CN107666216B - High-efficiency flat wire generator rectifier structure and assembly method - Google Patents
High-efficiency flat wire generator rectifier structure and assembly method Download PDFInfo
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- CN107666216B CN107666216B CN201710740291.1A CN201710740291A CN107666216B CN 107666216 B CN107666216 B CN 107666216B CN 201710740291 A CN201710740291 A CN 201710740291A CN 107666216 B CN107666216 B CN 107666216B
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- 238000000034 method Methods 0.000 title claims description 13
- 230000001681 protective effect Effects 0.000 claims abstract description 46
- 238000003466 welding Methods 0.000 claims abstract description 28
- 230000017525 heat dissipation Effects 0.000 claims description 25
- 238000004512 die casting Methods 0.000 claims description 21
- 238000001816 cooling Methods 0.000 claims description 10
- 238000001746 injection moulding Methods 0.000 claims description 10
- 238000005476 soldering Methods 0.000 claims description 10
- WABPQHHGFIMREM-UHFFFAOYSA-N lead(0) Chemical compound [Pb] WABPQHHGFIMREM-UHFFFAOYSA-N 0.000 claims description 6
- 238000002347 injection Methods 0.000 claims description 5
- 239000007924 injection Substances 0.000 claims description 5
- 238000009434 installation Methods 0.000 claims description 4
- 238000000465 moulding Methods 0.000 claims description 2
- 230000002457 bidirectional effect Effects 0.000 abstract description 2
- 230000002035 prolonged effect Effects 0.000 abstract description 2
- 238000010586 diagram Methods 0.000 description 5
- 238000005452 bending Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/04—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for rectification
- H02K11/049—Rectifiers associated with stationary parts, e.g. stator cores
- H02K11/05—Rectifiers associated with casings, enclosures or brackets
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- H02K11/046—
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
- H02M7/003—Constructional details, e.g. physical layout, assembly, wiring or busbar connections
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Synchronous Machinery (AREA)
- Motor Or Generator Cooling System (AREA)
Abstract
The invention discloses a high-efficiency flat wire generator rectifier structure, which comprises a conductive negative plate, a middle supporting insulating bracket, a conductive positive plate, a confluence bridge bracket, a positive output screw, a rectifier diode, tubular rivets, a generator rear fixing cover supporting boss and a plastic protective cover, and is characterized in that: the middle support insulating support replaces an insulating bushing, is arranged between the conductive negative plate and the conductive positive plate, the conductive negative plate is arranged below the rectifier and fixedly connected with the rear fixing cover support boss of the generator, the lower edge of the plastic protective cover is flush with the upper edge of the conductive negative plate, and the confluence bridge support is arranged above the conductive positive plate and fixedly connected with the stator wire of the generator in a threaded horizontal connection mode. The advantages are that: the bidirectional air inlet is adopted, so that the temperature gradient on the polar plate is uniform, the reliability of spot welding is ensured, the requirements of different output directions of customers can be met, the power and the product reliability of the generator are improved, and the overall service life of the high-efficiency generator is prolonged.
Description
Technical Field
The invention relates to an automobile rectifier structure, belongs to the field of automobile generators, and in particular relates to a high-efficiency flat wire generator rectifier structure and an assembly method.
Background
The automobile generator is a main power supply of an automobile, and has the functions of supplying power to all electric equipment (except a starter) and simultaneously charging a storage battery when an engine is in normal operation (above idle speed). Along with the development of electronic technology and the improvement of comfort requirements of people, vehicle-mounted electric appliances are continuously increased; meanwhile, due to the continuous tightening and improvement of environmental protection requirements, the automobile generator is developed towards the direction of small volume (weight) and high power. Therefore, new technology is continuously introduced in each country, the stator slot number of the generator is increased, and the efficiency of the generator under the same volume is improved. The flat wire stator is used in the market, and the temperature rise of the stator is greatly increased due to the structure, the volume and the power, so that a round wire stator which is normally used in the market is greatly increased, and the highest temperature after the stator is stabilized reaches more than 200 ℃; the stability of the conduction to the stationary cover after the generator also reaches 170 ℃ to 190 ℃, which puts higher demands on the rectifier.
