or insulation breakdown, and withstand high temperatures, vibrations, electric fields, and mechanical stresses during operation. It is a key structure to ensure the safe operation of the generator.
[0003] A search revealed that Chinese patent CN204442039U discloses an "insulation device for a hydro-generator rotor." This utility model discloses an insulation device for a hydro-generator rotor, comprising an insulating sleeve and a pad. The insulating sleeve and the pad are detachably connected. A seat block is fitted onto the rotor with the insulating sleeve. The pad has threaded holes and is bolted to the generator. The inner wall of the insulating sleeve has a brush, and the end of the insulating sleeve has a tapered structure. Multiple perforations are evenly distributed on the side wall of the insulating sleeve. A bearing is provided between the tapered end and the rotor. This effectively prevents the rotor insulation from deteriorating, but the following drawbacks still exist:
[0004] (1) In the insulation structure at the stator and rotor ends of the generator, the weld is a key weak point in mechanical strength and electrical safety. If the weld cannot be inspected in 360°, potential defects will not be discovered, which will lead to a series of chain effects such as mechanical failure, deterioration of insulation performance, and operation accidents.
[0005] (2) If a combination of soldering and bonding is used, and induction soldering is employed, the welding strength is lower than that of vacuum soldering. If individual strands become loose or open during operation, an avalanche effect will occur. Therefore, an insulation structure for the stator and rotor ends of a generator is proposed. Utility Model Content
[0006] The purpose of this invention is to address the problem that, in the current generator stator and rotor end insulation structure, the weld seam is a key weak point in terms of mechanical strength and electrical safety. If the weld seam cannot be inspected 360° around the entire circumference, potential defects will go undetected, leading to a series of chain reactions such as mechanical failure, deterioration of insulation performance, and operational accidents.
[0007] To achieve the above-mentioned objectives, this utility model provides the following technical solution:
[0008] The present invention is as follows: an insulation structure at the stator and rotor ends of a generator, including a fixing frame and a water box cover. A fixed end of a servo motor is fixedly installed on the top of the fixing frame. A reciprocating lead screw is fixedly installed on the output end of the servo motor. A fixed end of a second servo motor is fixedly installed on the top of the fixing frame. A detection mechanism is provided on the surface of the fixing frame. The detection mechanism includes a sliding button, which is threaded onto the circumferential surface of the reciprocating lead screw. A fixed end of an electric push rod is fixedly installed on the left side of the sliding button. An ultrasonic detection head is fixedly installed on the output end of the electric push rod. A miniature spring is provided on the surface of the ultrasonic detection head.
[0009] As a preferred technical solution of this utility model, the output end of the servo motor is fixedly mounted with a rotating base, and an air pump is provided on the surface of the rotating base.
[0010] As a preferred technical solution of this utility model, a suction nozzle is provided at the bottom of the rotating seat, and the air pump is connected to the suction nozzle.
[0011] As a preferred technical solution of this utility model, the number of air pumps and nozzles is set to two, and they are symmetrical to each other along the vertical central axis of the rotating seat.
[0012] As a preferred technical solution of this utility model, a locking mechanism is provided inside the water box cover. The locking mechanism includes a clamping rod, which is fixedly installed inside the water box cover. A coil is provided on the surface of the clamping rod, and a silver-plated conductive surface is provided on the inner wall of the water box cover.
[0013] As a preferred technical solution of this utility model, the silver-plated conductive surface is provided with a flexible connecting piece, and the surface of the flexible connecting piece is provided with a pressing sheet.
[0014] As a preferred technical solution of this utility model, an L-shaped rod is fixedly installed on the surface of the silver-plated conductive surface, a cover plate is rotatably installed on the surface of the L-shaped rod, and a limit strip is fixedly installed on the surface of the cover plate.
[0015] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0016] 1. By setting up the detection mechanism, the non-welded area of the water box cover is vacuum-adsorbed through the suction nozzle, thus fixing the water box cover. The extension or retraction of the output end of the electric push rod causes the miniature spring of the ultrasonic detection head to contact the weld seam of the water box cover. At the same time, due to the rotation of the water box cover, the weld seam is dynamically displayed, which automates the operation that originally required manual flipping or multiple adjustments of the workpiece. The electric push rod drives the ultrasonic detection head to move synchronously, always aligning with the rotating weld seam trajectory, achieving a full-circumference weld seam scan without dead angles.
