CN105099116A - Brushless claw pole power generator of electromobile range extender and fabrication method of brushless claw pole generator - Google Patents

Abstract

The invention proposes a brushless claw pole generator for an electric vehicle range extender and a manufacturing method thereof, the generator comprising an armature winding (2), an N pole claw pole (3), an S pole claw pole (4), Shaft (5), field winding (6), support (8), stator core (9) and fan (10). The N-pole claw pole (3) and the S-pole claw pole (4) are buckled together, the excitation winding (6) is wound on the bracket and located inside the claw pole, and the armature winding (2) is wound on the stator core (9) Located on the outer side of the claw poles, the inner wall of the generator housing (1) is die-cast with a plurality of convex lines, which fit into corresponding arc-shaped grooves on the outer edge of the stator. The invention has a brushless structure, reliable operation, and adjustable excitation current; only the claw poles rotate, and the moment of inertia is small, and is suitable for being installed on the outer end of the engine crankshaft of the range extender to form a brushless claw pole generator.

Description

A brushless claw pole generator for electric vehicle range extender and its manufacturing method

technical field

The invention provides a brushless claw-pole generator for an electric vehicle range extender and a manufacturing method thereof, belonging to the technical field of automobile motors and electrical appliances.

Background technique

Pure electric vehicles are energy-saving and environmentally friendly, and have the advantages of zero emission and zero pollution. However, the current battery technology is not enough to provide the ideal mileage, and often needs to be charged multiple times before reaching the destination. If there is no suitable charging place, the car If the power is exhausted, it will stop moving forward, and in the short term, no new technology can be developed for the storage battery, so a device that can use fuel to charge the storage battery is very necessary. At present, the generators used in automotive generators generally have disadvantages such as low efficiency, low reliability, and unstable output voltage.

At present, there are brushless generators for range extenders in China, for example, the patent application with application number 201410009399.X: A power generation type range extender generator set for vehicles, which proposes an outer rotor permanent magnet range extender generator. The invention patent with the authorization number ZL201110140865.4: speed-increasing generator for electric vehicle range extender, proposes a generator that places the generator between the engine body and the flywheel. There are essential differences in principle and structure between the above-mentioned permanent magnet generator and the electric excitation generator of the present application.

Contents of the invention

In order to invent a brushless claw-pole generator for electric vehicle range extender with compact structure, good heat dissipation, reliable operation and small moment of inertia, the technical scheme of the present invention is as follows:

1. A brushless claw pole generator for an electric vehicle range extender, characterized in that it consists of a generator casing (1), an armature winding (2), an N pole claw pole (3), and an S pole claw pole (4) , shaft (5), field winding (6), bracket (8), stator core (9) and fan (10);

The shaft (5) shared by the engine and the generator passes through the center hole of the bracket (8) and the N-pole claw pole (3). With a certain taper, the end of the shaft (5) has a nut and a key to lock the claw pole; the outer end surface of the N pole claw pole (3) is welded with a fan (10), and the outer diameter of the fan (10) is not larger than the inner diameter of the stator;

The N-pole claw pole (3) and the S-pole claw pole (4) are interlocked together, the N-pole claw pole (3) has a yoke, and there is no protrusion inside the yoke, and the S-pole claw pole (4) has no yoke. The N-pole claw pole (3) and the S-pole claw pole (4) are fixed together with non-magnetic materials; the bracket (8) is located on the inside of the claw pole and there is a second air gap between the claw poles, and the bracket (8) is tightened with screws Fixed on the engine casing (7), the half-section of the bracket (8) is a U-shaped structure, the end surface of the side close to the engine casing (7) is thicker, and the excitation winding (6) is wound on the U-shaped groove of the bracket (8) Inside, the central part around which the excitation winding (6) is wound is thicker and has stronger magnetic permeability; there is a third air gap between the inner side of the bracket (8) and the shaft (5);

The stator core (9) is located outside the circumference of the claw pole, and there is a first air gap between it and the claw pole. The armature winding (2) is wound on the iron core and there are multiple positioning slots on the outside of the circumference. The circumference of the generator casing (1) The inner surface also has a corresponding convex line, which can just fit into the positioning groove of the stator core (9); the generator casing (1) is fixed on the engine casing (7) and has multiple air vents.