The main current generators in the market are alternators, which are divided into internal generators and external generators according to the fixed positions of rectifiers and regulators. The built-in generator is complicated in assembly process, reworking and maintenance are inconvenient, the rectifier is closer to the stator coil, and the temperature rise of the rectifier is greatly influenced; but it has no plastic protective cover, and is convenient for manufacturing the motor with the pump. The external generator is simple and convenient to assemble, the reworking maintenance of the rectifier and the regulator is convenient, and the heat dissipation of the rectifier is better; however, the rectifier and the regulator need to be provided with a protective cover for protection, and the motor with the pump is difficult to implement.
In a high-power generator, a rectifier adopts a twelve-pipe structure; in the built-in rectifier, the negative plate is attached to the end cover, the end cover is used for helping heat dissipation, and the positive plate adopts a multi-tooth structure for heat dissipation; external rectifier, current structure are back fixed cover as negative plate or negative plate laminating and are covered the heat dissipation after the fixed, and the positive plate adopts die-casting plate structure heat dissipation. When the stator coil adopts a flat wire stator, the temperature of the rear fixing cover is higher due to heat conduction of the stator, and the rectifier diode on the rectifier generates heat in a rectifying way, so that the temperature conduction and the dissipation are poorer, and the junction temperature of the rectifier diode is reached, thereby leading to the failure of the rectifier.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a high-efficiency flat wire generator rectifier structure.
In order to achieve the above purpose, the invention discloses a high-efficiency generator rectifier structure, which comprises a conductive negative plate, a middle supporting insulating bracket, a conductive positive plate, a confluence bridge bracket, a positive output screw, a rectifier diode, a tubular rivet, a generator rear fixing cover supporting boss and a plastic protective cover. The rectifier diode converts alternating current into direct current, the conductive negative plate and the conductive positive plate play the roles of fixing the rectifier diode, conducting and radiating, the bus bridge bracket is connected with a stator wire to conduct current, the positive output screw rod outputs current to the outside, the rear cover of the generator supports the fixed rectifier, the plastic protective cover protects the rectifier and adjusts the air duct of the generator. The method is characterized in that: the middle support insulating bracket replaces an insulating bushing and is arranged between the conductive negative plate and the conductive positive plate, an open type plastic protection tube is arranged at a stator wire interface of the middle support insulating bracket, the conductive negative plate is arranged below the rectifier and is fixedly connected with a rear fixing cover supporting boss of the generator, the lower edge of the plastic protection cover is flush with the upper edge of the conductive negative plate, an inner side axial air channel and an outer side axial air channel are arranged on the plastic protection cover, when the generator works, the conductive positive plate is subjected to air intake and heat dissipation through the inner side axial air channel and the outer side axial air channel of the forward plastic protection cover, the front side and the inner side of the conductive negative plate are subjected to air flow heat dissipation through the conductive positive plate, and the back side of the conductive negative plate is subjected to radial V-shaped air channel heat dissipation through the conductive negative plate and the surface of the rear fixing cover of the generator; the inner side air channel I of the conductive positive plate, the inner side air channel II of the conductive negative plate and the inner side axial air channel of the plastic protective cover correspond. The conductive positive plate is provided with an outer air duct, web radiating teeth are arranged on the inner side of the conductive positive plate, radiating ribs are arranged on the web radiating teeth, and the conductive positive plate is provided with B+ screw holes and six rectifier diode mounting holes in a die-casting mode. Two rectifier diodes are arranged outside the conductive positive plate, four rectifier diodes are arranged inside the conductive positive plate, the four rectifier diodes inside are close to web radiating teeth, and two B+ output interfaces are arranged on the inner side of the conductive positive plate.
The conductive negative plate and the motor rear fixing cover are not attached to each other for heat dissipation, and heat dissipation teeth are arranged on the back surface of the conductive negative plate. The conductive negative plate is die-cast with six diode mounting holes II, namely an outer three diode mounting holes and an inner three diode mounting holes; three rectifying diodes are arranged on the outer portion of the conductive negative plate, three rectifying diodes are arranged in the conductive negative plate, the distance between the three rectifying diodes is relatively uniform, and radiating teeth are arranged on the periphery of the conductive negative plate.
The bus bridge support is molded together through bus bars and M5 nuts to form stator wire connecting threads, bus bar welding pieces are bent on the bus bars, and the bus bars of the bus bridge support are connected with the rectifier diode leads through single-sided spot welding. The busbar bridge bracket is arranged above the conductive positive plate and is horizontally connected and fixed with the stator wire connecting threads of the generator.
