A rotor coil winding frame for a brushless generator

Abstract

This utility model discloses a rotor coil winding frame for a brushless generator, including a rotor shaft, a modular assembly frame, rotor windings, and end caps. The rotor shaft has axially spaced mounting slots along its axial direction. One end of the modular assembly frame has an arc-shaped outer protective cover extending from its sidewall, with an axial locking pin at the end of the outer protective cover. The other end of the modular assembly frame has a guide sliding part that inserts into the axial mounting slots. The rotor windings are fitted onto the modular assembly frame. The rotor shaft passes through the center of the end cap, which has multiple locking holes. The axial locking pins and locking holes cooperate to fix the windings. This utility model provides a rotor coil winding frame for a brushless generator, which facilitates winding, provides high rigidity radial constraint, and supports partial replacement and repair.

Description

Technical Field

[0001] This utility model relates to the technical field of brushless generator manufacturing and motor structure design, and in particular to a rotor coil winding frame for a brushless generator. Background Technology

[0002] The rotor excitation winding of a high-power brushless generator is typically made of flat copper wire with a large cross-section. It is extremely rigid, has a large bending radius, and is very difficult to form. In the traditional brushless generator manufacturing process, the rotor winding generally adopts an "online in-situ" integral winding process. That is, ordinary insulating paper or simple insulating end plates are directly attached to the rotor core. The winding equipment must drive the rotor yoke, which weighs several tons and is bulky, to rotate and wind the entire winding. Alternatively, operators use special crowbars and other tools to manually pull, padded, and bent layer by layer within the extremely narrow tooth gaps between multiple magnetic poles.

[0003] This traditional in-situ winding process and wire frame structure have many obvious defects that are difficult to overcome: First, due to the spatial geometric limitations between the multiple magnetic poles of the rotor, the head of the heavy-duty automated wiring equipment cannot accurately probe in, resulting in extremely slow wiring speed and a long production cycle, which seriously restricts the mass production efficiency of brushless generators.

[0004] Secondly, large-section flat copper wires are prone to rigid and severe wear against narrow magnetic pole sidewalls or operating tools during strong pulling, squeezing, and frequent local bending. This can damage the insulating varnish layer on the surface of the enameled wire, which can easily lead to fatal inter-turn or inter-layer short circuit hazards under subsequent high-voltage and high-heat operating conditions.

[0005] Third, the existing wire frame structure lacks all-round rigid constraint on the conductors. Under the combined action of the huge alternating electromagnetic force and strong centrifugal force generated by the high-speed rotation of the rotor, the winding ends are prone to interlayer micro-slippage, local swelling and whip tip deformation. Over time, this will lead to insulation wear, aging and damage.

[0006] Fourth, this in-situ winding structure results in extremely poor motor maintainability. During after-sales maintenance, even if only one magnetic pole coil is partially burned out, it cannot be replaced individually. It often requires the complete destruction and cutting of all intact windings of all magnetic poles, resulting in incalculable maintenance and after-sales support costs. Utility Model Content

[0007] The purpose of this invention is to provide a rotor coil winding frame for a brushless generator that facilitates winding, provides high rigidity radial constraint force, and supports partial replacement and repair.

[0008] The technical solution adopted by the rotor coil winding frame of the brushless generator disclosed in this utility model is as follows: A rotor coil winding frame for a brushless generator includes a rotor shaft, a modular assembly frame, rotor windings, and end caps. The rotor shaft has axially spaced mounting slots along its axial direction. The modular assembly frame has an arc-shaped outer protective cover extending from one side wall, and an axial locking pin at the end of the outer protective cover. The modular assembly frame has a guide sliding part on the other side wall, and the guide sliding part is inserted into the axial mounting groove. The rotor winding is fitted onto a modular assembly frame; The rotor shaft passes through the middle of the end cover, and the end cover has multiple locking holes. The axial locking pin is fixed in place by cooperating with the locking holes.

[0009] As a preferred embodiment, the end of the axial locking pin is provided with a threaded hole, and the threaded hole corresponds to the locking hole; It also includes fasteners, which are secured by passing through locking holes and threaded holes in sequence.

[0010] As a preferred embodiment, the cross-section of the guide sliding part is a dovetail structure or a T-shaped structure.

[0011] As a preferred embodiment, an insulating sleeve is provided between the modular assembly frame and the rotor winding.

[0012] As a preferred embodiment, the insulating sleeve is provided with a first positioning rib, which is engaged in the gap between the rotor windings.

[0013] As a preferred embodiment, the axial locking pin is engaged with an end limiting plate at one end near the rotor winding.

