Magnetic attraction type fixed equalizing cap for pumped storage generator

Abstract

The application provides a magnetic suction type fixed voltage-sharing cap for a pumped storage generator, comprising a voltage-sharing cap body, a magnetic suction assembly and a magnetic conductive sleeve ring; the voltage-sharing cap body is a hollow cap body structure with an opening facing downward, and a cap body cavity for accommodating a outgoing line end of the generator is arranged inside the voltage-sharing cap body; the cap body cavity is a flat channel structure matched with the outgoing line end; the magnetic suction assembly is arranged on opposite surfaces of the inner wall of the cap body cavity and is arranged in a length direction of the inner wall of the cap body cavity at intervals, and is used for generating an adsorption magnetic field; the magnetic conductive sleeve ring is a ferromagnetic sleeve piece structure matched with the outgoing line end and is sleeved outside the outgoing line end; the magnetic conductive sleeve ring can realize the connection and fixation of the outgoing line end and the voltage-sharing cap body through magnetic adsorption with the magnetic suction assembly. The application has a compact structure and can quickly realize the connection and fixation of the outgoing line end through magnetic adsorption.

Description

Technical Field

[0001] This application relates to the field of equalizing accessories for generator testing, and in particular to a magnetically attached fixed equalizing cap for pumped storage generators. Background Technology

[0002] In power systems, pumped-storage generators are crucial devices for regulating peak and valley loads on the power grid. Their long-term operational safety and stability directly impact the grid's frequency regulation, peak shaving, and emergency backup capabilities. To ensure the insulation performance of pumped-storage generators meets operational requirements, the industry standard DL / T 492-2009, "Guideline for Aging Assessment of Epoxy Mica Stator Winding Insulation of Generators," clearly specifies the testing items for partial discharge in the windings. Particularly at the generator stator output terminals, effective shielding and voltage equalization treatment is necessary to obtain accurate test data. Therefore, installing a reasonably structured and stably fitting voltage equalization cap at the generator output terminals is one of the key auxiliary means to ensure the reliability of test results.

[0003] The equalizing caps used in existing technologies are mostly sleeve structures made of rigid insulating materials, and their installation mainly relies on mechanical means such as manual fitting, snap-fit ​​positioning, or elastic clamping. Although these structures can achieve basic fixation in some motor equipment, in scenarios where the output terminal of a pumped storage generator is in the form of a flat copper busbar, the installation space is narrow, and the electric field environment is complex, existing equalizing caps are prone to problems such as loose fitting, positional misalignment, and unstable contact, resulting in poor voltage equalization effect and thus affecting the accuracy of partial discharge testing.

[0004] The key problem with existing equalizing cap structures lies in the lack of a fastening method that can quickly and securely achieve adhesion while adapting to the shape of flat cable outlets. Traditional mechanical snap-fit ​​methods are not only cumbersome to operate, but also prone to loosening during testing due to vibration or electromagnetic interference. On the other hand, using clamping or threaded structures makes it difficult to achieve universality and rapid assembly for different cable outlet specifications. Therefore, there is an urgent need for an equalizing cap structure that is simple in structure, reliable in fixation, highly adaptable, and capable of interference-free adhesion and fixation using magnetic force. Utility Model Content

[0005] This application provides a magnetically attached equalizing cap for pumped storage generators to solve the problem that existing equalizing caps are not convenient for reliably fixing flat outgoing terminals.

[0006] This application provides a magnetically attached fixed equalizing cap for a pumped storage generator, including an equalizing cap body, a magnetic component and a magnetic collar; The equalizing cap body is a hollow cap structure with the opening facing downwards, and the inside is a cap cavity for accommodating the output end of the generator. The cap cavity is a flat channel structure that matches the output end. The magnetic attraction components are disposed on opposite surfaces of the inner wall of the cap cavity and are arranged at intervals along the length of the inner wall of the cap cavity to generate an adsorption magnetic field. The magnetic collar is a ferromagnetic sleeve structure that fits snugly against the outlet end and is sleeved on the outside of the outlet end. The magnetic collar can connect and fix the outlet end to the equalizing cap body through magnetic adsorption with the magnetic attraction component.