The radial V-shaped air duct air inlet cooling conductive negative plate back and generator rear fixing cover, and the axial air duct air inlet inside the protective cover cools the conductive positive plate and the conductive negative plate inside and front.
The inner side axial air duct of the plastic protective cover is the same as the inner side air duct I of the conductive positive plate and the inner side air duct II of the conductive negative plate, and other air ducts are arranged on the outer side.
The inner side of the plastic protection cover is fixed by adopting two B+ output points, and the outer side of the plastic protection cover is fixed by adopting a plastic buckle formed with the outer edge of the bus bar bracket mounting hole, so that the air duct cannot deviate during product assembly.
The conductive positive plate is subjected to air inlet and heat dissipation through the axial air duct of the forward plastic protective cover and the axial air duct at the outer side.
The inner side air duct of the conductive positive plate corresponds to the inner side axial air duct of the protective cover.
The radiating ribs on the web radiating teeth of the conductive positive plate extend to the periphery of the rectifier diode hole under the condition that the product installation and assembly process is not affected.
The heat dissipation teeth on the back of the conductive negative plate are in an emission-shaped V shape, and a V-shaped air channel is formed under the condition that the product installation and assembly process is not affected.
The front and the inner side of the conductive negative plate dissipate heat through axial wind.
The inner side air duct of the conductive negative plate corresponds to the inner side axial air duct of the plastic protective cover.
The open type plastic protection tube is of a step shape, and the upper opening is larger.
The single-sided spot welding position of the bus bar of the bus bridge bracket is provided with a convex rib to improve the resistance and ensure the reliability of spot welding.
The convex ribs are arc bulges, and the height of the convex ribs is 0.3mm.
And the bus bar of the bus bridge bracket and the rectifier diode are in spot welding in the tangential direction.
And the connecting thread of the confluence bridge bracket and the stator wire is M5, and a plastic bracket injection nut structure is adopted.
And the busbar support is provided with vent holes, so that the axial wind flow can cool the conductive positive plate 2.
And the bus bar welding sheet on the bus bridge bracket is parallel to the radius direction of the rectifier diode hole.
And the bus bar of the bus bridge bracket is connected with the lead of the rectifier diode by adopting resistance welding.
Another object of the invention is to provide a method for assembling a high-efficiency flat wire generator rectifier: is realized by the following steps:
firstly, developing a die-casting conductive positive plate, wherein when a die is formed, inner side web type radiating teeth are die-cast to form an inner side air duct of the positive plate; the outer side of the conductive positive plate is provided with an outer air duct, the outer side of the conductive positive plate is provided with an outer second diode hole and an inner fourth diode hole in a die casting mode, and then a conductive positive plate B+ screw hole is formed in the die casting mode; simultaneously, six mounting holes are die-cast, and the die-cast diode holes and the B+ screw holes are required to be machined to ensure the sizes;
secondly, developing a die-casting conductive negative plate, wherein the back surface of the conductive negative plate is provided with conductive negative plate radiating teeth to form a radial V-shaped air duct, and the inner side of the conductive negative plate is provided with an inner side air duct; simultaneously, six diode holes are formed in the outer three and the inner three in a die-casting mode; simultaneously, six mounting holes are die-cast;
secondly, developing an injection molding middle support insulating bracket, wherein an open type plastic protection pipe is formed during mold forming, and the open type plastic protection pipe is in a step shape;
fourthly, developing a stamping forming bus bar, wherein a bus bar soldering lug is bent on the stamping forming bus bar, and before the soldering lug is bent and formed, extruding forming bus bar soldering joint convex ribs;
and fifthly, developing an injection molding busbar bracket, using the busbar and the M5 nut to perform injection molding together to form stator wire connecting threads, and simultaneously forming a bracket end plastic protection cover buckle and six mounting holes.