A method for manufacturing a brushless claw pole generator for an electric vehicle range extender, characterized in that:

The first step, the assembly of the excitation winding (6) and the bracket (8): first fasten the forged bracket (8) on the engine casing (7) with screws, and then wind it in the U-shaped groove of the bracket (8) Field winding (6);

The second step, rotor assembly: forging the N-pole claw pole (3) and the S-pole claw pole (4) with tapered holes and yokes, fine grinding the tapered holes and shafts on the N-pole claw pole (3) ( 5) For the cone at the end, weld the N-pole claw pole (3) and the S-pole claw pole (4) with a non-magnetic material, and put the N-pole claw pole (3) claw toward the engine so that the claw pole is press-fitted on the shaft ( 5) Put on and lock the claw poles with nuts;

The third step, stator assembly: Punch and cut the silicon steel sheet into a stator punch, with U-shaped grooves and arc-shaped grooves on the outer edge of the punch, stack the punched sheets in the same order as the stamping burrs, weld the U-shaped groove and wind it Three-phase armature winding (2);

The fourth step, housing assembly: Align the position of the convex line on the inner surface of the generator housing and the arc groove of the stator core (9), assemble the stator into the generator housing (1), and apply adhesive between the two Fix, fasten the generator casing (1) to the engine casing (7) with screws to complete the assembly.

Compared with the traditional brushless electric excitation generator, the invention has no protrusion on the claw pole yoke, the axial magnetic field in the middle of the excitation winding is conducted through the excitation bracket, and the claw pole yoke does not provide a magnetic conduction channel, so the claw pole is light in weight . In order to better realize this effect, the present invention also proposes to use a cone to fix the claw poles, so that the claw poles can improve the center positioning accuracy. In addition, in order to achieve a better heat dissipation effect, the present invention also adopts the claw pole and fan integration technology and designs an air duct for simultaneous cooling of the excitation winding and the armature winding.

Therefore, compared with the existing technology, the cooling effect of the present invention has been greatly improved. The air is sucked in from the vent hole on the circumferential surface of the generator and blown from the end face of the generator, taking away the internal heat of the generator, ensuring the range extender generator The reliability of the work under high temperature environment; the taper design of the contact part between the claw pole and the shaft ensures the accuracy of assembly; the no protrusion of the claw pole yoke reduces the moment of inertia of the rotor; the overall structure of the motor is compact and suitable for installation in range extenders use on.

Description of drawings

Fig. 1 is a longitudinal sectional view of a brushless claw pole generator for an electric vehicle range extender according to the present invention. Among them: 1. Generator casing; 2. Armature winding; 3. N pole claw pole; 4. S pole claw pole; 5. Shaft; 6. Excitation winding; 7. Range extender shell; 8. Bracket; 9. Stator; 10. Fan.

Fig. 2 is a cross-sectional view of a claw pole of a brushless claw pole generator of an electric vehicle range extender according to the present invention. The number of stator slots is 36, and the number of N-pole claw poles and S-pole claw poles is 6. Among them: 1. Shell; 3. N pole claw pole; 4. S pole claw pole; 5. Shaft; 6. Excitation winding; 9. Stator; 10. Arc groove; 11. U-shaped groove.

Fig. 3 is a manufacturing flow chart of a brushless claw-pole generator for an electric vehicle range extender according to the present invention.

Fig. 4 is an air flow diagram for heat dissipation of a brushless claw-pole generator for a range extender of an electric vehicle according to the present invention.

