WO2019061127A1

WO2019061127A1 - Axle-end generator assembly, wheel set and bogie

Info

Publication number: WO2019061127A1
Application number: PCT/CN2017/103893
Authority: WO
Inventors: Ganjun ZHU; Ran GUAN; Eduard Aul; Zhihui PAN
Original assignee: Schaeffler Technologies AG & Co. KG
Priority date: 2017-09-28
Filing date: 2017-09-28
Publication date: 2019-04-04

Abstract

An axle-end generator assembly is provided. The axle-end generator assembly comprises a tubular rotor (3) with a chamber (35) defined therein, the tubular rotor (3) comprising a first end and a second end, the first end being configured to be mounted at an axle end of an axle (1) to rotate with the axle (1), and a stator (4) located in the chamber (35) for at least its main part, the stator (4) being fixed by a fixing means such that rotation of the stator (4) with the tubular rotor (3) is prevented, wherein the fixing means is fed though the second end of the tubular rotor (3).

Description

AXLE-END GENERATOR ASSEMBLY, WHEEL SET AND BOGIE

FIELD

This disclosure relates to an axle-end generator assembly, a wheel set and a bogie.

RELATED ART

Railway freight wagons used to have no electric power supplier, because in the past few electrical applications were implemented on railway freight wagons.

However, with the development of the railway freight wagons, more sensors and mechatronics parts are implemented on the freight wagons, and the electric power solution becomes a critical demand.

A disc type permanent magnet generator has been proposed as the electric power supplier for railway freight wagons. The disc type generator is an easy-mounting, reliable and economical power supply solution for railway applications. The disc type generator can be mounted onto a wagon bogie via fitting to an axle box, which is robust in the operation condition.

The disc type generator has a rotor and a stator. The rotor is mounted to an axle end, and thus the generator can also be called as an axle-end generator. The stator of the axle-end generator needs to be mounted to a stable and strong position, and in addition, the mounting position should have precisely controlled manufacturing tolerance and assembly tolerance.

The axle box is a perfect position to mount the stator. The stator can be screwed on four corners of the axle box, and thus a stable operation condition is obtained.

However, most wagon bogies have no axle box structure, instead, they use conventional adapter. The conventional adapter gives a big challenge to the railway axle-end generator, because the stator can only be fixed on the adapter at one side (the upper side of the stator) . The asymmetric mounting structure results inevitable vibration and drifting of the stator, and thus the railway generator may be easily damaged.

Furthermore, the conventional adapter is attached to the axle usually by a bearing and retainer rings (for example, a backing ring and seal wear rings) , and thus a big assembly tolerance appears. It follows that a big play exists in the axial direction, which adds difficulties in the axle-end generator mounting, especially for the disc type generator.

SUMMARY

In view of the above condition, this disclosure provides an axle-end generator assembly, a wheel set and a bogie.

This disclosure provides an axle-end generator assembly comprising

a tubular rotor with a chamber defined therein, the tubular rotor comprising a first end and a second end, the first end being configured to be mounted at an axle end of an axle to rotate with that axle, and

a stator located in the chamber for at least its main part, the stator being fixed by a fixing means such that rotation of the stator with the tubular rotor is prevented,

wherein the fixing means is fed though the second end of the tubular rotor.

In at least one embodiment of this disclosure, the tubular rotor comprises a tube-shaped element and magnets mounted on an inner circumferential surface of the tube-shaped element, and the stator comprises at least one coil.

In at least one embodiment of this disclosure, the tubular rotor comprises a tube-shaped element and at least one coil mounted on an inner circumferential surface of the tube-shaped element, and the stator comprises magnets.

In at least one embodiment of this disclosure, slots are formed in the inner circumferential surface of the tube-shaped element, the magnets being partly mounted in the slots respectively.

In at least one embodiment of this disclosure, the axle-end generator assembly further comprises a first cover, the tube-shaped element of the tubular rotor being mounted on the axle end via the first cover.

In at least one embodiment of this disclosure, the stator comprises a core made of material comprising magnetic permeability and the at least one coil wound on the core at an outer portion of the core.

In at least one embodiment of this disclosure, the stator further comprises a shaft extending beyond the core in an axial direction of the generator for connecting with the fixing means.

In at least one embodiment of this disclosure, a part of the fixing means extends into the tube-shaped element and fixes the stator.

In at least one embodiment of this disclosure, the axle-end generator assembly further comprises a first cover and a second cover mounted on ends of the tubular rotor in an axial direction of the generator respectively, and the stator is supported at a center position of the tubular rotor by at least one of the axle-end surface, the first cover and the second cover, in such a way that rotation of the first and/or second covers together with the tubular rotor is permitted.

In at least one embodiment of this disclosure, at least one of the first cover and the second cover has a hole, the stator is configured to extend through or into the hole.