[0014] As a preferred embodiment, the modular assembly frame, outer protective cover, axial locking pin, and guide sliding part are integrally formed structures.

[0015] As a preferred embodiment, the end cap is provided with a contoured clamping ring, which contacts the rotor winding.

[0016] As a preferred embodiment, the conformal clamping ring has a second positioning rib at one end near the rotor winding, and the second positioning rib is engaged in the gap between the rotor windings.

[0017] As a preferred embodiment, the side wall of the conformal clamping ring is provided with a guide platform, and the guide platform contacts the side wall of the axial locking pin.

[0018] The beneficial effects of the rotor coil winding frame of the brushless generator disclosed in this utility model are as follows: By setting an independent modular assembly frame, the rotor winding can be completely separated from the bulky main shaft body, and can be independently wound and arranged with high precision on an external fully automated production line. This significantly improves mass production efficiency and rotor slot fill factor, while fundamentally eliminating mechanical scratches on the wire insulation varnish layer and eliminating the risk of interlayer short circuits. At the same time, the sliding engagement of the guide sliding part at the bottom of the frame with the axial mounting groove of the rotor shaft provides rigid support. Combined with the arc-shaped outer protective cover extending from the side wall of the frame covering the outer periphery of the winding, a strong radial physical barrier is formed. Under high speed and high dynamic load conditions of the motor, the rotor winding is firmly restricted, which completely avoids the micro-slippage and whip tip deformation of the winding due to alternating electromagnetic force and centrifugal force, and significantly extends the insulation life. In addition, the frame adopts an axial sliding fit and is fixed by the locking hole on the end cover and the axial locking pin extending from the frame, thus creating a perfect split strip reversible assembly. In the later after-sales maintenance, if a certain magnetic pole winding is partially burned, the end cover can be removed to achieve single non-invasive replacement of the faulty magnetic pole, without having to cut off and scrap the entire winding, reducing maintenance costs by more than 80%. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the assembly structure of the rotor coil winding frame, rotor shaft and end cover of a brushless generator according to this utility model. Figure 2 This is a schematic diagram of the assembly structure of the rotor coil winding frame, rotor shaft, and modular assembly frame of a brushless generator according to this utility model. As shown in the figure, specific structures and devices are marked in the figure to clearly illustrate the structure of the embodiments of this utility model. However, this is only for illustrative purposes and is not intended to limit this utility model to the specific structure, device and environment. According to specific needs, those skilled in the art can adjust or modify these devices and environments, and such adjustments or modifications are still included in the scope of the appended claims. Detailed Implementation

[0020] The present invention will be further described and illustrated below with reference to specific embodiments and the accompanying drawings. It should also be noted that, in order to make the embodiments more detailed, the following embodiments are the best and preferred embodiments, and those skilled in the art can also use other alternative methods to implement some known technologies; moreover, the accompanying drawings are only for more specific description of the embodiments and are not intended to specifically limit the present invention.

[0021] Please refer to Figure 1 and Figure 2A rotor coil winding frame for a brushless generator includes a rotor shaft 10, a modular assembly frame 20, a rotor winding 30, and an end cap 40.

[0022] The rotor shaft 10 has axially spaced mounting slots 11 along its axial direction.

[0023] The modular assembly frame 20 has an arc-shaped outer protective cover 21 extending from one side wall. The outer protective cover 21 has an axial locking pin 22 at one end. The modular assembly frame 20 has a guide sliding part 23 on the other side wall. The guide sliding part 23 is inserted into the axial mounting groove 11.

[0024] The rotor winding 30 is mounted on the modular assembly frame 20.

[0025] The rotor shaft 10 passes through the middle of the end cover 40, and the end cover 40 has multiple locking holes 41. The axial locking pin 22 is fixed in place by cooperating with the locking holes 41.

[0026] By setting up an independent modular assembly frame 20, the rigid rotor winding 30 can be completely separated from the heavy and bulky rotor shaft 10 body, and directly wound with high precision and arranged in all directions on an external fully automated production line or precision tooling. This not only avoids the rough operation of manually pulling the wire in the narrow magnetic pole gap in the traditional process, thus multiplying the production efficiency and rotor slot fill rate, but also fundamentally eliminates the mechanical scratches and wear on the insulating varnish layer of the enameled wire surface during the winding process, eliminating the fatal risk of interlayer short circuits.

