Method for adjustable junction box for electric motor

Abstract

The present invention provides a design method for an adjustable junction box for an electric motor, the method comprising the following steps: step 1, fixing a transition copper busbar having adjustable cable fixing holes and an insulating connection assembly to a junction box body by means of bolts, wherein a plurality of PG cable glands are evenly distributed on the junction box body according to the number of outgoing cables required by the electric motor; step 2, connecting two ends of the transition copper busbar having adjustable cable fixing holes to the insulating connection assembly, and adjusting a stator end-ring connecting busbar based on the position of a rigid copper busbar; and step 3, forming a plurality of rows of threaded holes or oblong holes in the transition copper busbar having adjustable cable fixing holes and aligning same with the plurality of PG cable glands on the junction box body for cable connection. In the present invention, precise connection and positioning of the rigid copper busbar and a conductive busbar are ensured, which is conducive to cable lead-out of a wind power generator.

Description

[Amended according to Rule 26, 2006.01.2025] A method for an adjustable junction box for a motor. Technical Field

[0001] This invention relates to the field of motor design, and more particularly to a design method for an adjustable junction box for motors. Background Technology

[0002] In current large wind turbine designs, rigid copper busbars are typically used as the outgoing line method. These rigid copper busbars need to be welded to the conductive busbars inside the junction box, or directly mechanically connected to the cable, which then exits from the junction box's outlet hole. Both connection methods require precise welding positions between the rigid copper busbars and the winding end rings. However, after impregnation, the spatial position of the rigid copper busbars is fixed and cannot be adjusted.

[0003] During the connection process between rigid copper busbars and conductive busbars, and in the connection between conductive busbars and cable exit points, it is crucial to ensure accurate positioning of the rigid copper busbars and conductive busbars. On one hand, inaccurate positioning can lead to misalignment, insufficient overlap area, uneven contact surfaces, and poor welding quality. On the other hand, inaccurate positioning of the rigid copper busbars can force the cable into a bent, potentially damaging the fixing bolts or even preventing the cable from exiting properly. In the most severe cases, these problems can cause the motor to overheat, leading to cable burnout or even generator burnout. Therefore, ensuring accurate positioning of the rigid copper busbars and conductive busbars is essential for ensuring the normal operation of the motor and extending its service life.

[0004] The wiring structure of a motor is a crucial component of motor design, affecting its electrical connections and overall layout. The wiring structure includes a junction box fixed to the outer surface of the motor housing, stator lead-out rigid copper busbars, conductor busbars, cable holders, and cable tightening fittings. The junction box is located at a corner of the motor housing. The stator lead-out rigid copper busbars and conductor busbars connect to the junction box and are connected to the cables. The cables are secured by the cable tightening fittings and led to the outside. However, with increasing motor power, the number of cables increases, and motor structures tend to become more compact, wiring abnormalities caused by inaccurate positioning of the stator lead-out rigid copper busbars and conductor busbars are becoming increasingly common. Summary of the Invention

[0005] To address the aforementioned issues, this invention discloses a design method for an adjustable junction box for motors, ensuring precise connection and positioning of the rigid copper busbar and the conductive busbar, thereby avoiding a series of problems caused by inaccurate positioning.

[0006] Step 1: Secure the insulating connection assembly to the junction box. Distribute several locking pins evenly on the junction box according to the number of outgoing cables required by the motor.

[0007] Step 2: Several transition copper busbars with adjustable cable fixing holes are arranged sequentially from top to bottom inside the junction box; both ends of each transition copper busbar with adjustable cable fixing holes are connected to the insulating connection assembly through a connection structure; the connection structure is a fixing end provided at both ends of the transition copper busbar with adjustable cable fixing holes; the transition copper busbar with adjustable cable fixing holes is provided with a stator end ring connection busbar.

[0008] Step 3: Multiple rows of threaded holes or elliptical elongated holes are opened on the transition copper busbar of each of the adjustable cable fixing holes for connecting cables, so as to facilitate alignment with multiple locking PGs on the junction box.