[0007] In one optional embodiment, the magnetic attraction component includes a plurality of neodymium iron boron permanent magnets, which are respectively embedded on two wide surfaces of the inner wall of the cap cavity and are distributed in a relative manner.

[0008] In one alternative embodiment, the surface of the neodymium iron boron permanent magnet is coated with an insulating protective coating having a thickness of 50 μm to 200 μm.

[0009] In one optional embodiment, the magnetic guide ring is a U-shaped steel sheet structure, which is fitted and installed on the two wide surfaces and one narrow surface of the outlet end, and fixed to the outlet end by means of buckle or bolt connection; the magnetic guide ring is made of low carbon steel, silicon steel sheet or 430 type stainless steel.

[0010] In one optional embodiment, the bottom end of the equalizing cap body is provided with a fixing cavity through which the insulating sheath connected to the outlet end can pass. The fixing cavity is a cylindrical structure. The opening at the bottom end of the equalizing cap body is circular and located at the bottom end of the fixing cavity. The edge of the opening at the bottom end of the equalizing cap body is uniformly provided with a limiting protrusion in the circumferential direction.

[0011] In one optional embodiment, the equalizing cap body adopts a double-layer structure, the equalizing cap body includes an outer aluminum shell and an insulating inner shell bonded and fixed to the inner wall of the aluminum shell, the insulating inner shell being provided with a cap cavity.

[0012] In one optional embodiment, the outer wall surface of the aluminum housing is provided with a plurality of protruding ribs extending along the length direction, and the plurality of protruding ribs are evenly spaced on the outer wall surface of the aluminum housing.

[0013] In one optional embodiment, an insulating pad is provided between the magnetic collar and the output end to isolate the copper busbar surface of the output end from the magnetic collar.

[0014] In one optional embodiment, the magnetic attraction component is fixed to the equalizing cap body by structural adhesive, which is an epoxy resin-based insulating adhesive.

[0015] Compared with the prior art, this application has the following beneficial effects: 1. This application provides a magnetically attached equalizing cap for a pumped storage generator. In terms of structural design, this application introduces an equalizing cap body with a hollow cap body structure with an opening facing downwards. The equalizing cap body has an opening at the bottom and an internal structure of a cap body cavity. The cap body cavity has a flat channel structure as a whole, and its shape matches the wide and flat copper busbar on the generator's output terminal, reducing loosening and displacement caused by structural mismatch, thereby enhancing the fit and fixing stability during installation.

[0016] 2. This application provides magnetic suction components on opposite surfaces of the inner wall of the cap cavity, arranged at intervals along the length of the inner wall. After the equalizing cap body is installed, the magnetic suction components can form an adsorption magnetic field in the central region of the cavity, thus providing continuous adsorption force without using traditional mechanical structures. Simultaneously, a magnetically conductive collar is fitted around the cable outlet. This collar can establish an effective magnetic coupling with the magnetic suction components, achieving connection and fixation between the cable outlet and the equalizing cap body through magnetic attraction. In this way, the equalizing cap body eliminates the need for bolts, clips, or other external components, relying solely on magnetic attraction to securely cover the cable outlet, reducing dependence on installation space and making the overall structure more suitable for compact wiring environments.

[0017] 3. The application of magnetic fixing in this application fundamentally changes the installation method of the equalizing cap, eliminating the need for clamps or adjustment tools and enabling rapid positioning and stable adsorption of the flat copper busbar. When the magnetic components and the magnetic collar interact magnetically, the equalizing cap body adheres securely to the surface of the copper busbar at the output end, preventing displacement or detachment due to vibration during operation and reducing the impact of external interference. This not only improves the structural reliability of the electrical interface area but also reduces local electric field disturbances, providing a more stable equalizing environment for discharge testing. It offers advantages in terms of ease of installation, electrical safety, and environmental adaptability. Attached Figure Description

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

[0019] Figure 1 A schematic diagram of the overall structure of a magnetically attached equalizing cap for a pumped storage generator provided in an embodiment of this application; Figure 2 This is a schematic diagram showing the equalizing cap body and the output terminal not connected according to an embodiment of this application; Figure 3A schematic diagram of the installation of a magnetically conductive collar on the output end according to an embodiment of this application; Figure 4 This is a schematic diagram of the structure of the equalizing cap body provided in an embodiment of this application.