In at least one embodiment of this disclosure, the stator is supported on at least one of the axle-end surface, the first cover and the second cover by a bearing and/or a bush.

In at least one embodiment of this disclosure, the tubular rotor is located at the center of the tube-shaped element.

In at least one embodiment of this disclosure, a valid length of the stator is different from that of the magnets in an axial direction of the generator.

In at least one embodiment of this disclosure, a part of the stator with the valid length covers the magnets in the axial direction.

In at least one embodiment of this disclosure, the valid length which covers the magnets in the axial direction is larger than that of the magnets by 6 cm to 10 cm.

In at least one embodiment of this disclosure, extension of the magnets is in a range of extension of the coil in an axial direction of the generator.

In at least one embodiment of this disclosure, the axle-end generator assembly further comprises an adapter being stationary relative to an axle having two axle ends, the tubular rotor is mounted on at least one of the axle ends to rotate with the axle, and the stator is fixed by the fixing means connecting with the adapter such that rotation of the stator with the tubular rotor is prevented.

In at least one embodiment of this disclosure, the fixing means comprises a supporting bar fixing the stator and a connecting bar connecting the supporting bar to the adapter.

In at least one embodiment of this disclosure, two supporting bar are connected with the adapter by two connecting bars, respectively.

In at least one embodiment of this disclosure, the two connecting bars extend parallel with each other and the two supporting bars form a V shape structure when seen in an axial direction of the generator.

In at least one embodiment of this disclosure, the supporting bar fixes a shaft extending beyond a core of the stator.

In at least one embodiment of this disclosure, the axle-end generator assembly is a railway axle-end generator assembly.

In at least one embodiment of this disclosure, the adapter mounted on the axle though a bearing.

In at least one embodiment of this disclosure, the adapter surrounds part of the axle in a circumferential direction.

This disclosure also provides a wheel set comprising an axle having two axle ends and at least one axle-end generator assembly described herein, wherein the axle-end generator assembly is mounted to at least one of the axle ends.

This disclosure also provides a bogie comprising at least two wheel sets, wherein at least one wheel set is configured according to this disclosure.

Further features of this disclosure will become apparent from the following description of exemplary embodiments with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1A schematically shows a railway axle-end generator assembly in this disclosure, which is seen in an axial direction of an axle.

Fig. 1B schematically shows the railway axle-end generator assembly in Fig. 1A, which is a cross section view in the axial direction passing through a supporting bar.

List of reference numbers

1 axle

2 adapter

3 rotor

31 tube-shaped element

32 magnet

33 first cover

331 hole

34 second cover

35 chamber

341 hole

4 stator

41 core

42 coil

43 shaft

51 connecting bar

53, 54 supporting bar

6, 7 bearing

X length of the magnet

Y length of the coil

N North pole

S South pole

DESCRIPTION OF THE EMBODIMENTS

The following describes in detail preferable exemplary embodiments of this disclosure with reference to the attached drawings.

This embodiment provides a solution to mount a railway axle-end generator onto a wagon bogie which has no axle box structure. In this mounting structure for the railway axle-end generator, the conventional adapter is used.

As shown in Figs. 1A and 1 B, it provides an axle-end generator assembly in which a tubular rotor 3 surrounds a stator 4.

The tubular rotor (hereinafter referring simply as rotor) 3 has a tube-shaped element 31 with a chamber 35 defined therein. The rotor 3 has a first end and a second end, the first end being mounted on an axle end of an axle 1 such that the rotor 3 can rotate with the axle 1. The rotor 3 further has magnets 32 mounted on an inner circumferential surface of the tube-shaped element 31.

The magnets 32 are mounted to the inner circumferential surface of the tube-shaped element 31 at even interval in a circumferential direction of the tube-shaped element 31. To enhance the mounting strength of the magnets 32, slots can be formed in the tube-shaped element 31, and at least a part of each of the magnets 32 is inserted in each of the slots. Adhesive can also be used to glue the magnets 32 in the slots.

As shown by the North pole (N) and the South pole (S) in Fig. 1B, the magnets 32 are magnetized in a radial direction of the tube-shaped element 31. The magnets 32 can also have a curved inner surface towards the stator 4 and a curved outer surface towards the tube-shaped element 31.

The axle-end generator assembly has two

covers

33, 34 mounted on the first end and the second end of the rotor 3, respectively, to be specific, on two ends of the tube-shaped element 31 in an axial direction of the axle 1. The tube-shaped element 31 is mounted on the axle end via the first cover 33.

The first cover 33 and the second cover 34 have a shape of ring.

Holes

331 and 341 are formed at centers of the first cover 33 and the second cover 34 respectively. The first cover 33 may be mounted on the axle end of the axle 1 by for example screws. The first cover 33 can also be configured to press against a bearing (not shown) surrounding the axle 1. The two covers 33, 34 and the tube-shaped element 31 are mounted to each other by for example screws. The first cover 33 and the tube-shaped element 31 can also be formed by one piece.