[0027] The sliding engagement of the guide sliding part 23 at the bottom of the modular assembly frame 20 with the axial mounting groove 11 of the rotor shaft 10 provides extremely stable radial frame support for the rotor winding 30. Simultaneously, the arc-shaped outer protective cover 21 extending from one end of the modular assembly frame 20 directly covers the outer periphery of the rotor winding 30, forming a strong radial physical barrier. When the motor operates at high speeds, this outer protective cover 21 effectively restrains the rotor winding 30, resisting enormous centrifugal force and alternating electromagnetic stress, completely preventing interlayer micro-slippage, local swelling, and whip tip deformation at the winding ends, thus extending the overall insulation life of the motor.

[0028] The modular assembly frame 20 adopts an axial sliding fit and is rigidly locked by the locking hole 41 on the end cover 40 and the axial locking pin 22 extending from the frame, making the entire rotor pole an independent and detachable rigid unit. In later maintenance, if the winding of a certain pole overheats or burns out, the maintenance personnel only need to remove the end cover 40 to achieve single non-invasive replacement of the faulty pole. There is no need to transport the entire rotor back to the factory, nor is it necessary to cut off and scrap all the other intact windings of the whole machine, reducing the later operation and maintenance and after-sales support costs of the generator by more than 80%.

[0029] Because the locking hole 41 on the end cover 40 directly engages with the axial locking pin 22 on the frame, the axial positioning force of the winding and the frame is reasonably transmitted and dispersed through the end cover 40. This design avoids drilling numerous deep holes on the heavy rotor shaft 10 end face to lock each coil, thus maximizing the continuity of the magnetic circuit and the mechanical strength of the rotor shaft 10, and avoiding the risk of the entire spindle being scrapped due to stripped traditional threads.

[0030] Furthermore, in order to ensure the rigidity and connection reliability of the entire rotor system under high speed and strong vibration conditions, the axial locking pin 22 in this embodiment is provided with a threaded hole 221 at its end, and the position of the threaded hole 221 is precisely axially corresponding to the locking hole 41 on the end cover 40.

[0031] By screwing axial locking pins 22 into the locking holes 41 and threaded holes 221 of the end cap 40 in sequence with fasteners (preferably high-strength bolts in this embodiment), a rigid structure directly locked by fasteners is established.

[0032] The cross-section of the guide sliding part 23 is preferably a dovetail structure or a T-shaped structure. This embodiment uses a T-shaped structure, and the cross-sectional shape of the axial mounting groove 11 on the rotor shaft 10 is correspondingly adapted to a T-shaped groove. Through this interference fit or precision sliding fit mortise and tenon geometric locking, not only can the modular assembly frame 20 be smoothly guided to slide in axially, but a strong physical barrier is also formed in the radial direction, effectively resisting the centrifugal force generated when the rotor rotates at high speed. This achieves excellent limiting and guiding accuracy for the coil module in both the radial and circumferential directions.

[0033] In terms of electrical insulation and structural protection, an insulating sleeve 24 is further fitted between the modular assembly frame 20 and the rotor winding 30 to improve the dielectric strength between the winding and the metal frame. Preferably, the outer surface of the insulating sleeve 24 is provided with an integrally formed first positioning rib 241. After the winding is completed, the first positioning rib 241 can be precisely engaged in the wire gap between the rotor winding 30 (coil turns), thereby forming radial and axial micro-limiting between coil layers and turns, preventing the coil ends from slipping slightly under high electromagnetic stress.

[0034] Furthermore, in order to achieve axial rigid blocking of the rotor winding 30 end, an end limiting plate 25 is engaged with one end of the axial locking pin 22 near the rotor winding 30. This end limiting plate 25 acts as an end retaining wall, which can effectively limit the axial outward swelling and local whip-like deformation of the rotor winding 30.

[0035] To maximize overall mechanical rigidity and simplify the manufacturing and assembly process, the modular assembly frame 20, outer protective cover 21, axial locking pin 22, and guide sliding part 23 adopt an integral molding structure. This highly integrated integral molding design not only eliminates the cumulative tolerances between components but also significantly enhances the mechanical integrity of the frame structure against external impacts.

[0036] Furthermore, to further enhance the rigid constraint and vibration damping protection of the rotor winding 30 end, a conformal clamping ring 42 is provided on the side of the end cover 40 facing inwards from the shaft. When the end cover 40 is rigidly locked to the side wall of the rotor shaft 10, the conformal clamping ring 42 directly abuts against and presses against the end of the rotor winding 30 in the axial direction. To implement more precise limiting of the coil end, a second positioning rib 421 is also provided at the end of the conformal clamping ring 42 near the rotor winding 30. This second positioning rib 421 also engages in the wire spacing between the coils at the end of the rotor winding 30.