[0020] Explanation of reference numerals in the attached figures: 100-Equalizing cap body; 101-Aluminum shell; 1011-Raised rib; 102-Insulating inner shell; 110-Cap cavity; 120-Fixing cavity; 200-Magnetic attraction assembly; 210-NdFeB permanent magnet; 300-Magnetic guide ring; 400-Outlet end; 500-Limiting flange. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions in the embodiments of this application are described clearly and completely below. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are also within the scope of protection of this application.

[0022] In the description of this application, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0023] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0024] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly, for example, they can refer to a fixed connection, a detachable connection, or an integral connection. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0025] First, let me explain the terms used in this application: Pumped-storage generator: This refers to the power generation equipment used in pumped-storage power stations. This equipment pumps water to a high-level reservoir for energy storage during periods of low electricity demand, and then releases water to drive a turbine to generate electricity during peak demand periods. Its operating state changes frequently, its structure is subject to complex stresses, and its electrical connections require excellent insulation and stability.

[0026] Outgoing terminal: refers to the interface in a pumped storage generator where the three-phase current is led out to the external busbar or cable. It is usually composed of multiple copper busbars and is covered with an insulating sheath. It is an important node connecting the generator to the transformer or power grid.

[0027] Equalizing cap: A protective component used in this industry to cover and secure the generator output terminals. Its functions include electrical isolation, dust and moisture protection, and reducing local electric field gradients. The structure, materials, and installation method of the equalizing cap have a significant impact on the safe operation of the generator.

[0028] Neodymium iron boron (NdFeB) permanent magnets are currently the most widely used strong magnetic materials, possessing high energy product and high coercivity. They are widely used in motors, sensors, and magnetic attraction devices. When used in high humidity or high temperature environments, surface protection treatment is required.

[0029] Epoxy insulating material: a cured resin material widely used in power equipment, possessing excellent insulation, heat resistance, and adhesion. In this application, it can be used to manufacture the inner shell of an equalizing cap and to bond magnets.

[0030] Please see Figures 1-4 , Figure 1 A schematic diagram of the overall structure of a magnetically attached equalizing cap for a pumped storage generator provided in an embodiment of this application; Figure 2 This is a schematic diagram showing the equalizing cap body and the output terminal not connected according to an embodiment of this application; Figure 3 A schematic diagram of the installation of a magnetically conductive collar on the output end according to an embodiment of this application; Figure 4 This is a schematic diagram of the structure of an equalizing cap body provided in an embodiment of this application. Figures 1-4As shown in the figure, this application provides a magnetically attached equalizing cap for a pumped-storage generator, including an equalizing cap body 100, a magnetically attached assembly 200, and a magnetically conductive collar 300. The equalizing cap body 100 is a hollow cap structure with its opening facing downwards. Inside, there is a cap cavity 110 for accommodating the generator's output terminal 400. The cap cavity 110 is a flat channel structure that matches the output terminal 400. The magnetically attached assembly 200 is disposed on opposite surfaces of the inner wall of the cap cavity 110 and is spaced apart along the length of the inner wall of the cap cavity 110 to generate an adsorption magnetic field. The magnetically conductive collar 300 is a ferromagnetic sleeve structure that fits snugly against the output terminal 400 and is sleeved on the outside of the output terminal 400. The magnetically conductive collar 300 can connect and fix the output terminal 400 to the equalizing cap body 100 through magnetic adsorption with the magnetically attached assembly 200.

[0031] To address the issue of securing the equalizing cap firmly on the flat output terminal of a pumped storage generator, this embodiment introduces an equalizing cap body 100 with a downward-facing hollow cap structure. The equalizing cap body 100 has an opening at the bottom and an internal structure of a cap cavity 110. The cap cavity 110 has a flat channel structure, and its shape matches the wide and flat copper busbar on the generator's output terminal 400. This reduces loosening and misalignment caused by structural mismatch, thereby enhancing the fit and stability during installation.

