JP2927288B2 - AC generator for vehicles - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicular alternator driven by an internal combustion engine of a vehicle, and more particularly to a vehicular alternator mounted on a passenger car, truck or the like.

[0002]

2. Description of the Related Art As engine rooms have become increasingly smaller in recent years due to the need for slant nose to reduce vehicle running resistance and the need to secure interior space inside the vehicle, there is room for mounting space for vehicle alternators. It's gone. on the other hand,
In order to improve fuel efficiency, the engine speed has been reduced and the vehicle alternator has also been reduced. However, on the other hand, an increase in the electric load of the safety control device and the like is required, and an improvement in the power generation capacity is increasingly required. That is, there is a demand for providing a small, high-output vehicle alternator at low cost.

[0003] In recent years, engine noise has been increasingly reduced in recent years due to social demands for reducing noise outside the vehicle and the aim of improving the productiveness by improving the quietness of the interior of the vehicle. The fan noise and the magnetic noise of the airplane have become easy to hear. Conventionally, stator windings commonly used in vehicle alternators are:
A configuration in which a continuous wire is attached to the stator core is adopted,
Under such a stator winding configuration, various improvements have been proposed in order to meet the above demands of small size, high output, and low noise.

[0004] For example, as disclosed in Japanese Patent Application Laid-Open No. 7-303351, the winding can be shortened from the viewpoint of reducing the winding resistance in order to reduce the size and increase the output, and the phases of the winding are reduced. There is a 2 / 3π short-section winding technique of winding so as not to interfere in the radial direction. However, there is a problem that the winding coefficient is greatly deteriorated and the power generation voltage is significantly reduced, and furthermore, there is a problem that the winding operation becomes difficult.

[0005] Techniques have been proposed in which coil ends that interfere with each other at the time of winding are preformed, or only the coil ends are made thin, but winding work is difficult and the winding resistance value increases. Furthermore, in such a winding technique, the interference of the coil ends is not fundamentally solved, and the coil is biased in the slot in the slot, and the half of the cross-section that can be geometrically accommodated is obtained.
Only the following parts could be stored, preventing low resistance. Also, due to the deviation in the slot, the coil shape of each phase is different, so that the resistance and inductance of the windings are not uniform, and the current flow of each phase is deviated, and the performance due to local temperature rise There was also a problem that deterioration and magnetic noise increased.

For example, a coil end is formed into a flat shape to improve ventilation.
No. 159,638 is known. However, in such a configuration, sufficient cooling performance cannot be obtained due to the high ventilation resistance at the coil end, and noise reduction cannot be satisfied. Furthermore, there is a method for improving the magnetic flux by reducing the air gap between the rotor and the stator in order to reduce the size and increase the output. However, it is necessary to increase the stator core cross-sectional area by an amount corresponding to the increase in the magnetic flux, and the compression of the slot area increases the winding resistance, so that the effect of improving the output hardly occurs. That is, the balance between the iron core and the windings constituting the stator is important.

[0007] Even if it is possible to obtain a constant output improvement effect by optimizing the design values of the iron core cross-sectional area and the windings, there still remains a problem of cooling the coil end which is a heat source.
For example, in order to cool through the insulating coating film and the fixing material on the surface of the electric conductor, it is necessary to enlarge the fan and to blow air close to the fan. However, in the conventional winding, the coil end becomes uneven due to the interference between phases, so that high-order fan noise increases. In the current situation where noise is easily heard as described above, in order to solve this, for example, the inner surface of the coil end facing the fan is made an ideal smooth surface by a complicated winding process, or the air volume is reduced at the expense of fan efficiency. It was necessary to reduce the noise by dropping it.

Further, when pursuing a compact and high output, there is a problem that the magnetic force acting between the rotor and the stator also increases and the magnetic noise increases. Generally, a vehicle alternator has a rectifier and cuts an output voltage to charge a battery of a constant voltage, so that the generated voltage becomes a rectangular wave. For this reason, it is known that the spatial harmonic of the air gap between the stator and the rotor contains many third harmonic components, and a magnetic force having the square frequency component is generated between the stator and the rotor. It is known to work on and produce magnetic pulsation. As a countermeasure against this magnetic noise, for example, as shown in Japanese Patent Application Laid-Open No. Hei 4-26345, two sets of three-phase windings shifted by a position having an electrical phase difference of 30 ° are adopted.
There is also known a technique for canceling the magnetic pulsation by mutually combining these outputs. However, in addition to the interference of the coil end caused by the conventional winding shape, these techniques have twice as many outputs. The need for slots necessitates careful winding of each of the thin windings, leading to more difficult problems. That is, there has been a problem that the device becomes more obvious when the size and output are increased.