Secondly, developing an injection molding plastic protective cover, wherein an inner axial air duct of the protective cover and an outer axial air duct of the protective cover are formed during molding, simultaneously, two conductive sheets are injection molded to be matched with a rectifier B+ screw rod, and two inverted buckles are formed on the outer side to be matched with the plastic protective cover at the support end in a buckling manner;
seventhly, using the developed conductive positive plate, and using a press-fitting fixture to press-fit six positive rectifying diodes and two positive output screws onto the conductive positive plate to form a positive plate assembly;
(eight) using the developed conductive negative plate, and using a press-fitting fixture to press-fit six negative rectifying diodes onto the conductive negative plate to form a negative plate assembly;
assembling the positive plate component, the negative plate component, the middle support insulating bracket and the bus bridge bracket together, wherein three mounting holes are riveted into a whole by three tubular rivets, and then welding the rectifier diode lead wire to a bus bar welding piece of the bus bridge bracket by using a resistance welder, so that the rectifier diode lead wire and a bus bar welding point convex rib form a welding point to form a current loop, thereby forming a rectifier;
(ten) assembling the rectifier on a support boss of a rear fixing cover of the generator, so that a radial V-shaped air duct is formed by the conductive negative plate and the rear fixing cover of the generator, locking the rectifier on a rear end cover of the generator by using six fixing screws, installing the regulator, assembling a developed plastic protection cover on the rectifier, assembling two points with a B+ screw rod together, and forming inverted buckle fixation by two outer buckles with the plastic protection cover at the support end; the side lower surface of the rectifier of the plastic protective cover is flush with the upper surface of the conductive negative plate, so that the smoothness of the radial V-shaped air duct is ensured; the axial air duct at the inner side of the positive protective cover, the air duct at the inner side of the conductive positive plate and the air duct at the inner side of the conductive negative plate are corresponding, so that smoothness of the air duct at the inner side, cooling of the inner sides of the conductive positive plate and the conductive negative plate and cooling of the inner side of the generator are ensured.
The beneficial effects of the invention are as follows: the bidirectional air inlet is adopted, reliable insulation of the conductive positive plate and the conductive negative plate is guaranteed, temperature gradient on the plates is uniform, reliability of spot welding is guaranteed, shaking space of the stator wire is reduced, requirements of different output directions of customers can be met, power and product reliability of the generator are improved, and overall service life of the efficient generator is prolonged.
Drawings
The invention will be further described with reference to the accompanying drawings and examples.
FIG. 1 is a schematic diagram of a conventional internal twelve-pipe rectifier;
FIG. 2 is a schematic diagram of a conventional end cap negative plate twelve-pipe rectifier;
FIG. 3 is a schematic diagram of a twelve-tube rectifier with a heat dissipation structure of a negative plate attached to an end cover;
FIG. 4 is a schematic side view of the assembled whole of the present invention;
FIG. 5 is a schematic view of the front appearance of the assembled whole of the present invention;
FIG. 6 is a schematic view of the assembly of the present invention with the plastic boot removed;
FIG. 7 is a schematic diagram of a forward looking rectifier according to the present invention;
fig. 8 is a schematic diagram showing the reverse appearance of the rectifier according to the present invention.
Fig. 9 is an exploded view of the rectifier of the present invention.
In the figure: 1. positive output screw, 2, conductive positive plate, 3, busing bridge bracket, 4, rectifier diode, 5, conductive negative plate, 6, insulating bushing, 7, intermediate support insulating bracket, 8, end cap negative plate, 9, generator rear mounting cover, 10, plastic boot, 11, radial V-shaped duct, 12, generator rear mounting cover support boss, 13, inner axial duct, 14, outer axial duct, 15, open plastic protective tube, 16, tubular rivet, 17, bracket end plastic boot snap, 18, bus bar, 19, stator wire connection threads, 20, web heat dissipating tooth, 21, protruding ribs, 22, busing tab, 23, inner duct I, 24, conductive negative plate back, 25, heat dissipating tooth, 26, conductive negative plate V-shaped duct, 27, inner duct II, 28, plate outer duct, 29, diode mounting hole I, 30, conductive positive plate B+ screw hole, 31.