[0032] Based on this, in this embodiment, magnetic attraction components 200 are provided on opposite surfaces of the inner wall of the cap cavity 110, and these magnetic attraction components 200 are spaced apart along the length of the inner wall of the cap cavity 110. After the equalizing cap body 100 is installed in place, the magnetic attraction components 200 can form an adsorption magnetic field in the central region of the cavity, thereby providing a continuous adsorption force without using traditional mechanical structures. At the same time, a magnetically conductive collar 300 is sleeved on the outside of the cable outlet 400. This magnetically conductive collar can establish an effective magnetic coupling relationship with the magnetic attraction components, and the connection and fixation between the cable outlet 400 and the equalizing cap body 100 are achieved through magnetic attraction with the magnetic attraction components 200. In this way, the equalizing cap body 100 does not require external parts such as bolts and clips, and can be firmly covered on the cable outlet 400 by magnetic attraction alone, reducing the dependence on installation space and making the overall structure more suitable for compact wiring environments.

[0033] Furthermore, in this embodiment, the application of magnetic fixing fundamentally changes the installation method of the equalizing cap. It eliminates the need for clamps or adjustment tools, enabling rapid positioning and stable adsorption of the flat copper busbar. When the magnetic assembly 200 and the magnetic collar 300 interact magnetically, the equalizing cap body 100 adheres securely to the surface of the copper busbar at the output end, reducing the likelihood of displacement or detachment due to vibration during operation and minimizing the impact of external interference. This not only improves the structural reliability of the electrical interface area but also reduces local electric field disturbances, providing a more stable equalizing environment for discharge testing. It offers advantages in terms of ease of installation, electrical safety, and environmental adaptability.

[0034] In some embodiments, the magnetic attraction component 200 includes a plurality of neodymium iron boron permanent magnets 210, which are respectively embedded on two wide surfaces of the inner wall of the cap cavity 110 and are distributed in a relative manner.

[0035] In the above embodiment, a magnetic attraction assembly 200 composed of multiple neodymium iron boron permanent magnets 210 is used, and these magnets are respectively embedded on two relatively wide surfaces of the inner wall of the cap cavity 110. This distribution method has significant advantages in terms of magnetic field control and the stability of the adsorption structure. The neodymium iron boron permanent magnets 210 are characterized by small size and strong magnetism, and can provide a large adsorption force in a small space, which is beneficial to improving the connection and fixation effect between the equalizing cap body and the output end 400.

[0036] Magnets are positioned on both sides of the inner wall of the cap cavity 110, with their magnetic force directed directly towards the magnetically conductive collar 300 on the surface of the wire outlet 400. This allows for effective magnetic flux introduction and the formation of a relatively concentrated closed path, enhancing the connectivity and adsorption performance of the magnetic structure. The relative arrangement of magnets allows for simultaneous adsorption forces on both sides of the cap, reducing the risk of tilting or displacement due to unilateral force. Furthermore, the magnets are spaced apart along the length of the cap, resulting in a more even distribution of the adsorption force throughout the cavity, structurally reducing the possibility of loosening or detachment in localized areas due to weak magnetic force.

[0037] This structural optimization not only enhances the adsorption stability of the magnetic component 200 under actual working conditions, but also improves the ability of the equalizing cap to retain the output end during the test, making the overall adhesion state more reliable.

[0038] In some embodiments, the surface of the neodymium iron boron permanent magnet 210 is coated with an insulating protective coating, the thickness of which is 50 μm to 200 μm.

[0039] Based on the above embodiments, this embodiment further adds an insulating protective coating to the neodymium iron boron permanent magnet 210, with its thickness ranging from 50μm to 200μm. This design aims to enhance the stability and service life of the magnet in complex operating environments. As a high-performance magnetic material, the neodymium iron boron permanent magnet 210 exhibits excellent magnetic properties, but it is inherently sensitive to environmental factors, especially in the output terminal area where the electric field is significant and humidity fluctuations are large. If the magnet surface is directly exposed, oxidation or corrosion can easily occur, affecting magnetic output and structural integrity. After coating the surface of the neodymium iron boron permanent magnet 210 with an insulating protective coating, the magnet surface can be effectively sealed, making it difficult for external moisture and corrosive components to contact the magnetic core, thereby slowing down the material aging rate. Furthermore, this coating also provides a certain degree of electrical insulation, helping to reduce the risk of stray current interference caused by the potential difference between the magnet and adjacent metal structures. The insulating protective coating thickness is controlled between 50μm and 200μm, providing basic protection without significantly weakening the magnetic field, which is beneficial for maintaining the adsorption capacity of the magnetic component 200.