As described above, it has been difficult for a stator winding formed by winding a continuous wire, which has been widely used in automotive alternators, to meet mutually contradictory requirements such as small size, high output and low noise. On the other hand, in a generator of a general large induction machine type or the like, for example, two conductors in the stator slot are formed, two layers are formed in the radial direction, and the conductors of different phases are connected by alternately connecting the conductors of the inner and outer layers. Some have eliminated interference.

However, there is a problem that such a device cannot be used as it is for a vehicle generator. That is,
A vehicle alternator must supply power to the vehicle electrical load at idle speeds where the engine is the slowest, i.e., around 1500 rpm generator speed. For this purpose, the rotation speed, that is, a voltage obtained by adding a battery voltage and a diode drop at about 1500 rpm or less, is about 15
V must be generated. However, ordinary passenger cars,
In a 1-2 kW class vehicle alternator for a truck or the like, mainly due to the restriction of the amount of magnetic flux determined by the physical size, in the structure as seen in the general large-sized generator described above, You cannot get the output of when. In particular, it was difficult to obtain an output at a low rotation speed with a small number of conductors of about two, which is found in the above-mentioned general large-sized generator. Furthermore, the idling speed has tended to be reduced in order to improve fuel efficiency in recent years, and the structure of the above-mentioned general large-sized generator has become more and more inadequate.

As one means for improving the output at a low rotation speed, it is conceivable to operate at a high frequency by increasing the number of poles. A silent rotor is used. In such a silent rotor, when the number of magnetic poles is increased, the winding space in the rotor is reduced, so that the magnetomotive force of each magnetic pole is reduced, so that it is difficult to improve the output. That is, it is difficult to satisfy the performance required for the above-described vehicle alternator.

Further, in the silent type rotor, it is difficult to provide a gap inside the rotor. There is a cooling problem that the cooling air cannot be introduced. Further, U-shaped electric conductors called conductor bars or the like are used to constitute a stator winding of an automotive alternator.
-274335 and JP-A-64-5340 have been proposed. However, in such a configuration, since the stator core is formed in a cylindrical shape by being laminated along the circumferential direction, the magnetic resistance increases in the magnetic flux passing direction, and required performance cannot be realized. In addition, there are many problems to be solved, such as securing practical strength.

[0013] WO92 / 06527 also proposes a configuration in which a conductor bar is used for a stator of an automotive alternator. According to the configuration shown here, four electric conductors are arranged in a square in one slot. In such a configuration, if the cross section of the electric conductor is increased to reduce the electric resistance value to increase the output, a gap cannot be provided between the coil ends. Further, it is also difficult to form a gap between each of the joints with the electric conductors from the other slots at the ends of the coil ends of the two electric conductors in one slot arranged in the circumferential direction. However, there is also a problem that the short circuit is likely to occur.

In order to cool the automotive alternator, a ventilation structure having a cooling fan outside the frame and flowing cooling air in the axial direction has been adopted in the past. The mainstream configuration has a cooling fan and directs cooling air to the coil end. Under such a cooling structure, in the structure of the prior art electric conductor as described above,
If the cross-sectional area of the electric conductor is increased to increase the output, there is a problem that high cooling performance cannot be obtained.

That is, in the configuration shown in WO92 / 06527, since the cross-sectional area of the electric conductor is restricted, it is difficult to increase the space factor of the stator for high output. On the other hand, a configuration in which two electric conductors are provided in one slot to form a gap is also conceivable, but with such a small number of conductors, it is impossible to obtain an output at idle rotation, that is, at low rotation. It cannot be used as a vehicle alternator.

Furthermore, US Pat. No. 2,289,963 proposes an AC generator having a rundle type field rotor using a conductor bar as a stator. However, this prior art does not disclose the configuration of the stator winding for achieving high output and high cooling performance. In addition, the configuration disclosed in this prior art is a configuration having no ventilation structure in the axial direction or having a cooling fan, and no improvement has been taken with respect to the improvement of cooling performance for miniaturization and high output. Furthermore, in the configuration disclosed herein, the number of conductors per slot is two, and it is difficult to obtain an output at a low rotation as described above.