[0009] Furthermore, the insulating connection assembly employs two structures to ensure the electrical distance between the transition copper busbar of the adjustable cable fixing hole and the junction box.

[0010] Furthermore, the insulating connection assembly includes an insulating block, a bolt fixing pin, and a bolt; the fixing end is a straight plate with two symmetrical U-shaped grooves at the end; wherein the fixing end is placed on one end of the insulating block, and a first locking bolt passes through the U-shaped groove and is fastened to the insulating block; the other end of the insulating block is provided with an insertion bolt fixing pin, and the fixing pin bolt passes through the junction box and is screwed into the threaded hole of the bolt fixing pin.

[0011] Furthermore, the bolt fixing pin is a cylindrical pin with a threaded hole in the middle.

[0012] Furthermore, the insulating connection assembly includes an insulator and a fixing copper busbar bolt; the fixing end is an upwardly protruding bent portion; wherein the fixing copper busbar bolt passes through the threaded hole of the insulator and is fixed to the junction box body.

[0013] Furthermore, the connection between the bent portion and the transition copper busbar of the adjustable cable fixing hole is an arc-shaped transition.

[0014] Furthermore, the insulator is cylindrical and has threaded holes on both ends.

[0015] Furthermore, the two structures used in the insulating connection assembly can be used in combination or one of them can be selected.

[0016] The beneficial effects of this invention are:

[0017] 1. Resolved installation abnormalities caused by inaccurate positioning of rigid copper busbars and conductive busbars during manufacturing; resolved cable outage issues caused by inaccurate positioning of rigid copper busbars.

[0018] 2. It reduces the manufacturing difficulty for applications with high requirements on the position of the motor lead wires.

[0019] 3. The adjustable junction box method described in this invention is beneficial for the wind turbine cable outlet; it ensures the precise connection and positioning of the rigid copper busbar and the conductive busbar, thereby avoiding a series of problems caused by inaccurate positioning. Attached Figure Description

[0020] Figure 1. Schematic diagram of the structure of the present invention;

[0021] Figure 2. Axonometric view of the present invention;

[0022] Figure 3, second isometric view of the present invention.

[0023] Figure 4 is a magnified view of part II in Figure 2;

[0024] Figure 5 is a magnified view of part I in Figure 3;

[0025] Figure 6 is a schematic diagram of the fixed end structure with a U-shaped groove;

[0026] List of reference numerals in the attached diagram: 1-Transition copper busbar for adjustable cable fixing hole; 2-Insulation connection assembly; 3-Locking PG; 4-Stator end ring connection busbar; 5-Junction box body; 6-Bolt fixing pin; 7-Fixing pin bolt; 8-Insulating block; 9-Fixing copper busbar bolt; 10-Insulator; 11-Fixing end; 12-First locking bolt. Detailed Implementation

[0027] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, and the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0028] As shown in Figure 1, a design method for an adjustable junction box for a motor according to this embodiment includes the following steps:

[0029] Step 1: Secure the insulating connection assembly 2 to the junction box 5, and distribute several locking PG3 evenly on the junction box 5 according to the number of outgoing cables required by the motor.

[0030] Step 2: Several adjustable cable fixing holes are arranged sequentially from top to bottom in the junction box 5. The two ends of each adjustable cable fixing hole transition copper busbar 1 are connected to the insulation connection assembly 2 through a connection structure. The connection structure is a fixing end 11 set at both ends of the adjustable cable fixing hole transition copper busbar 1. The adjustable cable fixing hole transition copper busbar 1 is provided with a stator end ring connection busbar 4.

[0031] Step 3: Each adjustable cable fixing hole has multiple rows of threaded holes or oval elongated holes on the transition copper busbar 1 for connecting cables, which facilitates alignment with the multiple locking PGs 3 on the junction box 5.

[0032] As shown in Figures 2-6, the insulating connection assembly 2 employs two structures to ensure the electrical distance between the transition copper busbar 1 of the adjustable cable fixing hole and the junction box 5.