[0040] In some embodiments, the magnetic collar 300 is a U-shaped steel sheet structure, which is fitted and installed on the two wide surfaces and one narrow surface of the outlet end 400, and is fixed to the outlet end 400 by means of buckle or bolt connection; the magnetic collar 300 is made of low carbon steel, silicon steel sheet or 430 type stainless steel.

[0041] In this embodiment, the structural form, installation method, and material selection of the magnetic guide ring 300 are specified in more detail. The magnetic guide ring 300 adopts a U-shaped steel sheet structure, which can simultaneously cover the two wide surfaces and one narrow surface of the output end 400, forming a three-dimensional, tightly fitted shape. This layout helps to expand the magnetic flux coverage area, forming a more sufficient magnetic field coupling when the magnetic attraction component 200 is working, reducing adsorption deviation caused by insufficient local magnetic flux. Furthermore, the U-shaped steel sheet structure of the magnetic guide ring 300 itself also has a certain limiting function, which can suppress ring swaying in the lateral direction, thereby maintaining a stable fit under operating or vibration conditions. For installation, the magnetic guide ring 300 can be securely attached to the surface of the output end 400 through a snap-fit ​​structure or bolt connection, facilitating quick installation and positioning, and preventing misalignment due to assembly interference or external force. In terms of materials, low-carbon steel, silicon steel sheets, and 430 stainless steel all possess excellent magnetic permeability, effectively constructing magnetic flux channels while also offering ease of processing and durability, making them suitable for the specific application requirements of different types of copper busbars. Through the combined design of the above-mentioned structure and materials, this embodiment achieves a more balanced performance in terms of magnetic attraction, structural stability, and environmental adaptability of the magnetically conductive collar 300, providing crucial support for the stable adsorption of the equalizing cap body.

[0042] In some embodiments, the bottom end of the equalizing cap body 100 is provided with a fixing cavity 120 through which the insulating sheath connected to the outlet terminal 400 can pass. The fixing cavity 120 is a cylindrical structure. The opening at the bottom end of the equalizing cap body 100 is circular and located at the bottom end of the fixing cavity 120. The edge of the opening at the bottom end of the equalizing cap body 100 is uniformly provided with a limiting protrusion 500 in a circumferential direction.

[0043] Based on the original structure, this embodiment introduces a fixing cavity 120 and a limiting flange 500 to further optimize the positioning method between the equalizing cap body 100 and the outlet end 400. The fixing cavity 120 is located at the bottom end of the equalizing cap body 100 and has a cylindrical structure. Its internal space provides a pressing channel for the insulating sheath provided on the outlet end 400. Through this structural design, the equalizing cap can be smoothly pressed down from the outside of the sheath to the outlet end position, achieving stable installation without interfering with the original insulation layer. Moreover, the cylindrical structure itself facilitates the centered positioning of the insulating sheath, which helps to improve the alignment effect and smoothness during installation.

[0044] Furthermore, to prevent slippage during assembly, multiple limiting flanges 500 are evenly distributed circumferentially along the bottom edge of the fixing cavity 120. These limiting flanges 500 form a contact interface with the outer edge of the insulating sleeve after the equalizing cap body 100 is pressed into place, thus structurally providing a stop function. When the equalizing cap is subjected to axial force, the limiting flanges 500 provide abutment support at the boundary position without the need for additional auxiliary structures, reducing the possibility of further sinking of the equalizing cap body 100. This limiting design provides a clearer positioning reference for the equalizing cap body 100 in the installed state and reduces the risk of cap displacement due to vibration or external disturbances during equipment operation. Overall, the combination of the fixing cavity 120 and the limiting flanges 500 enables the equalizing cap to achieve structural limiting function while completing magnetic attachment, thereby improving assembly reliability and structural stability without adding additional fasteners, and providing a more stable physical support foundation for subsequent testing operations.

[0045] In some embodiments, the equalizing cap body 100 adopts a double-layer structure. The equalizing cap body 100 includes an outer aluminum shell 101 and an insulating inner shell 102 bonded and fixed to the inner wall of the aluminum shell 101. The insulating inner shell 102 is provided with a cap cavity 110. Optionally, the insulating inner shell 102 is made of epoxy insulating material.