[0017]

SUMMARY OF THE INVENTION In view of the above-mentioned problems of the prior art, the present invention provides an improved vehicle having a high practicality that can satisfy the performance required of today's automotive alternators. It is an object to provide an AC generator for use. Another object of the present invention is to provide a vehicle alternator having both small size, high output, and low noise.

Still another object of the present invention is to provide a structure of a rotor and a stator winding capable of securing an output from a low-speed rotation required for an AC generator for a vehicle, and a novel coil end of the stator winding. By providing the configuration for cooling, it is possible to secure the high output required for the vehicle alternator,
In addition, it is an object of the present invention to provide an automotive alternator in which a decrease in efficiency and a decrease in output due to heat generation are suppressed.

Still another object of the present invention is to improve the space factor of the stator winding in the slot, while providing high cooling performance and low noise outside the slot by cooperation with the rotor. It is an object of the present invention to provide a vehicle alternator capable of exhibiting the following. Still another object of the present invention is to provide an automotive alternator that suppresses a local rise in the temperature of a stator winding and further suppresses the generation of magnetic noise.

[0020]

In order to achieve the above object, a field rotor which alternately forms NS poles along the circumferential direction of rotation, a stator core arranged opposite to the rotor, and In a vehicle alternator having a stator having a multi-phase stator winding mounted on a stator core, and a frame supporting the rotor and the stator, the field rotor includes the N pole And a rundle-shaped core having a plurality of claw-shaped magnetic poles for providing the S pole, wherein the stator core includes a laminated core formed with a plurality of slots extending through a laminated plate; lines, comprising a plurality of conductor segments, the plurality of conductor segments are, within said slot, said arrayed form a pair or more pairs as the inner and outer layers with respect to the depth direction of the slot, insulated from each other within said slot Is accommodated Te, in outside the slots are arranged extending out to the end surface of the stator core, away corresponds to the NS magnetic pole pitch of the rotor
A coil end is formed by a connection pattern that connects different layers in the interposed slot in series, and as a result, a coil end group that mainly repeats the connection pattern is formed on the end face side of the stator core. The plurality of conductor segments at the coil end are arranged so as to extend in a direction intersecting with the ventilation direction of the cooling air in the frame, and are arranged so as to be separated from each other , across the plurality of conductor segments at the coil end. A configuration is provided in which cooling air flows, wherein the plurality of slots are provided.
Are spaced according to the magnetic pole pitch of the field rotor.
Multiple slots as a group of slots for one phase,
A first slot group consisting of a slot group of
Second slot set shifted by a predetermined electrical angle from one slot set
It includes the door, the multi-phase stator windings, the first Ro
A plurality of slots contained in the slot group included in the slot set
The first winding is formed by the conductor segment, and
A plurality of slots accommodated in the slot group included in the two-slot group
A number of said conductor segments form a second winding;
A plurality of the slot groups included in the first slot set
An output of the accommodated multiphase first winding and a second slot.
The number of slots accommodated in the plurality of slot groups included in the
A technical means is adopted in which the output of the second winding of the phase is combined and output .

Thus, the NS magnetic pole pitch of the rotor
By adopting a connection pattern in which two conductor segments arranged as different layers in different slots corresponding to each other are connected in series, a conductor segment forming a predetermined layer in one slot and another slot Are connected in series with a conductor segment forming a layer different from the predetermined layer. As a result, interference between the coil ends of each phase can be suppressed, and the space of the stator winding can be increased, so that the output can be improved. Further, since the inside of the coil end cooling air traverses, remarkably effective surface area is increased relative to the coil end of a conventional stator winding, the conductor of this portion segment
It is possible to dramatically improve the bets cooling, it is possible to higher output. In addition, since the conductor length and leakage inductance of the stator winding of each phase due to the position in the slot of the conductor segment are equalized, the current flowing through the stator winding is equalized, and the heat generation amount of each phase is equalized. Is also the same. Therefore, local heat generation of the stator winding and magnetomotive force imbalance can be prevented, and the temperature can be reduced and the noise can be reduced. Furthermore, since the coil end has no irregularities and a uniform repetitive pattern is formed, and since the cooling wind crosses the inside of the coil end,
Noise generated with the cooling air can also be reduced. Further, since the combination with the Landel-type rotor is used, it is easy to change the number of poles and increase the number of poles only by changing the shape of the iron core (hereinafter referred to as a pole core). In addition, the claw-shaped magnetic pole has centrifugal resistance,
In addition, since the field coil can be securely attached to the boss at the center of the pole core, the centrifugal resistance of the rotor can be ensured, and operation can be performed at a rotation ratio of two to three times the engine speed.