Detailed Description
As shown in fig. 4, 5, 6, 7, 8 and 9: the invention comprises a conductive negative plate 5, an intermediate support insulating bracket 7, a conductive positive plate 2, a busbar bracket 3, a positive output screw 1, a rectifier diode 4, tubular rivets 16, a generator rear fixing cover 9, a generator rear fixing cover support boss 12 and a plastic protective cover 10. The rectifier diode 4 converts alternating current into direct current, the conductive negative plate 5 and the conductive positive plate 2 play roles of fixing the rectifier diode, conducting and radiating, the bus bridge bracket 3 is connected with a stator wire to be connected, the positive output screw 1 outputs current to the outside, the generator rear cover support boss 12 supports the fixed rectifier, and the plastic protection cover 10 protects the rectifier and adjusts the generator air duct. The middle support insulating bracket 7 is arranged between the conductive positive plate 2 and the conductive negative plate 5 instead of the insulating bushing 6, an open type plastic protection tube 15 is arranged at the stator wire interface of the middle support insulating bracket 7, the open type plastic protection tube 15 is of a step shape, and the upper opening is larger. The conductive negative plate 5 is arranged below the rectifier and is fixedly connected with the rear fixed cover support boss 12 of the generator, the lower edge of the plastic protective cover 10 is flush with the upper edge of the conductive negative plate 5, an inner axial air duct 13 and an outer axial air duct 14 are arranged on the plastic protective cover 10, when the generator works, the conductive positive plate 2 dissipates heat through air inlet of the inner axial air duct 13 and the outer axial air duct 14 of the forward plastic protective cover 10, the front surface and the inner side of the conductive negative plate 5 dissipate heat through air flow of the conductive positive plate 2, and the back surface 24 of the conductive negative plate 5 dissipates heat through the conductive negative plate 5 and the surface of the rear fixed cover 9 of the generator to form a radial V-shaped air duct 26; the inner air duct I23 of the conductive positive plate, the inner air duct II 27 of the conductive negative plate 5 and the inner axial air duct 13 of the plastic protecting cover 10 correspond. An outer air duct 28 is arranged on the conductive positive plate 2, web radiating teeth 20 are arranged on the inner side of the conductive positive plate 2, radiating ribs are arranged on the web radiating teeth 20, and B+ screw holes 30 and six rectifier diode mounting holes I29 are die-cast on the conductive positive plate 2. Two rectifier diodes 4 are arranged outside the conductive positive plate 2, four rectifier diodes 4 are arranged inside the conductive positive plate 2, the four rectifier diodes 4 inside are close to web radiating teeth 20, and two B+ output interfaces are arranged on the inner side of the conductive positive plate 2.
The conductive negative plate 5 and the rear fixed cover 9 of the generator are not attached to each other for heat dissipation, and heat dissipation teeth 25 are arranged on the back surface of the conductive negative plate. Six diode mounting holes II 31 are formed in the outer three and the inner three of the conductive negative plate 5 in a die-casting mode; three rectifying diodes 4 are arranged on the outer portion of the conductive negative plate 5, three rectifying diodes 4 are arranged on the inner portion of the conductive negative plate, the distance is relatively uniform, and radiating teeth 25 are arranged on the periphery of the conductive negative plate.
The busbar bracket 3 is injection-molded together with the M5 nut through the busbar 18 to form the stator wire connecting screw 19, the busbar 18 is bent and provided with a busbar soldering lug 22, and the busbar 18 of the busbar bracket 3 and the rectifier diode lead wire are connected by single-sided spot welding. The busbar bracket 3 is arranged above the conductive positive plate 2 and is horizontally connected and fixed with the connecting screw thread 19 of the stator wire of the generator.
The radial V-shaped air duct 11 is used for cooling the back surface of the conductive negative plate 5 and the rear fixed cover 9 of the generator, and the inner axial air duct 13 of the protective cover is used for cooling the inner side and the front surface of the conductive positive plate 2 and the conductive negative plate 5.
The inner axial air duct 13 of the plastic protective cover 10 is the same as the inner air duct I23 of the conductive positive plate 5 and the inner air duct II 27 of the conductive negative plate, and other air ducts are arranged on the outer side.
The inner side of the plastic protection cover 10 is fixed by adopting two B+ output points, and the outer side of the plastic protection cover is fixed by adopting a plastic buckle formed with the outer edge of the mounting hole of the bus bridge bracket, so that the air duct cannot deviate during product assembly.
An assembly method of a high-efficiency flat wire generator rectifier comprises the following steps: is realized by the following steps:
firstly, developing a die-casting conductive positive plate 2, wherein when a die is formed, inner side web radiating teeth 20 are die-cast to form a positive plate inner side air duct 23; the outer side of the conductive positive plate is provided with an outer air duct 28, the outer side of the conductive positive plate is provided with an outer diode hole 29 and an inner diode hole 29 in a die casting mode, and a conductive positive plate B+ screw hole 30 is formed in the die casting mode; simultaneously, six mounting holes are die-cast, and the die-cast diode holes I29 and the die-cast B+ screw holes 30 are required to be machined to ensure the sizes.