[0046] In this embodiment, the equalizing cap body 100 adopts a double-layer structure design, consisting of an outer aluminum shell 101 and an inner insulating shell 102. This structure satisfies both mechanical support and electrical isolation requirements. The outer aluminum shell 101 has strong rigidity and impact resistance, enabling it to withstand external mechanical forces during generator operation without easily deforming, thus playing a positive role in maintaining the structural stability of the cap body. The inner insulating shell 102 can be made of epoxy resin, which has good insulation properties and can form an effective electrical isolation barrier within the structure, reducing the risk of electrical interference between the cap body and the output terminal 400.

[0047] Furthermore, the insulating inner shell 102 is fixed to the inner wall of the aluminum shell 101 by adhesive bonding. The insulating inner shell 102 is provided with a cap cavity 110, forming an integrally molded inner cavity layout. In addition, the double-layer structure design facilitates the maintenance and replacement of components in the later stage. The aluminum outer shell provides good protective shell function, while the insulating inner shell undertakes the responsibility of electrical safety. In use, it forms a structural system with clear functional division and complementary performance.

[0048] In some embodiments, the insulating inner shell 102 is made of heat-resistant epoxy resin material, preferably a bisphenol A type epoxy resin system with high insulation and heat resistance. The epoxy resin can be liquid bisphenol A type epoxy resin of type E-51, which is cured at room temperature or with heat in conjunction with aliphatic polyamines or epoxy curing agents. The volume resistivity of this material after curing is higher than 10 Ω·cm. 14 Ω·cm, dielectric strength not less than 20kV / mm, long-term heat resistance rating of B (130℃) or above, suitable for generator output terminal working environment.

[0049] In some embodiments, the outer wall surface of the aluminum housing 101 is provided with a plurality of protruding ribs 1011 extending along the length direction, and the plurality of protruding ribs 1011 are evenly spaced on the outer wall surface of the aluminum housing 101.

[0050] In this embodiment, the outer wall surface of the aluminum shell 101 is provided with a plurality of protruding ribs 1011 extending along the length direction. These protruding ribs 1011 are arranged at uniform intervals. This structural design not only optimizes the appearance of the shell, but also brings positive effects on mechanical performance. The presence of the protruding ribs 1011 as reinforcing ribs significantly improves the axial bending stiffness of the shell, which helps to enhance the structural support capacity of the cap body against external impacts and continuous loads during handling, installation, or operation.

[0051] Based on the relatively lightweight yet rigid nature of aluminum, the addition of ribs effectively suppresses localized deformation caused by stress concentration, thereby reducing the possibility of deformation or damage to the device during use. Simultaneously, the ribs 1011 provide a degree of anti-slip properties, offering operators a convenient contact surface for gripping and applying force, making assembly or disassembly of the equalizing cap body 100 easier and enhancing the convenience and control of construction.

[0052] Furthermore, the raised rib structure also increases the surface area of ​​the shell to a certain extent, allowing for more thorough heat exchange with the surrounding air during generator operation. This helps to reduce heat accumulation on the cap during prolonged adsorption, improving overall heat dissipation performance and extending its service life. This structural optimization not only enhances the product's mechanical strength but also improves the user's operational experience in practical applications, demonstrating high practical value.

[0053] In some embodiments, an insulating pad is provided between the magnetic collar 300 and the output terminal 400 to isolate the copper busbar surface of the output terminal 400 from the magnetic collar 300.

[0054] In this embodiment, an insulating gasket is provided between the magnetic collar 300 and the output terminal 400 to achieve electrical isolation while maintaining structural connection. This structural arrangement avoids direct metal-to-metal contact between the magnetic collar 300 and the copper busbar surface, thereby reducing the possibility of electrical interference. Since the generator output terminal is often in a high-voltage environment during operation, if the magnetic structure is in direct contact with a conductor, it is prone to problems such as discharge, breakdown, or electro-corrosion under conditions such as slight displacement, vibration, or humidity fluctuations. Therefore, using an insulating gasket as a spacer is necessary.