[0033] As shown in Figure 4, the insulating connection assembly 2 includes an insulating block 8 (such as EPGC308 material), a bolt fixing pin 6, and a pin bolt 7; wherein the bolt fixing pin 6 is inserted into the middle circular hole of the insulating block 8, and the fixing pin bolt 7 is screwed into the threaded hole of the bolt fixing pin 6 and fixed to the junction box body 5; the bolt fixing pin 6 is a cylindrical pin with a threaded hole in the middle part.

[0034] As shown in Figure 5, another type of insulating connection component 2 has a structure that includes an insulator 10 (made of materials such as resin, mica, or alumina) and a fixing copper busbar bolt 9; the insulator 10 is cylindrical and has threaded holes on both ends.

[0035] The fixed end 11 is an upwardly protruding bent portion; wherein the fixing copper bus bolt 9 passes through the threaded hole of the insulator 10 and is fixed to the junction box body 5; wherein the connection between the bent portion and the transition copper bus 3 of the adjustable cable fixing hole is an arc-shaped transition.

[0036] The insulating connection component 2 in this embodiment can be combined left and right, top and bottom, or used alone according to different requirements, which increases the convenience of operation.

[0037] The technical means disclosed in this invention are not limited to those disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features.

Claims

1. A design method for an adjustable junction box for a motor, characterized in that: Includes the following steps: Step 1: Secure the insulating connection assembly (2) to the junction box (5), and distribute several locking PGs (3) evenly on the junction box (5) according to the number of outgoing cables required by the motor. Step 2: Several adjustable cable fixing holes are arranged in the junction box (5) from top to bottom; the two ends of each adjustable cable fixing hole transition copper busbar (1) are connected to the insulating connection assembly (2) through a connection structure; the connection structure is a fixing end (11) set at both ends of the adjustable cable fixing hole transition copper busbar (1); the adjustable cable fixing hole transition copper busbar (1) is provided with a stator end ring connection busbar (4); Step 3: Multiple rows of threaded holes or elliptical elongated holes are opened on the transition copper busbar (1) of each of the adjustable cable fixing holes for connecting cables, so as to facilitate alignment with multiple locking PGs (3) on the junction box (5).

2. The design method of an adjustable junction box for a motor according to claim 1, characterized in that: The insulating connection assembly (2) employs two structures to ensure the electrical distance between the transition copper busbar (1) of the adjustable cable fixing hole and the junction box body (5).

3. A design method for an adjustable junction box for a motor according to claim 1 or 2, characterized in that: The insulating connection assembly (2) includes an insulating block (8), a bolt fixing pin (6), and a pin bolt (7); the fixing end (11) is a straight plate with two symmetrical U-shaped grooves at the end; wherein the fixing end (11) is placed on one end of the insulating block (8), and the first locking bolt (12) passes through the U-shaped groove and is fastened to the insulating block (8); the other end of the insulating block (8) is provided with an insertion bolt fixing pin (6), and the fixing pin bolt (7) passes through the junction box body (5) and is screwed into the threaded hole of the bolt fixing pin (6).

4. The design method of an adjustable junction box for a motor according to claim 3, characterized in that: The bolt fixing pin (6) is a cylindrical pin with a threaded hole in the middle.

5. A design method for an adjustable junction box for a motor according to claim 1 or 2, characterized in that: The insulating connection assembly (2) includes an insulator (10) and a fixing copper busbar bolt (9); the fixing end (11) is an upwardly protruding bent part; wherein the fixing copper busbar bolt (9) passes through the threaded hole of the insulator (10) and is fixed to the junction box body (5).

6. The design method of an adjustable junction box for a motor according to claim 5, characterized in that: The connection between the bent portion and the transition copper busbar (3) of the adjustable cable fixing hole is an arc-shaped transition.

7. The design method of an adjustable junction box for a motor according to claim 5, characterized in that: The insulator (10) is cylindrical and has threaded holes on both ends.

8. The design method of an adjustable junction box for a motor according to claim 2, characterized in that: The two structures used in the insulating connection assembly (2) can be used in combination or one of them can be selected.