Detailed ways

The present invention will be further described below in conjunction with accompanying drawing:

Fig. 1 is a longitudinal sectional view of a brushless claw-pole generator for an electric vehicle range extender according to the present invention. The electric vehicle range extender brushless claw pole generator includes: generator housing 1, armature winding 2, N pole claw pole 3, S pole claw pole 4, shaft 5, excitation winding 6, range extender shell 7. Bracket 8, stator core 9 and fan 10. The motor includes shaft 5 , bracket 8 , field winding 6 , claw poles, stator core 9 , armature winding 2 and motor casing 1 from inside to outside. The field winding 6 is made on a support 8, and the support 8 is fixed on the engine casing by screw connection; the outside of the field winding 6 is the N pole claw pole 3 and the S pole claw pole 4, and the N pole claw pole 3 and the S pole claw pole The number of poles and 4 poles are 6, the N pole claw pole has a yoke, the S pole claw pole has no yoke, the two are buckled together and connected with a non-magnetic material, the shaft passes through the center hole of the N pole claw pole The claw poles are connected, and the connecting part adopts a tapered surface to increase the positioning accuracy. Both the bracket 8 and the claw poles 3 and 4 are made of non-oriented magnetically conductive materials. A fan is welded on the back of the claw pole of the N pole to dissipate heat from the excitation winding and the armature winding, and the claw pole and the fan are axially locked with a nut at the shaft end.

It can be seen from Figure 1 that the inner end face of the claw pole 3 of the N pole is flat, and the claw pole yoke has no protrusions. The axial magnetic field in the middle of the excitation winding is conducted through the excitation bracket, and the claw pole yoke does not provide a magnetic conduction channel. The claws are therefore extremely light in weight.

Fig. 2 is a cross-sectional view of a brushless claw-pole generator for an electric vehicle range extender according to the present invention. The number of stator slots of the generator is 36, the number of claw poles 3 for N poles and 4 poles for S poles is 6, and there is an air gap outside the claw poles, and the stator core is outside the air gaps. Among them: 1. Shell; 3. N pole claw pole; 4. S pole claw pole; 5. Shaft; 6. Excitation winding; 9. Stator. The inner wall of the motor casing is die-cast with 6 convex strips, and there are 6 arc-shaped grooves at corresponding positions around the stator core, and the convex strips can be just embedded in the arc-shaped grooves to prevent the relative rotation of the two.

The blackened part between the stator and the housing in Figure 2 is a schematic diagram of the adhesive, and the bonding of the stator and the housing can prevent the axial relative movement of the stator and the housing.

Fig. 3 is a manufacturing flow chart of a brushless claw-pole generator for an electric vehicle range extender according to the present invention. The first step is the assembly of the field winding and the bracket: first, fasten the forged field winding bracket to the engine casing with screws, and then wind the field winding in the U-shaped groove of the bracket.

The second step, rotor assembly: use the precision forging method to forge N-pole claw poles and S-pole claw poles with holes and yokes, finely grind the holes on the claw poles, and use non-magnetic materials to connect N-pole claw poles and S-pole claw poles. The claw poles are connected, and the claw poles of the N pole are facing the engine so that the claw poles are pressed on the shaft and the claw poles are locked with nuts.

The third step, stator assembly: punching and cutting silicon steel sheets into stator punching sheets, with U-shaped grooves and arc-shaped grooves on the outer edge of the punching sheets, stacking the punching sheets in the same order as the stamping burrs and welding the U-shaped grooves, and finally winding Three-phase armature winding.

The fourth step, housing assembly: Align the positions of the convex lines on the inner surface of the generator housing and the arc grooves of the stator core, assemble the stator into the generator housing, apply adhesive between the two to fix it, and screw the generator The casing is fastened to the engine casing to complete the assembly.

Fig. 4 is an air flow diagram for heat dissipation of a brushless claw-pole generator for a range extender of an electric vehicle according to the present invention. The air flows in the direction of the arrow in the figure, enters from the vent holes on the circumferential surface and blows out from the vent holes on the end face, taking away the heat inside the generator.

Description of the working principle of the brushless claw-pole generator for the electric vehicle range extender proposed by the present invention.