Secondly, developing a die-casting conductive negative plate 5, wherein the back surface 24 of the conductive negative plate is provided with conductive negative plate radiating teeth 25 to form a radial V-shaped air duct 26, and the inner side of the conductive negative plate is provided with a conductive negative plate inner side air duct 27 when the die-casting conductive negative plate is formed; simultaneously, six diode holes II 31 are formed in the outer three and the inner three in a die-casting mode, and six mounting holes are formed in the die-casting mode;
secondly, developing an injection molding middle support insulating bracket 7, wherein an open type plastic protection pipe 15 is formed during mold forming, and the open type plastic protection pipe is in a step shape;
(IV) developing a stamping forming bus bar 18, bending a bus bar soldering lug 22, and using extrusion forming bus bar soldering lug ribs 21 before bending and forming the soldering lug;
(V) developing an injection molding bus bar bracket 3, injecting together with the M5 nut by using the bus bar 18 to form stator wire connecting threads 19, and simultaneously forming a bracket end plastic protection cover buckle 17 and six mounting holes;
secondly, developing an injection molding plastic protective cover 10, forming an inner axial air duct 13 of the protective cover and an outer axial air duct 14 of the protective cover, simultaneously injecting two conductive sheets to be matched with a rectifier B+ screw, and forming two inverted buckles on the outer side to be matched with a bracket end plastic protective cover buckle 17;
(seventh) using the developed conductive positive plate 2, using a press-fitting jig, press-fitting six positive plate rectifying diodes 4 and two positive output screws 1 onto the conductive positive plate 2 to form a positive plate assembly;
(eight) using the developed conductive negative plate 5, using a press-fitting jig, press-fitting 6 conductive negative plate rectifying diodes 4 onto the conductive negative plate 5 to form a negative plate assembly;
(nine) assembling the positive plate assembly, the negative plate assembly, the middle insulating support 17 and the bus bar support 3 together, wherein 3 mounting holes are riveted into a whole by three tubular rivets 16, and then welding the lead wires of the rectifier diode 4 onto bus bar welding pieces 22 of the bus bar support 3 by using a resistance welder, so that welding points are formed between the lead wires of the rectifier diode and bus bar welding point ribs 21 to form a current loop, thereby forming a rectifier;
and (ten) assembling the rectifier to a support boss 12 of a rear cover of the generator, so that the conductive negative plate 5 and the rear cover 9 of the generator are fixed to form a radial V-shaped air duct 11, locking the rectifier to the rear cover of the generator by using 6 fixing screws, installing the regulator, assembling the developed plastic protection cover 10 on the rectifier, assembling two points with a B+ screw rod together, and forming inverted fastening and fixing by two outer side buckles with a bracket end plastic protection cover buckle 17. The lower surface of the plastic protective cover 10 on the rectifier side is flush with the upper surface of the conductive negative plate 5, so that the radial V-shaped air duct 11 is ensured to be unblocked; the axial air duct 13 on the inner side of the forward protective cover, the air duct I23 on the inner side of the conductive positive plate 2 and the air duct 27 II on the inner side of the conductive negative plate are corresponding, so that smoothness of the air ducts on the inner side, cooling of the inner sides of the conductive positive plate 2 and the conductive negative plate 5 and cooling of the inside of the generator are ensured.