[0055] Insulating gaskets are typically made of high-dielectric-strength, non-conductive materials, which neither affect the effective formation of the magnetic flux path nor hinder the formation of a relatively stable electrical isolation layer. This design creates a barrier between the magnetic structure and the electrical structure, helping to reduce stray current interference and improve electrical stability during long-term operation. Furthermore, this structure effectively suppresses the risk of partial discharge caused by wear or positional deviations, even under conditions of high-frequency testing or repeated assembly and disassembly.

[0056] In subsequent maintenance and repairs, the presence of insulating gaskets can reduce the probability of abnormal electrical contact caused by installation deviations, thereby improving the overall safety level of the equipment to a certain extent. Overall, by introducing a simple but functionally defined dielectric layer at key connection points, this structure not only optimizes safety performance in high-voltage electrical environments but also gives the magnetic fixing structure greater engineering adaptability and operational stability.

[0057] In some embodiments, the magnetic attraction component 200 and the equalizing cap body 100 are bonded together with structural adhesive, which is an epoxy resin-based insulating adhesive. In this embodiment, the magnetic attraction component 200 and the equalizing cap body 100 are connected and fixed with epoxy resin-based insulating adhesive, replacing the traditional mechanical connection method using screws. This bonding method exhibits greater adaptability under compact structural conditions and is particularly suitable for areas with limited space or irregular shapes.

[0058] Furthermore, epoxy resin-based insulating adhesives exhibit excellent electrical properties, achieving electrical insulation while bonding, thus preventing potential current paths between the magnetic component 200 and the aluminum housing 101. This structural arrangement plays a positive role in improving the overall electrical safety of high-voltage equipment, especially in humid environments, environments with frequent temperature changes, or long-term high-voltage testing environments, where it can better suppress the risk of leakage or breakdown.

[0059] Meanwhile, this type of adhesive does not rely on high-temperature heating during curing, thus having minimal impact on the thermal stability of the cap structure, making it suitable for rapid assembly processes in industrial production. Its excellent adhesion maintains the long-term stable positioning of the magnetic assembly 200, helping to maintain the relative positional accuracy between internal components of the equalizing cap body 100 and reducing performance fluctuations caused by assembly errors. Overall, this non-mechanical bonding method, while ensuring electrical isolation, safety, and structural stability, also optimizes manufacturing efficiency and product consistency, making it suitable for widespread application in the manufacturing of compact electrical accessories.

[0060] The following describes the usage process of the magnetically attached equalizing cap for a pumped storage generator provided in the embodiments of this application: The magnetically attached equalizing cap of this embodiment is mainly used for fixing and protecting the output terminal of a pumped-storage generator. Before installation, the surface of the output terminal 400 must be cleaned to remove dust, oil stains, and impurities to facilitate the tight adhesion of all components. After cleaning, the magnetically conductive collar 300 is installed on the outside of the output terminal 400. This collar has a U-shaped structure and can cover the two wide sides and one narrow side of the output terminal. Depending on the specific structural characteristics of the output copper busbar, a snap-fit ​​connection or bolt fastening method can be used for secure installation. During installation, an insulating gasket can be placed between the magnetically conductive collar 300 and the copper busbar to structurally create an electrical isolation barrier and reduce the possibility of electrical faults such as short circuits.

[0061] After the magnetic collar 300 is installed, the equalizing cap body 100, pre-installed with the magnetic attraction component 200, is vertically fitted from above the outlet end 400. The cap body cavity 110 can surround and cover the external structure of the outlet end. Multiple neodymium iron boron permanent magnets 210 are spaced along the length of both sides of its inner wall. As the neodymium iron boron permanent magnets 210 approach the magnetic collar 300, a stable magnetic coupling is formed between them, causing the cap body to automatically align and adhere to the outside of the outlet end. The entire process does not require traditional threaded or welded structures, facilitating rapid on-site assembly and reducing structural errors caused by complex connection methods.

[0062] As the cap is gradually fitted in, the fixing cavity 120 at the bottom provides a guiding space for the insulating sleeve. This fixing cavity has a cylindrical structure, which, together with the limiting protrusion 500 located at the bottom edge, forms a stop structure evenly distributed along the circumference, thereby enhancing the structural stability after assembly.