When the brushless claw pole generator of the present invention is in working state, the excitation winding is energized to generate magnetic flux, and the magnetic flux passes through the support, the first additional air gap, the N pole claw pole, the main air gap, the S pole claw pole, and the second additional air gap. The gap returns to the bracket to form a closed loop, and there is a flux link in the armature winding. When the claw pole rotates, the flux linkage in the armature winding will change, thereby generating an induced electromotive force, controlling the magnitude of the excitation current to adjust the magnitude of the output voltage.

Compared with the existing technology, the cooling effect of the present invention has been greatly improved, ensuring the reliability of the range extender generator working in a high-temperature environment, and the taper design of the contact part between the claw pole and the shaft ensures the accuracy of assembly. The absence of protrusions on the claw pole yoke reduces the moment of inertia of the rotor, and the overall design of the motor is compact, which is suitable for installation on the engine as a range extender generator.

Claims (2)

1. A brushless claw pole generator for an electric vehicle range extender, characterized in that: it consists of a generator casing (1), an armature winding (2), an N pole claw pole (3), and an S pole claw pole (4) , shaft (5), field winding (6), bracket (8), stator core (9) and fan (10); The shaft (5) shared by the engine and the generator passes through the center hole of the bracket (8) and the N-pole claw pole (3). With a certain taper, the end of the shaft (5) has a nut and a key to lock the claw pole; the outer end surface of the N pole claw pole (3) is welded with a fan (10), and the outer diameter of the fan (10) is not greater than the inner diameter of the stator; The N-pole claw pole (3) and the S-pole claw pole (4) are interlocked together, the N-pole claw pole (3) has a yoke, and there is no protrusion inside the yoke, and the S-pole claw pole (4) has no yoke. The N-pole claw pole (3) and the S-pole claw pole (4) are fixed together with non-magnetic materials; the bracket (8) is located on the inside of the claw pole and there is a second air gap between the claw poles, and the bracket (8) is tightened with screws Fixed on the engine casing (7), the half-section of the bracket (8) is a U-shaped structure, the end surface of the side close to the engine casing (7) is thicker, and the excitation winding (6) is wound on the U-shaped groove of the bracket (8) Inside, the central part around which the excitation winding (6) is wound is thicker and has stronger magnetic permeability; there is a third air gap between the inner side of the bracket (8) and the shaft (5); The stator core (9) is located outside the circumference of the claw pole, and there is a first air gap between it and the claw pole. The armature winding (2) is wound on the iron core and there are multiple positioning slots on the outside of the circumference. The circumference of the generator casing (1) The inner surface also has a corresponding convex line, which can just fit into the positioning groove of the stator core (9); the generator casing (1) is fixed on the engine casing (7) and has multiple air vents. 2. A method for manufacturing a brushless claw pole generator for an electric vehicle range extender, characterized in that: The first step, the assembly of the excitation winding (6) and the bracket (8): first fasten the forged bracket (8) on the engine casing (7) with screws, and then wind it in the U-shaped groove of the bracket (8) Field winding (6); The second step, rotor assembly: forging the N-pole claw pole (3) and the S-pole claw pole (4) with tapered holes and yokes, fine grinding the tapered holes and shafts on the N-pole claw pole (3) ( 5) For the cone at the end, weld the N-pole claw pole (3) and the S-pole claw pole (4) with a non-magnetic material, and put the N-pole claw pole (3) claw toward the engine so that the claw pole is press-fitted on the shaft ( 5) Put on and lock the claw poles with nuts; The third step, stator assembly: Punch and cut silicon steel sheets into stator punches, with U-shaped grooves and arc-shaped grooves on the outer edge of the punched sheets, stack the punched sheets in the same order as the stamping burrs, weld the U-shaped grooves and wind them Three-phase armature winding (2); The fourth step, housing assembly: Align the position of the convex line on the inner surface of the generator housing and the arc groove of the stator core (9), assemble the stator into the generator housing (1), and apply adhesive between the two Fix, fasten the generator casing (1) to the engine casing (7) with screws to complete the assembly.