[0017] 2. By setting up a locking mechanism, when connecting the coil, the coil is first placed in the clamping rod to be temporarily fixed. Then, the coil is inserted into the silver-plated conductive surface. The flexible connecting pieces on the upper and lower silver-plated coils are pressed onto the silver-plated conductive surface by stainless steel bolts and pressure plates. A disc spring is placed between the bolts and the pressure plates. After the bolts are tightened to the specified torque, the bolts lock the coil. The tightening force of the pressure plates and stainless steel bolts makes the silver-plated surface fit tightly, reducing Joule heat loss during current transmission and preventing local overheating from burning the insulation layer. The self-adaptive contact of the flexible connecting pieces has a certain elastic deformation capability and can adapt to the micro-unevenness of the silver-plated surface under pressure, increasing the actual contact area and further reducing the fluctuation of contact resistance. Attached Figure Description
[0018] Figure 1 A schematic diagram of the generator stator and rotor end insulation structure provided by this utility model;
[0019] Figure 2 A schematic diagram of the location of the detection mechanism for the end insulation structure of the generator stator and rotor provided by this utility model;
[0020] Figure 3 A schematic diagram showing the position and structure of the water box cover and locking mechanism of the generator stator and rotor end insulation structure provided by this utility model;
[0021] Figure 4 A schematic diagram of the locking mechanism of the generator stator and rotor end insulation structure provided by this utility model;
[0022] Figure 5 The generator stator and rotor end insulation structure provided by this utility model Figure 4 Enlarged schematic diagram of part A in the middle.
[0023] The diagram shows: 1. Fixing frame; 2. Water tank cover; 3. Servo motor one; 4. Reciprocating lead screw; 5. Servo motor two; 6. Detection mechanism; 60. Sliding button; 61. Electric push rod; 62. Ultrasonic detection head; 63. Rotating seat; 64. Air pump; 65. Suction nozzle; 7. Locking mechanism; 70. Clamping rod; 71. Coil; 72. Silver-plated conductive surface; 73. Flexible connecting piece; 74. Pressure plate; 75. L-shaped rod; 76. Cover plate; 77. Limiting strip. Detailed Implementation
[0024] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model.
[0025] Therefore, the following detailed description of the embodiments of this utility model is not intended to limit the scope of the claimed utility model, but merely to illustrate some embodiments of the utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort are within the scope of protection of this utility model.
[0026] It should be noted that, unless otherwise specified, the embodiments and features and technical solutions in the present invention can be combined with each other.
[0027] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.
[0028] like Figure 1 and Figure 2 As shown, this embodiment proposes an insulation structure for the stator and rotor ends of a generator, including a fixing frame 1 and a water box cover 2. The top of the fixing frame 1 is fixedly mounted with the fixed end of a servo motor 3, and the output end of the servo motor 3 is fixedly mounted with a reciprocating lead screw 4. The top of the fixing frame 1 is fixedly mounted with the fixed end of a servo motor 5. A detection mechanism 6 is provided on the surface of the fixing frame 1. The detection mechanism 6 includes a sliding button 60, which is threaded onto the circumferential surface of the reciprocating lead screw 4. The left side of the sliding button 60 is fixedly mounted with the fixed end of an electric push rod 61, and the output end of the electric push rod 61 is fixedly mounted with an ultrasonic detection head 62. The surface of the ultrasonic detection head 62 is provided with a micro spring. The weld surface may have microscopic unevenness. Through the elastic characteristics of the micro spring, the detection head can automatically extend and retract with the surface unevenness when contacting the weld, ensuring that the detection head and the weld surface always maintain surface contact.
[0029] like Figure 2 As shown, in a preferred embodiment, based on the above method, a rotating seat 63 is fixedly installed at the output end of the servo motor 2 5, and an air pump 64 is provided on the surface of the rotating seat 63 to vacuum adsorb the non-welded area of the water box cover 2 through the suction nozzle 65.
[0030] like Figure 2 As shown, in a preferred embodiment, based on the above method, a suction nozzle 65 is further provided at the bottom of the rotating seat 63, and the air pump 64 is connected to the suction nozzle 65. No further details are provided.
[0031] like Figure 2 As shown, in a preferred embodiment, based on the above method, the number of air pump 64 and suction nozzle 65 is further set to two, and they are symmetrical to each other along the vertical central axis of the rotating seat 63, without any further additions.
[0032] like Figure 4 and Figure 5 As shown, in a preferred embodiment, based on the above method, a locking mechanism 7 is further provided inside the water tank cover 2. The locking mechanism 7 includes a clamping rod 70, which is fixedly installed inside the water tank cover 2. A coil 71 is provided on the surface of the clamping rod 70, and a silver-plated conductive surface 72 is provided on the inner wall of the water tank cover 2. The flexible connecting pieces 73 on the silver-plated upper and lower coils 71 are pressed onto the silver-plated conductive surface 72 by stainless steel bolts and pressure plates 74.
[0033] like Figure 4 and Figure 5 As shown, in a preferred embodiment, based on the above method, the silver-plated conductive surface 72 is further provided with a flexible connecting piece 73, and a pressure piece 74 is provided on the surface of the flexible connecting piece 73. A disc spring is placed between the bolt and the pressure piece 74. After the bolt is tightened to a specified torque, the bolt locks the coil 71.
[0034] like Figure 4 and Figure 5 As shown, in a preferred embodiment, based on the above method, an L-shaped rod 75 is fixedly installed on the surface of the silver-plated conductive surface 72, a cover plate 76 is rotatably installed on the surface of the L-shaped rod 75, and a limiting strip 77 is fixedly installed on the surface of the cover plate 76. When the bolt is rotated to the maximum torque, the limiting strip 77 is inserted into the surface of the bolt by rotating the cover plate 76, so that the bolt is fixed.
