Winding structure of high-reliability automobile generator

Abstract

The utility model belongs to the technical field of automobile generator armature winding, and disclose a winding structure of high reliability automobile generator, through the cooperation of assembly realizes stable and efficient power generation, simultaneously resists the influence of vehicle vibration, core revolves around electromagnetic induction power generation, structural stability guarantee and insulation protection, it adopts three -phase twenty -four slot four -pole coil winding scheme, coil inserts the coil slot of stator iron core according to specific pitch, can weaken the harmonic, ensure that the electromotive force waveform is stable. Stator iron core is fixed by silicon steel sheet unit piece through cross -hole nail stacking, outer ring positioning groove and shell convex strip inlay, form the symmetrical stress point, guarantee structural stability, the agglomeration of coil slot polyimide insulating film piece realizes physical isolation, front and rear sealing piece press together film piece end and block the coil and the core contact, first, second thickening ring reinforced support. The material and process of each assembly adapt to the complex working condition of automobile, offset the vibration load in cooperation, block the wear path, ensure long -term high reliable operation.

Description

Technical Field

[0001] This utility model relates to the field of armature winding technology for automotive generators, specifically the winding structure of a high-reliability automotive generator. Background Technology

[0002] In the modern automotive industry, the generator, as a core power supply component, plays a crucial role in powering the vehicle's electrical systems and charging the battery. Its operational reliability directly affects the vehicle's driving safety and user experience. With the continuous improvement of vehicle electrification and intelligence, the number of onboard electrical devices is constantly increasing, placing more stringent requirements on the generator's output power, stability, and durability. Currently, most automotive generators employ a three-phase AC power generation structure, and the stability of its core component, the armature winding, is crucial for ensuring power generation efficiency. However, when a car travels under complex road conditions, it inevitably generates continuous vibrations, which are transmitted to the generator through the vehicle body. This can easily lead to winding displacement, and in some cases, the stator core may cut into the coils, causing wear on the conductive core insulation. Utility Model Content

[0003] To address the shortcomings of existing technologies, this utility model provides a winding structure for a highly reliable automotive generator, thereby solving the problems mentioned in the background art, such as frequent vibration of automotive generators leading to loose windings and wear of the core wire insulation layer.

[0004] To achieve the aforementioned objectives, this utility model provides the following technical solution: a winding structure for a high-reliability automotive generator, comprising a three-phase, twenty-four-slot, four-pole coil, characterized in that it further comprises: The stator core has twenty-four sets of coil slots inside; Front and rear seals are disposed on both sides of the stator core and are coaxial with the stator core. A positioning structure is disposed on the outer circumferential surface of the stator core.

[0005] The stator core is composed of multiple stacked unit sheets, and the unit sheets are 50W350 silicon steel sheets.

[0006] Preferably, the unit piece has six sets of through-holes, which are symmetrically distributed in a circle.

[0007] Preferably, a through-pin is provided in the through-pin rivet hole, and multiple sets of unit pieces are fixedly stacked by the through-pin.

[0008] Preferably, the front and rear seals include a front seal and a rear seal, which are fixed to both sides of the stator core by adhesive.

[0009] Preferably, the front sealing sheet is provided with a first thickening ring.

[0010] Preferably, the rear sealing plate is provided with a second thickening ring, and the side of the second thickening ring opposite to the stator core is provided with multiple sets of mating protrusions.

[0011] Preferably, the positioning structure includes six sets of positioning slots, which are parallel to the centerline of the stator core.

[0012] Preferably, the six sets of positioning grooves are symmetrically distributed in a circle, and the positioning grooves are staggered with the through-hole rivet holes.

[0013] Preferably, an insulating film is provided in the coil groove. The insulating film is made of polyimide, and the front and rear sealing sheets are pressed onto the ends of the insulating film.

