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Improved design of 5kW passenger car generator Liu Baoming\Li Lipeng 2, Wu Shaoping 3 (1 Quartet Vehicle Research Institute, Qingdao 266031, Shandong; 2. Taiyuan Railway Branch, Taiyuan 030013, Shanxi; 3. Fuzhou Depot of Shanghai Railway Bureau, Fuzhou 350013, China) . This paper briefly introduces the main technical performance and application description of the improved 5kWf generator (KFT-2).
Type 2; technical performance; Application: U270.38+1: B 1 Improvement of the necessity of successful trial production, is an AC brushless three-phase motor because it does not have contact reversing problem, and the maintenance workload is small, However, it is very popular among users. However, as the main component of the shaft drive power supply, the defects of the KFh1 generator are obvious. Especially after the train speed is increased, the problem is more prominent, and the technical improvement is urgently needed. The limitation of time, technical materials and technology, the design of KFTi 1 generator basically depends on the design theory and parameters of three-phase asynchronous motor, such as its stator punch and J02-614 asynchronous motor. Consistently and in fact, the AC induction motor is a pulsating magnetic field motor with a magnetic flux utilization ratio that is about half that of a conventional three-phase generator. Different principles, naturally should use different design methods and calculation methods. Type 1 5kW generators have problems such as high quality, low electromagnetic utilization, low efficiency, excessive temperature rise, excessive excitation current, etc., although many problems have been proposed. Improvement measures, but not fully implemented 1.2 Problems in actual use Due to high temperature rise, unsatisfactory output characteristics, and the problem of the power supply system itself, the phenomenon of motor burnout often occurs in actual operation. The wrap angle of the pulley is too small, often The phenomenon of belt falling off occurs with the speed of the train. This phenomenon is common. Even the phenomenon of excessive belt wear and smoke is high. The quality of the speed-increasing train is safely operated in the speed-increasing train, even on the steering frame of the suspended generator. Reinforcement measures were taken, but there was still a crack in the bogie frame, and even electricity occurred: 2001-12-19 due to the increase of train speed, the bearing damage of the generator was serious, and the "broom" had many faults, which affected the generator.甩2 improvement time is ripe 2.1 technical reserves are fully used in the use of KFTi1 type generators, the majority of car electricians carry out More in-depth study in 1988, the Quartet Institute of vehicles on the 5 kW generator improved design (stereotyped as KFT | 1A, but there is no mass production and promotion), in order to improve the electrical performance of the generator and to reduce manufacturing costs improved after 5kW The generator has not only been greatly improved in electrical performance but also its quality has been reduced to 155kg (the quality of the old motor is 169kg). In 1992, the successful experience of the KFT-1A generator design by the Quartet provided the export of Myanmar buses. More than 200 KFTi3 3kW induction sub-generators, whose performance indicators and quality have reached the advanced level of foreign countries 2.2 New technologies, new materials and new technology support With the help of computer-aided design, the design of AC induction generators can be more inclined reasonable, and more convenient calculation and improve the registration sulfur magnetically conductive material is also a significant weight loss performance 5 kW generator provides the material basis.
Design Type 2 5kW generator (1) must be matched with the original power shaft drive system; (2) the structure and working principle has been mastered to coincide field generator K FT-1; (3) does not change the motor The axial length and hanging structure; (4) the electrical performance is improved compared with the KFT-1 type and meets the iron standard; (5) the electromagnetic design is reasonable, the motor quality has greatly reduced its main parameters and compared with other 5kW generators. See Table 1 Table 1 Main parameters of various 5kW passenger car generators Model power / kW stator outer diameter / mm small slot number excitation small slot number current density / (A.mm-2) thermal load excitation current / A armature winding temperatureå‡/K excitation winding temperature rise / K voltage adjustment rate % body material ductile iron cast steel quality / kg From the data comparison of Table 1, it can be seen that the quality of the KFTi2 type generator has been greatly reduced, the reduction is over 22% and the electrical performance is also It is improved. 4 Instructions for use The axial length and installation method of the 2 kW generator are exactly the same as those of the KFTi1. The structure of the motor is also the same, and it can be combined with KI! The 2A type control box is matched, so it can be well connected with the original system, which is convenient for on-site mastery. The main problems in use as follows: diameter of alternator pulley 4.1 alternator pulley (KFh1 generator pulley diameter of 125mm, type 160mm diameter pulley KFh 2), advantageously the operation of the generator: First, a large pulley After that, at the same speed, the actual speed of the generator is reduced, which is beneficial to the operation of the motor bearing. For example, the speed of the 850 1 generator is about 42km/h, and the speed of the KFh2 generator is about 53km/ h; Second, the pulley diameter of the belt wrap angle ambassador added, reducing the shedding phenomenon belts and belt grinding whipped speed, the average speed trains are most at 60 km / h or more, therefore, does not affect the increase pulley diameter The work of the system. In fact, some road bureaus have replaced the pulley of KFh1 generator with 160mm before 2a, and the effect is relatively pregnant. However, for short-distance or suburban trains, the pulley should remain unchanged. The rotor of KFh2 generator is 8 teeth. That is, the generator is an 8-pole motor, and the diameter of the pulley is large. When debugging with the KPi2A control box, pay attention to the measurement of the actual speed of the generator.
4.2 Generator's starting speed 1 type generator Due to the large amount of magnetic field design, the effective mass of the iron core is large, so that the residual magnetism of the generator is more, and the starting speed is low, generally 400r/min~500r/min. The electric power of the KFr2 generator is much reduced due to the effective mass of the iron core. Therefore, compared with the KFh1 type generator, the residual magnetism is small, the electrification speed is slightly improved, and the magnetic flux of the KP-2A control box is not large. When starting from 500r/min~600r/min, the speed of the train will increase slightly after the train speed increases, which will not affect the work of the power supply system. In addition, because the remanence of the new motor is less, if the direction of the magnetizing current and remanence On the contrary, when the initial matching is used, the starting speed of the electrification may be higher, but as long as the generator generates electricity, the remanence and magnetic flux directions are smoothed, and the generator's electrification speed should be stable within the allowable range. Of course, a proper large magnetic flux can also reduce the starting speed of the generator, but considering the need to adjust the control box already in use, this method should be avoided as much as possible.
4.3 Temperature rise of the generator As the volume of the generator is reduced, the body is thinned. At the initial stage of the temperature rise test, the temperature rise rate of the body is faster than that of the KFT-1 type generator, and the time to reach the temperature rise is relatively shortened.
Improved design type 5 Conclusion 2 5 kW generator, using advanced computer-aided design, the application of relatively good motor manufacturing materials to achieve the desired objective has now passed the technical assessment, it is promoting the application.
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