[0035] Specifically, in use, the non-welded area of the water box cover 2 is vacuum-adsorbed by the suction nozzle 65, thus fixing the water box cover 2. At this time, the output end of the servo motor 2 5 drives the rotating seat 63 to rotate. The rotation of the rotating seat 63 drives the suction nozzle 65 to move, causing the water box cover 2 to rotate. At this time, the output end of the servo motor 3 drives the reciprocating screw 4 to rotate. The rotation of the reciprocating screw 4 causes the sliding button 60 to move up and down. While the sliding button 60 moves, it drives the fixed end of the electric push rod 61 to move. The movement of the fixed end of the electric push rod 61 drives the ultrasonic detection head 62 to move. The extension or retraction of the output end of the electric push rod 61 causes the miniature spring of the ultrasonic detection head 62 to contact the weld of the water box cover 2. At the same time, due to the rotation of the water box cover 2, the weld is dynamically displayed, so that the operation that originally required manual flipping or multiple adjustments of the workpiece is automated. The electric push rod 61 drives the ultrasonic detection head 62 to move synchronously, always aligned with the rotating weld trajectory, realizing 360° full-circumference weld scanning without dead angles.
[0036] This embodiment only shows a portion of the structure at coil 71. When connecting coil 71, coil 71 is first placed in clamping rod 70 for temporary fixation. Then, coil 71 is inserted into silver-plated conductive surface 72. Flexible connecting pieces 73 on the upper and lower silver-plated coils 71 are pressed onto silver-plated conductive surface 72 by stainless steel bolts and pressure plates 74. A disc spring is placed between the bolt and pressure plate 74. After the bolt is tightened to the specified torque, the bolt locks coil 71. The tightening force of pressure plate 74 and stainless steel bolt ensures that the silver-plated surface is tightly fitted, reducing Joule heat loss during current transmission and preventing local overheating that could burn the insulation layer. The self-adaptive contact of flexible connecting piece 73 has a certain elastic deformation capability and can adapt to the micro-unevenness of the silver-plated surface under pressure, increasing the actual contact area and further reducing contact resistance fluctuations. When the bolt is rotated to the maximum torque, the limiting strip 77 is inserted into the surface of the bolt by rotating cover plate 76, thus fixing the bolt.
[0037] All technical features in this embodiment can be freely combined according to actual needs.
[0038] The above embodiments are preferred implementations of this utility model. In addition, this utility model can also be implemented in other ways. Any obvious substitutions without departing from the concept of this technical solution are within the protection scope of this utility model.
Claims
1. A generator stator-rotor end insulation structure comprising a fixing frame (1) and a water box cover (2), characterized in that, The top of the fixed frame (1) is fixedly installed with the fixed end of the servo motor one (3), the output end of the servo motor one (3) is fixedly installed with the reciprocating lead screw (4), the top of the fixed frame (1) is fixedly installed with the fixed end of the servo motor two (5), and the surface of the fixed frame (1) is provided with a detection mechanism (6). The detection mechanism (6) includes a sliding button (60), which is threaded onto the circumferential surface of the reciprocating lead screw (4). The left side of the sliding button (60) is fixedly mounted with the fixed end of an electric push rod (61), and the output end of the electric push rod (61) is fixedly mounted with an ultrasonic detection head (62). The surface of the ultrasonic detection head (62) is provided with a miniature spring.
2. A generator stator-rotor end insulation structure according to claim 1, wherein The output end of the servo motor 2 (5) is fixedly mounted with a rotating base (63), and an air pump (64) is provided on the surface of the rotating base (63).
3. A generator stator-rotor end turn insulation structure according to claim 2, wherein The bottom of the rotating seat (63) is provided with a suction nozzle (65), and the air pump (64) is connected to the suction nozzle (65).
4. A generator stator-rotor end turn insulation structure according to claim 2, wherein The number of air pumps (64) and suction nozzles (65) is set to two, and they are symmetrical to each other along the vertical central axis of the rotating seat (63).
5. A generator stator-rotor end turn insulation structure as defined in claim 1, wherein, The water box cover (2) is provided with a locking mechanism (7), which includes a clamping rod (70). The clamping rod (70) is fixedly installed inside the water box cover (2). The surface of the clamping rod (70) is provided with a coil (71), and the inner wall of the water box cover (2) is provided with a silver-plated conductive surface (72).
6. A generator stator-rotor end turn insulation structure according to claim 5, wherein The silver-plated conductive surface (72) is provided with a flexible connecting piece (73), and a pressure piece (74) is provided on the surface of the flexible connecting piece (73).
7. A generator stator-rotor end turn insulation structure as claimed in claim 5, wherein, An L-shaped rod (75) is fixedly installed on the surface of the silver-plated conductive surface (72), a cover plate (76) is rotatably installed on the surface of the L-shaped rod (75), and a limit strip (77) is fixedly installed on the surface of the cover plate (76).