[0014] Compared with the prior art, this utility model provides a winding structure for a highly reliable automotive generator, which has the following advantages: The winding structure of this high-reliability automotive generator features a three-phase, twenty-four-slot, four-pole coil, stator core, front and rear seals, and positioning structure. The entire armature winding is based on a three-phase, four-pole winding with twenty-four slots. The coil pitch is 5, the pole pitch is 6, and the short pitch is 1, which can reduce the 5th and 7th harmonics and ensure a stable electromotive force waveform. The stator core is positioned to ensure a stable connection with the outer casing, preventing loosening and ensuring high reliability. The front and rear seals prevent direct contact between the coil and the stator core, avoiding wear and tear on the core wires. Furthermore, the front and rear seals press down on the insulating film inside the coil slots, resulting in a stable overall structure and high reliability. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a schematic diagram of the unit sheet structure of this utility model; Figure 3 This is a schematic diagram of the stator core structure of this utility model; Figure 4 This is a schematic diagram of the front sealing sheet structure of this utility model; Figure 5 This is a schematic diagram of the stator core and rear sealing lamination structure of this utility model; Figure 6 This is a schematic diagram of the insulating film structure of this utility model.

[0016] In the diagram: 1. Stator core; 2. Coil slot; 3. Unit piece; 4. Through-core rivet hole; 5. Through-core rivet; 6. Front sealing piece; 7. First thickening ring; 8. Rear sealing piece; 9. Second thickening ring; 10. Butt joint protrusion; 11. Positioning groove; 12. Insulating film. Detailed Implementation

[0017] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0018] Please see Figure 1-6 The present invention provides the following technical solution: The winding structure of a high-reliability automotive generator includes a three-phase, twenty-four-slot, four-pole coil, and also includes: The stator core 1 has twenty-four sets of coil slots 2 inside it; the coils are wound using a standard method with a coil pitch of 5, a pole pitch of 6, and a short pitch of 1.

[0019] Front and rear seals are provided on both sides of the stator core 1 and are coaxial with the stator core 1. The positioning structure is located on the outer circumferential surface of the stator core 1.

[0020] Furthermore, the stator core 1 is composed of multiple stacked unit plates 3, and the unit plate 3 is a 50W350 silicon steel sheet.

[0021] Furthermore, the unit piece 3 has six sets of through-hole rivet holes 4, which are symmetrically distributed in a circle.

[0022] Furthermore, a through-pin 5 is provided inside the through-pin rivet hole 4, and multiple sets of unit pieces 3 are fixedly stacked by the through-pin 5.

[0023] Furthermore, the front and rear seals include a front seal 6 and a rear seal 8, which are fixed to both sides of the stator core 1 by adhesive.

[0024] Furthermore, a first thickening ring 7 is provided on the front cover 6. The first thickening ring 7 and the second thickening ring 9 are additively bonded to provide a boundary.

[0025] Furthermore, a second thickening ring 9 is provided on the rear cover plate 8, and multiple sets of mating protrusions 10 are provided on the side of the second thickening ring 9 opposite to the stator core 1. The mating protrusions 10 facilitate mating with the outer shell.

[0026] Furthermore, the positioning structure includes six sets of positioning grooves 11, which are parallel to the axis of the stator core 1. The inner wall of the outer casing is also provided with protrusions corresponding to the positioning grooves 11, which engage with the positioning grooves 11 to effectively prevent the stator core 1 from becoming loose.

[0027] Furthermore, the six sets of positioning grooves 11 are symmetrically distributed in a circle, and the positioning grooves 11 and the through-bolt rivet holes 4 are arranged alternately. The positioning grooves 11 and the through-bolt rivet holes 4 form twelve sets of symmetrically distributed force points in a circle, resulting in excellent mechanical properties.

[0028] Furthermore, an insulating diaphragm 12 is provided inside the coil slot 2. The insulating diaphragm 12 is made of polyimide, and the front sealing sheet 6 and the rear sealing sheet 8 are pressed onto the end of the insulating diaphragm 12. It is recommended to process the insulating diaphragm 12 first and then assemble the front sealing sheet 6 and the rear sealing sheet 8, so that the front sealing sheet 6 and the rear sealing sheet 8 can naturally press the insulating diaphragm 12 together.