[0037] To achieve self-alignment and provide lateral support during assembly, the sidewall of the contoured clamping ring 42 is also provided with a guide platform 422. In the assembled state where the end cap 40 is pushed axially in, the side of the guide platform 422 precisely contacts and adheres tightly to the sidewall of the axial locking pin 22. Through the mutual contact and engagement between the guide platform 422 and the sidewall of the axial locking pin 22, not only can the axial locking pin 22 be effectively guided to precisely align with the locking hole 41, but it also provides additional cantilevered lateral rigid support for the axial locking pin 22 in the circumferential direction. This further locks the entire wire frame module in multi-dimensional space, ensuring long-term stable operation of the brushless generator under ultra-high speed and high-impact conditions.

[0038] In this embodiment, the side wall of the axial locking pin 22 is flattened to make it fit the guide table 422 better.

[0039] This invention provides a rotor coil winding frame for a brushless generator. By setting an independent modular assembly frame, the rotor winding can be completely separated from the bulky main shaft body, and high-precision independent winding and alignment can be performed on an external fully automated production line. This significantly improves mass production efficiency and rotor slot fill factor, while fundamentally eliminating mechanical scratches on the wire insulation varnish layer and removing the risk of interlayer short circuits. Simultaneously, the sliding engagement of the guide sliding part at the bottom of the frame with the axial mounting slot of the rotor shaft provides rigid support. Combined with the arc-shaped outer protective cover extending from the side wall of the frame covering the outer periphery of the winding, a strong radial physical barrier is formed. Under high-speed and high-dynamic-load conditions, this effectively restricts the rotor winding, completely preventing micro-slippage and whip-end deformation of the winding due to alternating electromagnetic forces and centrifugal forces, thus significantly extending the insulation life. In addition, the frame adopts an axial sliding fit and is fixed by the locking hole on the end cover and the axial locking pin extending from the frame, thus creating a perfect split strip reversible assembly. In the later after-sales maintenance, if a certain magnetic pole winding is partially burned, the end cover can be removed to achieve single non-invasive replacement of the faulty magnetic pole, without having to cut off and scrap the entire winding, reducing maintenance costs by more than 80%.

[0040] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit the scope of protection of this utility model. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this utility model without departing from the essence and scope of the technical solutions of this utility model.

Claims

1. A rotor coil bobbin for a brushless electric generator, characterized by Includes a rotor shaft, wherein the rotor shaft has axially spaced mounting slots arranged at equal intervals along the axial direction; A modular assembly frame, wherein one end of the modular assembly frame has an arc-shaped outer protective cover extending from its side wall, the end of the outer protective cover has an axial locking pin, and the other end of the modular assembly frame has a guide sliding part that is inserted into an axial mounting groove; Rotor winding, which is sleeved on a modular assembly frame; The end cover has a rotor shaft passing through its center. The end cover has multiple locking holes, and the axial locking pin is fixed in place by engaging with the locking holes.

2. The rotor coil winding frame of a brushless generator as described in claim 1, characterized in that, The end of the axial locking pin is provided with a threaded hole, and the threaded hole corresponds to the locking hole; It also includes fasteners, which are secured by passing through locking holes and threaded holes in sequence.

3. The rotor coil winding frame of a brushless generator as described in claim 2, characterized in that, The cross-section of the guide sliding part is a dovetail structure or a T-shaped structure.

4. The rotor coil winding frame of a brushless generator as described in claim 3, characterized in that, An insulating sleeve is fitted between the modular assembly frame and the rotor winding.

5. The rotor coil winding frame of a brushless generator as described in claim 4, characterized in that, The insulating sleeve is provided with a first positioning rib, which is engaged in the gap between the rotor windings.

6. The rotor coil winding frame of a brushless generator as described in claim 5, characterized in that, The axial locking pin is engaged with an end limiting plate near one end of the rotor winding.

7. The rotor coil winding frame of a brushless generator as described in claim 6, characterized in that, The modular assembly frame, outer protective cover, axial locking pin, and guide sliding part are integrally formed structures.

8. The rotor coil winding frame of a brushless generator as described in claim 7, characterized in that, The end cap is provided with a contoured clamping ring, which contacts the rotor winding.

9. The rotor coil winding frame of a brushless generator as described in claim 8, characterized in that, The conformal clamping ring has a second positioning rib at one end near the rotor winding, and the second positioning rib is engaged in the gap between the rotor windings.

10. The rotor coil winding frame of a brushless generator as described in claim 9, characterized in that, The side wall of the contoured clamping ring is provided with a guide platform, and the guide platform contacts the side wall of the axial locking pin.

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