That is, unlike a general induction machine or the like, since it can operate at a high frequency, even if the number of electric conductors per slot is small, power is generated from a low speed such as 1000 rpm, which is lower than 1500 rpm corresponding to the vehicle idle speed. Can start. In addition, since the combination with the Landel type rotor is used, a space can be provided between the magnetic poles, and an advantage in cooling the field coil can be obtained. Further, the magnetic pole itself may be configured to send cooling air by rotation. Such a configuration can be used for air blowing in the axial direction or air blowing in the radial direction. Therefore, as compared with a solid type rotor having a solid cylindrical shape with no space between magnetic poles, which is used in a general induction machine, etc., the stator inner peripheral surface, the stator winding, It can cool magnetic coils and the like. Note that the space between the magnetic poles of the Landel type rotor may be filled with a non-magnetic material.

Further, the plurality of slots may include
Slots that are separated according to the pole pitch of the trochanter
As a group of slots for one phase,
A first slot set, and further from the first slot set.
And a second set of slots offset by a constant electrical angle.
The multi-phase stator windings are included in the first set of slots.
The plurality of conductor segments accommodated in the slot group
Thus, a first winding is formed and included in the second slot set.
A plurality of the conductor segments accommodated in the slot group
And a second winding is formed by the first slot set.
Before the multiphase housed in the plurality of slot groups included in
The output of the first winding and a plurality of outputs included in the second slot set.
The outputs of the multi-phase second windings accommodated in the number of the slot groups are combined and output. The windings having the same output phase refer to windings having electromotive forces having the same electrical phase. Thus, by connecting the conductor segments arranged in the same slot and inducing a common-mode electromotive force in series,
High output can be secured. Further, in the first slot set,
The plurality of slots contained in the plurality of slots
An output of the first winding and a plurality of outputs included in the second slot set
, The output as a composite value of the output of the polyphase second winding accommodated in the slot group of the first winding and the second winding.
Even when the output of each winding is relatively small, a high output can be ensured. For example, a configuration in which the first winding and the second winding are directly connected in series or in parallel to combine their outputs, or after the outputs of the first winding and the second winding are separately rectified, It is possible to adopt a configuration in which these outputs are combined by connecting them in series or in parallel.

The stator and the rotor output a voltage of 15 (V) or more to the winding end when the rotational speed of the engine that drives the rotor is within the idling rotational speed range. It is desirable that they are set as follows.
According to this, it is possible to supply electric power to the minimum necessary electric load of the vehicle even at the time of idling rotation, which occurs most frequently in traveling in an urban area. Therefore, when there is a demand for more than the power that can be supplied at the time of idling rotation, power is also supplied from the battery. It is possible to quickly return to the original state. Further, even when the idling speed is reduced, the fuel cell system has the above-described power generation performance, so that fuel efficiency can be improved.

The electric conductor housed in one slot and another electric conductor housed in another slot close to the one slot are a part of a stator winding of the same output phase. A configuration in which they are arranged in series may be adopted. In such a configuration, one AC output is output as a composite value of two AC outputs having different phases. For this reason, even when the output obtained from the electric conductor accommodated in one slot is relatively small, a higher output can be ensured by the output as the composite value. In particular, in the configuration in which the electric conductors are arranged and accommodated in a layer in the slot, the number of electric conductors accommodated in the slot is limited, and the output value of the same phase is limited. The required output can be obtained by compensating for such a defect. Therefore, the effect of improving the space factor in the slot and the effect of improving the cooling performance at the coil end can be realized while compensating for a decrease in output.

Incidentally, the winding structure is such that the N
A first slot group including a plurality of slots spaced apart corresponding to the S magnetic pole pitch, and a second slot group disposed adjacent to the first slot group; said conductor segments accommodated connected in series constituting said first winding, the conductor segments accommodated in the second slot group are connected in series to constitute the second winding Can be realized.