Claims (10)
1. The utility model provides a high-efficient flat wire generator rectifier structure, including electrically conductive negative plate, middle support insulating support, electrically conductive positive plate, the bridge support that converges, positive pole output screw rod, rectifier diode, tubular rivet, generator rear fixed cover supports boss and plastic protection cover, rectifier diode turns alternating current into direct current, electrically conductive negative plate, electrically conductive positive plate play fixed rectifier diode, electrically conductive and heat dissipation, the bridge support that converges connects the stator line and converges, positive pole output screw rod is to the external output current, generator rear cover supports the boss and supports fixed rectifier, plastic protection cover protects the rectifier and adjusts the generator wind channel; the method is characterized in that: the middle support insulating bracket replaces an insulating bushing, is arranged between the conductive negative plate and the conductive positive plate, and is provided with an open type plastic protection pipe at the stator wire interface of the middle support insulating bracket, wherein the open type plastic protection pipe is in a step shape, and the upper opening is larger; the electric conduction negative plate is arranged below the rectifier and is fixedly connected with the support boss of the rear fixing cover of the generator, the lower edge of the plastic protective cover is flush with the upper edge of the electric conduction negative plate, an inner side axial air duct and an outer side axial air duct are arranged on the plastic protective cover, when the generator works, the electric conduction positive plate performs air intake and heat dissipation through the inner side axial air duct and the outer side through axial air duct of the forward plastic protective cover, the front side and the inner side of the electric conduction negative plate perform air flow heat dissipation through the electric conduction positive plate, and the back side of the electric conduction negative plate forms radial V-shaped air duct heat dissipation through the electric conduction negative plate and the surface of the rear fixing cover of the generator; the inner side air duct I of the conductive positive plate, the inner side air duct II of the conductive negative plate and the inner side axial air duct of the plastic protective cover correspond to each other; an outer air duct is arranged on the conductive positive plate, web radiating teeth are arranged on the inner side of the conductive positive plate, radiating ribs are arranged on the web radiating teeth, and B+ screw holes and six rectifier diode mounting holes I are die-cast on the conductive positive plate; two rectifier diodes are arranged outside the conductive positive plate, four rectifier diodes are arranged inside the conductive positive plate, the four rectifier diodes inside are close to web radiating teeth, and two B+ output interfaces are arranged on the inner side of the conductive positive plate; the conductive negative plate and the motor rear fixing cover are not attached to each other for heat dissipation, heat dissipation teeth are arranged on the back surface of the conductive negative plate, and six diode mounting holes II, namely an outer three diode mounting hole and an inner three diode mounting hole, are formed in the conductive negative plate in a die-casting mode; three rectifying diodes are arranged outside the conductive negative plate, three rectifying diodes are arranged inside the conductive negative plate, the space is relatively uniform, and radiating teeth are arranged around the conductive negative plate; the bus bridge bracket is injection molded together through a bus bar and an M5 nut to form a stator wire connecting thread, a bus bar welding piece is bent on the bus bar, and the bus bar of the bus bridge frame is connected with a rectifier diode lead wire by single-sided spot welding; the busbar bridge bracket is arranged above the conductive positive plate and is horizontally connected and fixed with the stator wire connecting threads of the generator.
2. A high efficiency flat wire generator rectifier structure as in claim 1, wherein: the radial V-shaped air duct air inlet cooling conductive negative plate back and generator rear fixing cover, and the axial air duct air inlet inside the protective cover cools the conductive positive plate and the conductive negative plate inside and front.
3. A high efficiency flat wire generator rectifier structure as in claim 1, wherein: the inner side axial air duct of the plastic protective cover is the same as the inner side air duct I of the conductive positive plate and the inner side air duct II of the conductive negative plate, and other air ducts are arranged on the outer side; the inner side of the plastic protection cover is fixed by adopting two B+ output points, and the outer side of the plastic protection cover is fixed by adopting a plastic buckle formed with the outer edge of the mounting hole of the bus bridge bracket.
4. A high efficiency flat wire generator rectifier structure as in claim 1, wherein: the conductive positive plate is subjected to air inlet and heat dissipation through the axial air duct of the forward plastic protective cover and the axial air duct at the outer side, the air duct at the inner side of the conductive positive plate corresponds to the axial air duct at the inner side of the protective cover, and the heat dissipation ribs on the heat dissipation teeth of the web plate of the conductive positive plate extend to the periphery of the diode hole of the rectifier under the condition that the product installation and assembly process are not affected.
5. A high efficiency flat wire generator rectifier structure as in claim 1, wherein: the heat dissipation teeth on the back of the conductive negative plate are in an emission-shaped V shape, and a V-shaped air channel is formed under the condition that the product installation and assembly process is not affected; the front and the inner side of the conductive negative plate dissipate heat through axial wind; the inner side air channel of the conductive negative plate corresponds to the inner side axial air channel of the plastic protective cover.
6. A high efficiency flat wire generator rectifier structure as in claim 1, wherein: the single-side spot welding position of the bus bar of the bus bridge bracket is provided with a convex rib, the convex rib is arc-shaped and convex, and the height of the convex rib is 0.3mm.
7. A high efficiency flat wire generator rectifier structure as in claim 1, wherein: the bus bar of the bus bridge support and the rectifier diode are in spot welding in the tangential direction, the connecting thread of the bus bridge support and the stator wire is M5, a plastic support injection nut structure is adopted, and a vent hole is formed in the bus bridge support, so that the axial wind flow can cool the conductive positive plate.