[0029] Structural Description: Stator core 1: The core structure is composed of multiple stacked unit pieces 3, with coil slots 2 inside and positioning slots 11 outside, providing a mounting base and magnetic circuit channel for the windings; Coil slot 2: Twenty-four slots are opened in the stator core 1 to embed the coil and accommodate the insulating diaphragm 12, providing positioning space for the coil; Unit 3: A sheet structure made of 50W350 silicon steel sheet with through-pin rivet holes 4. Multiple sets are stacked to form stator core 1 to reduce eddy current loss. Through-pin rivet holes 4: Six sets of holes symmetrically distributed around the circumference of the unit piece 3, through which through-pins 5 pass to achieve stacking and fixing of unit pieces 3; Through-core 5: A connector inserted into the through-core rivet hole 4 to fasten and stack multiple sets of unit pieces 3 to ensure the integrity of the stator core 1; Front sealing plate 6: The sealing piece on one side of the stator core 1 is fixed with adhesive, and the end of the insulating film 12 is pressed together. It is provided with a first thickening ring 7 to block the coil from contacting the core. First thickening ring 7: The thickening structure on the front sealing sheet 6, together with the second thickening ring 9, provides a boundary and strengthens the support performance of the front sealing sheet 6; Rear sealing piece 8: The sealing piece on the other side of the stator core 1, fixed with adhesive, presses the end of the insulating film 12, and has a second thickening ring 9 to block the coil from contacting the core; Second thickening ring 9: The thickening structure on the rear sealing plate 8 has a mating protrusion 10 on the side away from the stator core 1, which cooperates with the first thickening ring 7 to provide a boundary; Docking convex 10: The protruding structure on the second thickened ring 9 facilitates the docking of the rear sealing plate 8 with the generator housing, enabling positioning and installation; Positioning groove 11: Six sets of grooves on the outer circumference of the stator core 1 are fitted with the outer shell protrusions, are circumferentially symmetrical and intersect with the through-pin rivet holes 4 to prevent the core from loosening; Insulating diaphragm 12: A membrane structure made of polyimide, located in the coil slot 2, with its ends pressed together by front and rear sealing plates to isolate the coil from the iron core slot wall and prevent wear.

[0030] Working principle: This high-reliability automotive generator achieves stable and efficient power generation through the synergistic effect of its winding structure and components, while its reinforced structural design resists the adverse effects of vehicle vibration. Its core operating logic revolves around three dimensions: electromagnetic induction power generation, structural stability assurance, and insulation protection.

[0031] In terms of the power generation mechanism, the core of the design is a three-phase, twenty-four-slot, four-pole coil winding scheme. Based on the three-phase, four-pole design framework, the coils are embedded in the twenty-four coil slots 2 of the stator core 1 with a short pitch (short pitch value 1) of 5 and a pole pitch of 6. This winding configuration effectively reduces the interference of the 5th and 7th harmonics. When the rotor rotates and generates an alternating magnetic field, the induced electromotive force waveform generated by the three-phase coils cutting the magnetic field lines is closer to a sine wave, reducing the disturbance of harmonic components to the output current, ensuring the stability of the generated voltage and frequency, and providing a continuous and stable power output for the vehicle's electrical system and battery. The combination of the multi-slot design and specific pitch parameters not only improves the space utilization of the windings but also achieves higher power output in the same volume through optimized distribution of electromagnetic coupling, meeting the increased power demand brought about by the electrification upgrade of automobiles.

[0032] Ensuring structural stability is a key highlight of this design, achieved through multiple positioning and fastening mechanisms. The stator core 1 is composed of multiple stacked unit plates 3, each made of 50W 350 silicon steel. Silicon steel itself has low iron loss characteristics, reducing eddy current losses under alternating magnetic fields and improving power generation efficiency. Six symmetrically distributed through-holes 4, each containing a through-hole 5, tightly fix the unit plates 3 into a unified, rigid core structure, preventing relative displacement between stacked layers due to vibration. Simultaneously, the six positioning grooves 11 on the outer ring of the stator core 1 form an interlocking structure with the inner wall protrusions of the outer casing. Combined with the symmetrical layout and staggered distribution of the through-holes 4, this creates twelve evenly distributed stress points, ensuring the connection between the core and the outer casing remains stable even during vehicle vibrations, preventing coil position shifts or abnormal friction between the core and coils due to loosening.