The slots are arranged at an interval of about 30 ° in electrical angle, and are arranged before being stored in the plurality of slots.
Among the conductor segments, the conductor segments are housed in the slots of the first slot group which are separated from each other by the magnetic pole pitch.
The conductor segments are electrically connected in series to each other to form a first series conductor group as the first winding, and each of the second slot groups adjacent to the first slot group has The stored conductor segment
Are electrically connected in series with each other to form a second series conductor group as the second winding, and the first series conductor group and the second series conductor group are connected in series to form a three-phase winding. Without
A configuration in which the winding end is connected to a rectifier may be employed.

According to this, among the conductors housed in the plurality of slots provided at an electrical angle of about 30 °, the conductors housed in the slots which are separated from each other by the magnetic pole pitch are connected in series. Are electrically connected to each other to form a first series conductor group, so that all the electric conductors generate electromotive voltages having the same phase and are arithmetically added, so that the power generation per electric conductor length is the highest. . Further, conductors housed in adjacent slots whose phases are closest to the electromotive voltage phase of the first series conductor group also form the second series conductor group, and similarly high power generation is obtained. Then, since the first series conductor group and the second series conductor group are connected in series to form one phase, they are vector-added, and the electromotive voltage per length becomes the highest as a whole. Moreover, since the slot spacing is approximately 30 ° in electrical angle as described above, the electrical angle between the first conductor group and the second conductor group adjacent to the first conductor group is approximately 30 °, and the magnetic pulsation which causes magnetic noise is generated. The force is reduced. Therefore, there is an effect of reducing magnetic noise. The electrical angle of about 30 ° is in the range of 29 ° to 31 °, and within this range, there is a sufficient effect for reducing the magnetic pulsation.

[0029] Further , a first rectifier for rectifying and outputting the AC output of the first winding and a second rectifier for rectifying and outputting the AC output of the second winding are provided. A configuration may be adopted in which the rectified output and the rectified output of the second rectifier are combined and output.

With this configuration, the low output of only the first winding or only the second winding can be compensated.
The winding structure includes a first slot group including a plurality of slots spaced apart corresponding to the NS magnetic pole pitch of the rotor, and a second slot group disposed adjacent to the first slot group. And the conductor segments accommodated in the first slot group are connected in series to form the first winding, and the conductor segments accommodated in the second slot group are included.
This can be realized by connecting the conductor segments in series to form the second winding.

The rectifier has two sets of rectifiers, and the slots are arranged at an interval of about 30 ° in electrical angle, and the conductor segments housed in the plurality of slots are separated from each other by a magnetic pole pitch. The conductor segments accommodated in each slot of the first slot group are electrically connected in series to each other to form a first series conductor group, and each of the second slot groups adjacent to the first slot group is connected. None the second series conductor groups conductor segments to each other housed in the slot is electrically connected in series to each other, the three further independently is with these first series conductor group and the second series conductor group
No phase windings, the output of each of the three-phase windings may be adopted that is connected to each of the rectifiers.

With such a configuration, the first series conductor group and the second series conductor group are formed. Then, in this configuration, the outputs of the conductor groups are rectified independently of each other and combined as necessary. Therefore, effects such as high output and low magnetic noise can be obtained. Further, when the outer diameter of the claw-shaped magnetic pole of the Landel-type iron core is L1 and the length in the rotation axis direction is L2, the ratio of these is represented by L1 / L2 ≧
It is desirably 1.5.

In such a configuration, L1 is limited due to the centrifugal resistance problem of the field-type coil and the like, and L2 is increased as a magnetic resistance reduction means for increasing the output.
While the ratio L1 / L2 is set to be relatively small, the centrifugal resistance of the Landel type rotor is superior to the centrifugal rotor, and the ratio L1 / L2 is set to 1.5 or more. . In this case, there is also an effect that the area for taking in cooling air from outside in the axial direction due to the rotation is increased, the amount of cooling air can be increased, and the cooling performance can be improved.

It is preferable that a plurality of the conductor segments accommodated in one slot are arranged only in a depth direction of the slot. According to such a configuration, the conductor is provided outside the slot.
All of the segments can be separated in the radial direction of the stator, so that multiple coil ends in the coil end group can be prevented from adhering to each other, facilitating ventilation through the coil end group and improving cooling. Thus, noise due to interference between the cooling air and the coil end can be reduced.

