Improvement Design of 5kW Passenger Car Generator Liu Baoming\Li Lipeng2, Wu Shaoping3(1Sifang Vehicle Research Institute,Qingdao,Shandong 266031;2.Taiyuan Railway Bureau,Taiyuan 030013,Shanxi;3.Fuzhou Depot of Shanghai Railway Administration,Fuzhou 350013,Fujian) . This article briefly introduces the main technical performance and application of the improved 5kWf generator (KFT-2).

Type 2; Technical Performance; Application: U270.38+1: B 1 The Necessity of Improvement A successful trial product is an AC brushless three-phase motor because it does not have a contact commutation problem, and the maintenance workload is small. However, it is welcomed by users. However, as the main component of the shaft drive power supply, the defects of the KFh1 generator are also obvious. Especially after the speed increase of the train, the problem is more prominent, and the technical improvement is urgently needed. 1.1 The design flaws are due to The limitations of time, technical materials and craftsmanship, etc., the design of the KFTi 1 generator basically depends on the design theory and parameters of the three-phase asynchronous motor, such as its stator punching and J02-614 asynchronous motor punching almost In fact, AC induction motor is a kind of pulsed magnetic field motor. Its flux utilization rate is about half that of ordinary three-phase generator. Different principles, nature should use different design methods and calculation methods Type 1 5kW generator has problems such as high quality, low electromagnetic utilization, low efficiency, excessive temperature rise, excessive excitation current, etc. Improvement measures, but not fully implemented. 1.2 Problems in actual use Due to high temperature rise, unsatisfactory output characteristics, plus problems with the power supply system itself, motor burnout often occurs during actual operation. The angle of the pulley is too small. The phenomenon of belt shedding occurs as the train speeds up. This phenomenon is numerous. Even the belt wear is too large and the phenomenon of smoking is of high quality. The speed of the train running in the speed-increasing train is affected, even though it is on the bogie frame of the suspended generator. Reinforcement measures were taken, but cracks in the bogie frames still occurred, and even electricity occurred: 2001-12-19 Due to the increase in the speed of the train, the bearing of the generator was seriously damaged, and there were many “broom” failures that affected the generators. The timing of rejection 2 has matured. 2.1 The technology reserves are fully utilized during the use of the KFTi1 generator. More in-depth research In 1988, Sifang Vehicle Research Institute improved the design of 5 kW generator (typed as KFT|1A, but there is no mass production and promotion) to improve the electrical performance of the generator and reduce the manufacturing cost. The improved 5kW The generator has not only been greatly improved in electrical performance, but also its quality has been reduced to 155kg (quality of the old motor is 169kg). In 1992, the successful experience of the KFT-1A generator design by the Quartet was provided for the export of Myanmar buses. More than 200 KFTi3 type 3kW induction generators, whose performance indicators and quality have reached the international advanced level 2.2 Support of new technologies, new materials and new processes With the help of computer-aided design, the design of AC induction generators can be more apt Reasonable, more convenient calculations and improved performance of quasi-sulfur magnetic and conductive materials also provide a material basis for a significant weight reduction of a 5 kW generator.

The design of Type 2 5kW generator (1) must be matched with the original shaft drive power supply system; (2) The structure and working principle must be consistent with the K FT-1 type generator already mastered by the site; (3) Do not change the motor Axial length and hanging structure; (4) Electrical performance is improved compared with KFT-1 type and meets the iron standard; (5) Reasonable electromagnetic design, motor quality is greatly reduced, its main parameters and comparison with other 5kW generators See Table 1 Table 1 Main Parameters of Various 5kW Bus Generators Model Power/kW Stator Outer Diameter/mm Small Slot Number Excitation Small Slot Number Current Density/(A.mm-2) Thermal Load Excitation Current/Armature Winding Temperature l/K field winding temperature rise/K voltage regulation % Body Material Ductile Iron Cast Steel Quality/kg From the data comparison in Table 1, it can be seen that the quality of the KFTi2 generator is greatly reduced, with a reduction of over 22% and electrical performance Increased 4 Instructions for use The axial length and mounting method of the 2kW 5kW generator is identical to that of the KFTi1. The structural principle of the motor is also consistent. The Type 2A control box is matched so that it can be well connected with the original system and is easy to grasp on site. The main problems in use are described as follows: 4.1 Generator pulley Large generator pulley diameter (125mm for the KFh1 generator pulley and 160mm for the KFh 2 pulley), which is beneficial for the operation of the generator: First, the pulley is large After that, at the same speed, the actual speed of the generator is reduced, which is beneficial to the operation of the motor bearings. For example, the corresponding speed of the 850 1 generator is about 42km/h, and the corresponding speed of the KFh2 generator is about 53km/hr. h; Second, the belt pulley angle of the ambassador of the pulley diameter is increased. After reducing the phenomenon of belt shedding and belt grinding, the average running speed of most trains is above 60 km/h. Therefore, increasing the pulley diameter will not affect System work. In fact, some roads had replaced the KFh1 generator's pulleys with 160mm before 2a. However, the effect was more obvious. However, for short-haul or suburban trains, the pulleys should remain unchanged. The rotor of the KFH2 generator is 8 teeth. That is, the generator is an 8-pole motor. With the large diameter of the pulley, it is necessary to pay attention to the measurement of the actual rotation speed of the generator when debugging with the KPi2A control box.

4.2 The speed of the generator's electrification 1 type generator due to the surplus of magnetic field design, the effective mass of the iron core, the remanence of the generator is more, the starting speed is low, generally 400r/min~500r/min can be As for the KFr2 generator, since the effective mass of the iron core is reduced by a lot, compared with the KFh1 generator, the remanence is small and the starting speed is slightly improved. When the KP-2A control box is used for the magnetizing current, it is generally When electrified at 500r/min~600r/min, after the train speeds up, the speed of electrification is slightly increased, which will not affect the work of the power supply system. In addition, since the remanence of the new motor is less, if the direction of the magnetizing current and remanence On the contrary, when used for the first time, the speed of the electrification may be higher, but as long as the generator generates electricity, the remanence and the direction of the magnetization are straightened, and the speed of the generator should be stable within the allowable range. Of course, an appropriate large magnetizing current can also reduce the speed of the generator, but considering the need to adjust the control box that has already been used, this approach should be avoided.

4.3 Temperature rise of the generator As the generator volume is reduced and the machine body is thinned, the temperature increase rate of the body is faster than that of the KFT-1 generator in the initial stage of the temperature rise test, and the time for achieving stable temperature rise is relatively shortened.

5 Concluding remarks The improved design of the Type 2 5 kW generator, with the aid of advanced computer-aided design, the application of relatively good motor manufacturing materials, has achieved the intended purpose and has now passed technical review and is being applied.

(Editor: He Fang) Subscription Information "Railway Vehicles" Booklet Addendum 1999 (25.5m air-conditioned double-decker bus operation 10th-anniversary album) Price: 10.00 yuan 2000 Supplement (City Rail Vehicle Symposium Album) Price: 10.00 yuan 2001 ) One per year, unit price: more than 100.00 yuan has included postage, welcome to units and individuals to purchase, letter, incoming money, please send the "railway vehicle" Editorial Department Address: No. 231, Ruichang Road, Qingdao City, Zip Code: 266031 next issue and new Breakthrough (continued) Overview of dynamic detection methods for wheel flat files Application of industrial modeling and aerodynamics in the design of streamlined trains Key points High-speed train steel lightweight body design Research on the dynamic parameters test method for truck bogies Export Australia Introduction of Freight Car Braking System Development of Diffusive Alumina Powder Tanker

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