[0033] The insulation protection system uses a multi-layer design to block direct contact between the conductive core wire and the iron core. The insulating film 12 laid in the coil slot 2 has high temperature resistance and wear resistance. The insulating film 12 is made of polyimide and physically isolates the coil from the wall of the iron core slot 2, preventing the insulation layer from being damaged by the iron core cutting the coil. The front and rear seals (front seal 6 and rear seal 8) further strengthen this protection: the front seal 6 and rear seal 8, which are fixed to both sides of the iron core with adhesive, not only block the contact between the coil end and the iron core, but their design of pressing them onto the end of the insulating film 12 (by installing the insulating film 12 first and then assembling the front seal 6 and rear seal 8) makes the insulating film 12 form a closed wrapping state in the slot, preventing the coil from coming out of the slot opening during vibration. The first thickening ring 7 of the front cover 6 and the second thickening ring 9 of the rear cover 8 are reinforced by structure. The first thickening ring 7 and the second thickening ring 9 provide a boundary through additive manufacturing, providing physical support for the boundary between the coil end and the external components, and reducing the collision loss caused by the shaking of the end coil.

[0034] Furthermore, the selection of materials and processes for each component serves overall reliability. The aging resistance and insulation performance of the polyimide insulating diaphragm 12, the optimized permeability of the 50W350 silicon steel sheet unit 3, and the rigid connection design of the through-bolt 5 and positioning slot 11 together construct a winding system adapted to the complex operating conditions of automobiles. When the vehicle travels on bumpy roads, the synergistic effect of the positioning slot 11 structure and the through-bolt 5 offsets radial and axial vibration loads. The double protection formed by the front sealing plate 6 and the rear sealing plate 8 and the insulating diaphragm 12 blocks the wear path of the iron core and coil, while the optimized coil parameters ensure that stable electromagnetic induction efficiency can be maintained even with slight structural changes, ultimately achieving high reliability operation of the generator under long-term vibration environments.

[0035] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-reliability automotive generator winding structure, comprising a three-phase, twenty-four-slot, four-pole coil, characterized in that, Also includes: Stator core (1), wherein twenty-four sets of coil slots (2) are provided inside the stator core (1); Front and rear seals are disposed on both sides of the stator core (1) and are coaxial with the stator core (1); A positioning structure is provided on the outer circumferential surface of the stator core (1).

2. The winding structure of the high-reliability automotive generator according to claim 1, characterized in that, The stator core (1) is composed of multiple stacked unit pieces (3), and the unit piece (3) is a 50W350 silicon steel sheet.

3. The winding structure of the high-reliability automotive generator according to claim 2, characterized in that, The unit piece (3) has six sets of through-holes (4), which are symmetrically distributed in a circle.

4. The winding structure of the high-reliability automotive generator according to claim 3, characterized in that, A through-pin (5) is provided in the through-pin rivet hole (4), and multiple sets of unit pieces (3) are fixedly stacked by the through-pin (5).

5. The winding structure of the high-reliability automotive generator according to claim 1, characterized in that, The front and rear seals include a front seal (6) and a rear seal (8), which are fixed to both sides of the stator core (1) by adhesive.

6. The winding structure of the high-reliability automotive generator according to claim 5, characterized in that, The front sealing sheet (6) is provided with a first thickening ring (7).

7. The winding structure of the high-reliability automotive generator according to claim 5, characterized in that, The rear sealing plate (8) is provided with a second thickening ring (9), and the second thickening ring (9) is provided with multiple sets of mating protrusions (10) on the side away from the stator core (1).

8. The winding structure of the high-reliability automotive generator according to claim 3, characterized in that, The positioning structure includes six sets of positioning slots (11), which are parallel to the axis of the stator core (1).

9. The winding structure of the high-reliability automotive generator according to claim 8, characterized in that, The six sets of positioning grooves (11) are symmetrically distributed in a circle, and the positioning grooves (11) are staggered with the through-hole rivet holes (4).

10. The winding structure of the high-reliability automotive generator according to claim 5, characterized in that, An insulating film (12) is provided in the coil groove (2). The insulating film (12) is made of polyimide. The front sealing film (6) and the rear sealing film (8) are pressed onto the end of the insulating film (12).

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