[0063] The entire cap is composed of an outer aluminum shell 101 and an inner insulating shell 102. The aluminum shell 101 has high mechanical strength and impact resistance, while the insulating shell 102 provides the necessary electrical insulation barrier. In addition, the outer surface of the aluminum shell 101 is provided with multiple axially extending ribs 1011, which not only enhances the overall rigidity of the shell, but also improves the grip stability during manual installation.

[0064] During generator testing, the equalizing cap remains on the outside of the outgoing terminal 400, providing structural protection. When equipment maintenance or component replacement is required, the equalizing cap can be quickly removed by pulling it out axially along the outgoing terminal 400. The entire disassembly and assembly process requires no special tools and will not cause physical damage to the copper busbars or insulating sheaths, making it suitable for repeated use and convenient on-site operation.

[0065] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A magnetically attached fixed equalizing cap for a pumped-storage generator, characterized in that, It includes the equalizing cap body (100), the magnetic attraction assembly (200), and the magnetic collar (300). The equalizing cap body (100) is a hollow cap structure with the opening facing downwards, and the inside is provided with a cap cavity (110) for accommodating the generator output terminal (400). The cap cavity (110) is a flat channel structure that matches the output terminal (400). The magnetic attraction components (200) are disposed on opposite surfaces of the inner wall of the cap cavity (110) and are arranged at intervals along the length of the inner wall of the cap cavity (110) to generate an adsorption magnetic field. The magnetic collar (300) is a ferromagnetic sleeve structure that fits into the outlet end (400) and is sleeved on the outside of the outlet end (400). The magnetic collar (300) can connect and fix the outlet end (400) and the equalizing cap body (100) through magnetic adsorption with the magnetic adsorption component (200).

2. The magnetically attached equalizing cap for a pumped-storage generator according to claim 1, characterized in that, The magnetic attraction component (200) includes multiple neodymium iron boron permanent magnets (210), which are respectively embedded on two wide surfaces of the inner wall of the cap cavity (110) and distributed in a relative manner.

3. The magnetically attached fixed equalizing cap for a pumped-storage generator according to claim 2, characterized in that, The surface of the neodymium iron boron permanent magnet (210) is coated with an insulating protective coating, the thickness of which is 50 μm to 200 μm.

4. The magnetically attached equalizing cap for a pumped-storage generator according to claim 1, characterized in that, The magnetic collar (300) is a U-shaped steel sheet structure, which is fitted and installed on the two wide surfaces and one narrow surface of the outlet end (400), and is fixed on the outlet end (400) by means of buckle or bolt connection; the magnetic collar (300) is made of low carbon steel, silicon steel sheet or 430 type stainless steel.

5. The magnetically attached equalizing cap for a pumped-storage generator according to any one of claims 1-4, characterized in that, The bottom end of the equalizing cap body (100) is provided with a fixed cavity (120) through which the insulating sheath connected to the outlet end (400) can pass. The fixed cavity (120) is a cylindrical structure. The opening at the bottom end of the equalizing cap body (100) is circular and located at the bottom end of the fixed cavity (120). The edge of the opening at the bottom end of the equalizing cap body (100) is uniformly provided with a limiting protrusion (500) in a circumferential direction.

6. The magnetically attached equalizing cap for a pumped-storage generator according to claim 1, characterized in that, The equalizing cap body (100) adopts a double-layer structure. The equalizing cap body (100) includes an outer aluminum shell (101) and an insulating inner shell (102) bonded and fixed to the inner wall of the aluminum shell (101). The insulating inner shell (102) is provided with a cap cavity (110).

7. The magnetically attached fixed equalizing cap for a pumped-storage generator according to claim 6, characterized in that, The outer wall surface of the aluminum shell (101) is provided with a plurality of protruding ribs (1011) extending along the length direction, and the plurality of protruding ribs (1011) are evenly spaced on the outer wall surface of the aluminum shell (101).

8. The magnetically attached equalizing cap for a pumped-storage generator according to claim 1, characterized in that, An insulating pad is provided between the magnetic collar (300) and the output end (400) to isolate the copper busbar surface of the output end (400) from the magnetic collar (300).

9. The magnetically attached equalizing cap for a pumped-storage generator according to claim 1, characterized in that, The magnetic attraction component (200) and the equalizing cap body (100) are bonded and fixed together by structural adhesive, which is an epoxy resin-based insulating adhesive.

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