8. A high efficiency flat wire generator rectifier structure as in claim 1, wherein: and the bus bar welding sheet on the bus bridge bracket is parallel to the radius direction of the rectifier diode hole.
9. A high efficiency flat wire generator rectifier structure as in claim 1, wherein: and the bus bar of the bus bridge bracket is connected with the lead of the rectifier diode by adopting resistance welding.
10. The method of assembling a high efficiency flat wire generator rectifier of claim 1 wherein: is realized by the following steps:
firstly, developing a die-casting conductive positive plate, wherein when a die is formed, inner side web type radiating teeth are die-cast to form an inner side air duct of the positive plate; the outer side of the conductive positive plate is provided with an outer air duct, the outer side of the conductive positive plate is provided with an outer second diode hole and an inner fourth diode hole in a die casting mode, and then a conductive positive plate B+ screw hole is formed in the die casting mode; simultaneously, six mounting holes are die-cast, and the die-cast diode holes and the B+ screw holes are required to be machined to ensure the sizes;
secondly, developing a die-casting conductive negative plate, wherein the back surface of the conductive negative plate is provided with conductive negative plate radiating teeth to form a radial V-shaped air duct, and the inner side of the conductive negative plate is provided with an inner side air duct; simultaneously, six diode holes are formed in the outer three and the inner three in a die-casting mode; simultaneously, six mounting holes are die-cast;
secondly, developing an injection molding middle support insulating bracket, wherein an open type plastic protection pipe is formed during mold forming, and the open type plastic protection pipe is in a step shape;
fourthly, developing a stamping forming bus bar, wherein a bus bar soldering lug is bent on the stamping forming bus bar, and before the soldering lug is bent and formed, extruding forming bus bar soldering joint convex ribs;
fifthly, developing an injection molding bus bridge bracket, injecting together with the M5 nut by using the bus bar to form a stator wire connecting thread, and simultaneously forming a bracket end plastic protection cover buckle and six mounting holes;
secondly, developing an injection molding plastic protective cover, wherein an inner axial air duct of the protective cover and an outer axial air duct of the protective cover are formed during molding, simultaneously, two conductive sheets are injection molded to be matched with a rectifier B+ screw rod, and two inverted buckles are formed on the outer side to be matched with the plastic protective cover at the support end in a buckling manner;
seventhly, using the developed conductive positive plate, and using a press-fitting fixture to press-fit six positive rectifying diodes and two positive output screws onto the conductive positive plate to form a positive plate assembly;
(eight) using the developed conductive negative plate, and using a press-fitting fixture to press-fit six negative rectifying diodes onto the conductive negative plate to form a negative plate assembly;
assembling the positive plate component, the negative plate component, the middle support insulating bracket and the bus bridge bracket together, wherein three mounting holes are riveted into a whole by three tubular rivets, and then welding the rectifier diode lead wire to a bus bar welding piece of the bus bridge bracket by using a resistance welder, so that the rectifier diode lead wire and a bus bar welding point convex rib form a welding point to form a current loop, thereby forming a rectifier;
(ten) assembling the rectifier on a support boss of a rear fixing cover of the generator, so that a radial V-shaped air duct is formed by the conductive negative plate and the rear fixing cover of the generator, locking the rectifier on a rear end cover of the generator by using six fixing screws, installing the regulator, assembling a developed plastic protection cover on the rectifier, assembling two points with a B+ screw rod together, and forming inverted buckle fixation by two outer buckles with the plastic protection cover at the support end; the side lower surface of the rectifier of the plastic protective cover is flush with the upper surface of the conductive negative plate, so that the smoothness of the radial V-shaped air duct is ensured; the axial air duct at the inner side of the forward protective cover, the air duct at the inner side of the conductive positive plate and the air duct at the inner side of the conductive negative plate are corresponding, so that smoothness of the air duct at the inner side, cooling of the inner sides of the conductive positive plate and the conductive negative plate and cooling of the inner side of the generator are ensured.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN109067095B (en) * | 2018-09-12 | 2019-11-29 | 浙江安美德汽车配件有限公司 | A kind of rectifier bridge rear cover integral structure |
| CN116345801B (en) * | 2023-04-06 | 2023-10-27 | 江苏绿能汽配科技有限公司 | Rectifier bridge support of automobile generator |
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