The stator 4 has a core 41 made of permeability material, a coil 42 wound on the core 41 at an outer portion of the core 41, and a shaft 43 extending beyond the core 41 in the axial direction. The shaft 43 and the core 41 can also be formed by one piece.

The stator 4 is inserted into the chamber 35 of tube-shaped element 31. The second cover 34 can protect the core 41, the coil 42, and the inner structure of the rotor 3 (that is, the magnets 32) . The magnets 32 are disposed around the coil 42 and an air gap appears between the magnets 32 and the coil 42.

One end of the stator 4, to be specific, one end of the shaft 43 penetrates or is supported in the first cover 33, in such a manner that rotation of the first cover 33 (the axle 1) relative to the shaft 43 (stator 4) is permitted. The other end of the stator 4, to be specific, the other end of the shaft 43, penetrates or is supported in the second cover 34, in such a manner that rotation of the second cover 34 (the axle 1) relative to the shaft 43 (stator 4) is permitted. In the case that the shaft 43 is supported by the first cover 33 and/or the second cover 34, the supporting strength of the stator 4 can be enhanced.

It is obvious that the one end of the shaft 43 can also be supported by the axle-end surface of the axle 1.

In one example,

bearings

6 and 7 for supporting the shaft 43 in the first cover 33 and the second cover 34 are mounted in the

holes

331 and 341. It is obvious that the

bearings

6 and 7 can also be substituted by bushes or other similar members.

To prevent the stator 4 from rotating with the rotor 3, the other end of the stator 4, to be specific, the other end of the shaft 43 is fixed by a fixing means fed though the second end of the rotor 3.

The fixing means comprises two supporting

bars

53, 54 and two connecting bars. The supporting bar 53 is connected to the adapter 2 that is stationary relative to the axle 1 at least in the axial direction and the radial direction of the axle 1 by a connecting bar 51 (of course, the axle 1 can rotate relative to the adapter 2) , and the supporting bar 54 is connected to the adapter 2 by another connecting bar not shown in the figures. The two supporting

bars

53, 54 extend in the radial direction and connect the shaft 43 to the adapter 2. The two connecting bars preferably extend parallel with each other. As seen in the axial direction, the two supporting

bars

53, 54 forms a V shape structure, and the shaft 43 can be supported by the supporting

bars

53, 54 stably.

In one example, the coil 42 has a length Y which is 6 cm to 10 cm longer than a length X of the magnets 32, this gives a sufferance to manufacturing tolerance and assembly tolerance and the play. In one example, the coil 42 or the magnets 32 may have a length in the range of 3 cm to 50 cm.

It is obvious that the length X of the magnets 32 can also be longer than the length Y of the coil 42.

In one example, the air gap between the coil 42 and the magnets 32 is 0.8 cm to 1.2 cm, this gives a sufferance to manufacturing tolerance and assembly tolerance and the play.

This axle-end generator assembly can be applied to current bogie and avoid the modification thereof.

It is obvious that the present solution can also be applied to an axle box structure, in which the rotor is mounted to the axle end and rotates together with the axle, and the stator is fixed on a cover for the axle box. In such a structure, the shaft of the stator can also be supported by the rotor, in such a manner that rotation of the rotor (the axle) relative to the shaft (stator) is permitted.

As compared with for example the disc type generator in the prior art, the following advantages can be obtained by the present embodiment.

1. The generator in this embodiment can be easily and stably mounted to the bogie with adapter, and also the bogie with an axle box；

2. The generator in this embodiment has a sufferance to manufacturing tolerance and assembly tolerance and a play in axial direction.

It is obvious that this disclosure is not limited to the railway axle-end generator, and the solutions and concepts of this disclosure can also be applied to other similar applications.

It is obvious that the screw can be substituted by for example a bolt, a fastener, a rivet, and a mixture thereof. Bonding by adhesive or welding can also be used in the present disclosure.

It is obvious that this disclosure is not limited to that the rotor comprises magnets and the stator comprises a coil. The condition that the rotor comprises a coil and the stator comprises magnets is also possible.

It is obvious that this disclosure is not limited to that the shaft of the stator extends beyond the second cover and is fixed by the supporting bar. The condition that a part of the fixing means extends into the tube-shaped element and fixes the stator is also possible.

The expression “the fixing means is fed though the second end of the tubular rotor” can be understood as the fixing means can fix or connect with the stator 4 though the second end of the rotor 3, and includes at least a condition that a part of the stator 4 extends beyond the second end of the rotor 3 and is fixed by the fixing means and a condition that a part of the fixing means extends into the second end of the rotor 3 and fixes the stator 4.

It is preferred that a valid length of the stator is different from that of the magnets in the axial direction, and a part of the stator with the valid length covers the magnets in the axial direction. The valid length can be interpreted as the length of the coil.

While this disclosure has been described with reference to exemplary embodiments, it is to be understood that this disclosure is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.

Claims

An axle-end generator assembly comprising

a tubular rotor with a chamber defined therein, the tubular rotor comprising a first end and a second end, the first end being configured to be mounted at an axle end of an axle to rotate with that axle, and

a stator located in the chamber for at least its main part, the stator being fixed by a fixing means such that rotation of the stator with the tubular rotor is prevented,

wherein the fixing means is fed though the second end of the tubular rotor.
The axle-end generator assembly according to claim 1, wherein the tubular rotor comprises a tube-shaped element and magnets mounted on an inner circumferential surface of the tube-shaped element, and the stator comprises at least one coil.
The axle-end generator assembly according to claim 1, wherein the tubular rotor comprises a tube-shaped element and at least one coil mounted on an inner circumferential surface of the tube-shaped element, and the stator comprises magnets.
The axle-end generator assembly according to claim 2, wherein slots are formed in the inner circumferential surface of the tube-shaped element, the magnets being partly mounted in the slots respectively.
The axle-end generator assembly according to any of the preceding claims, wherein the axle-end generator assembly further comprises a first cover, the tube-shaped element of the tubular rotor being mounted on the axle end via the first cover.
The axle-end generator assembly according to claim 2 or 4, wherein the stator comprises a core made of material comprising magnetic permeability and the at least one coil wound on the core at an outer portion of the core.
The axle-end generator assembly according to any of the preceding claims, wherein the stator further comprises a shaft extending beyond the core in an axial direction of the generator for connecting with the fixing means.
The axle-end generator assembly according to any of the preceding claims, wherein a part of the fixing means extends into the tube-shaped element and fixes the stator.
The axle-end generator assembly according to any of the preceding claims, wherein the axle-end generator assembly further comprises a first cover and a second cover mounted on ends of the tubular rotor in an axial direction of the generator respectively, and the stator is supported at a center position of the tubular rotor by at least one of the axle-end surface, the first cover and the second cover, in such a way that rotation of the first and/or second covers together with the tubular rotor is permitted.
The axle-end generator assembly according to any of the preceding claims, wherein at least one of the first cover and the second cover has a hole, the stator is configured to extend through or into the hole.
The axle-end generator assembly according to any of the preceding claims, wherein the stator is supported on at least one of the axle-end surface, the first cover and the second cover by a bearing and/or a bush.
The axle-end generator assembly according to any of the preceding claims, wherein the tubular rotor is located at the center of the tube-shaped element.
The axle-end generator assembly according to any of the preceding claims, wherein a valid length of the stator is different from that of the magnets in an axial direction of the generator.
The axle-end generator assembly according to any of the preceding claims, wherein a part of the stator with the valid length covers the magnets in the axial direction.
The axle-end generator assembly according to any of the preceding claims, wherein the valid length which covers the magnets in the axial direction is larger than that of the magnets by 6 cm to 10 cm.
The axle-end generator assembly according to any of the preceding claims, wherein extension of the magnets is in a range of extension of the coil in an axial direction of the generator.
The axle-end generator assembly according to any of the preceding claims, wherein the axle-end generator assembly further comprises an adapter being stationary relative to an axle having two axle ends, the tubular rotor is mounted on at least one of the axle ends to rotate with the axle, and the stator is fixed by the fixing means connecting with the adapter such that rotation of the stator with the tubular rotor is prevented.
The axle-end generator assembly according to any of the preceding claims, wherein the fixing means comprises a supporting bar fixing the stator and a connecting bar connecting the supporting bar to the adapter.
The axle-end generator assembly according to any of the preceding claims, wherein two supporting bar are connected with the adapter by two connecting bars, respectively.
The axle-end generator assembly according to any of the preceding claims, wherein the two connecting bars extend parallel with each other and the two supporting bars form a V shape structure when seen in an axial direction of the generator.
The axle-end generator assembly according to any of the preceding claims, wherein the supporting bar fixes a shaft extending beyond a core of the stator.
The axle-end generator assembly according to any of the preceding claims, wherein the axle-end generator assembly is a railway axle-end generator assembly.
The axle-end generator assembly according to any of the preceding claims, wherein the adapter mounted on the axle though a bearing.
The axle-end generator assembly according to any of the preceding claims, wherein the adapter surrounds part of the axle in a circumferential direction.
A wheel set comprising an axle having two axle ends and at least one axle-end generator assembly according to any of the preceding claims, wherein the axle-end generator assembly is mounted to at least one of the axle ends.
A bogie comprising at least two wheel sets, wherein at least one wheel set is configured according to the preceding claim.