It is preferable that all conductor segments electrically insulated in the slot are spatially separated from each other at coil ends formed at ends of the stator core. According to such a configuration, all the conductor segments are favorably cooled at the coil ends, and there is no variation in the cooling performance between the conductor segments , and uniform cooling can be obtained. Also,
At least one of the iron core tips located on both sides of the slot
Part of the slot is plastically deformed, and the opening on the inner peripheral side of the slot
The width is formed narrower than the distance between the inner walls in the slot
May be adopted. According to such a configuration, iron
Conductor segment in slot during plastic deformation of core tip
Is pushed further into the slot from the radially inner side.
Higher space factor can be achieved. Furthermore, the teeth of the stator core
Sufficient fixing increases the rigidity of the iron core and increases the stator iron core
Vibration can be suppressed, reducing magnetic noise
Wear. Also, by making the entrance narrower than the distance between the inner walls
Eliminates wedges and other locking members, reducing costs
Noh. Further processing by plastically processing the tooth tip
Due to the hardening, even when using rigid conductor segments
Does not jump out in the direction. In addition, such a configuration
It can be used regardless of the cross-sectional shape inside the slot.
Wear. However, the cross-sectional shape of the slot
It is desirable to use a parallel slot having a constant width. this
Even if the inner conductor and outer conductor have the same shape,
High space factor without gaps in lots
It is possible.

It is preferable that the conductor segment adopt a configuration in which a cross-sectional shape in the slot is substantially rectangular along the slot shape. According to such a configuration, it is easy to increase the space factor of the conductor segment in the slot. In addition, since the shape is substantially rectangular along the slot shape, there is an effect that heat transfer from the conductor segment to the stator core can be improved. In addition, as the substantially rectangular shape, it is important that the cross-sectional shape conforms to the shape in the slot, and in addition to a shape such as a square and a rectangle,
A shape composed of four planes and rounded corners, an elliptical shape in which the short side of a rectangle is circular, and the like can be used. In addition,
By using a square or a rectangle, the space factor in the slot can be improved. Also, a small guide cross-sectional area
For body segments , oval shapes may be used. The conductor segment having such a cross-sectional shape can be formed by pressing an electric conductor having a circular cross-section.

Further, the plurality of conductor segments are formed of a bare metal member, and the plurality of conductor segments are formed in the slots.
With a mutual conductor segments, the electrical insulation member which provides electrical insulation is interposed and between said plurality of conductor segments <br/> inner wall surface of the slot, the plurality of the conductor Se
A configuration may be adopted in which the segments are spaced apart from each other outside the slot.

According to this, the insulating film of the conductor segment can be eliminated, and the material cost can be greatly reduced. Further, the production process can be greatly simplified, for example, the conductor segments can be pressed without considering the damage of the insulating film, and the cost can be reduced. In addition, since the heat-resistant temperature of the stator winding can be increased by eliminating the insulating film having the lowest heat-resistant temperature in the past, there is also an effect of improving the reliability against heat generation. Further, the total length in the axial direction of the stator including the stator core and the conductor segments housed in the slots,
A configuration that is equal to or less than the total axial length of the field rotor may be employed. According to such a configuration, the stators that are short in the axial direction with respect to the rotor are arranged, so that these arrangements can be oval. For this reason, an egg-shaped generator outer shell including the frame can be provided, and the mounting space can be reduced, and magnetic noise can be reduced by improving mechanical strength.

[0039]

[0040]

Further, a configuration may be adopted in which at least a part of the portion of the conductor segment located outside the slot is substantially flat. According to such a configuration, the heat radiation area from the conductor segment in the coil end portion can be increased. Furthermore, by adopting a flat shape for each of the plurality of coil ends and arranging them in parallel with the radial direction, a gap between the coil ends can be secured, and furthermore, the ventilation resistance in the radial direction can be reduced. The conductor segments may be partially formed into a flat shape, or may be entirely flat outside the slots. Further, the entire structure including the inside of the slot may be formed to have a flat cross-sectional shape. As the flat shape, a rectangular cross section, an oblong cross section, or the like can be adopted.

Further, a configuration may be adopted in which a magnet is interposed between the magnetic poles of the field rotor, and a magnet magnetic flux is added to the field magnetic flux so as to be directed to the stator. According to such a configuration, it is possible to obtain effects such as high output and high efficiency by improving the performance of the Landel type field rotor. Moreover, such an effect can be sufficiently obtained by the effect of improving the heat dissipation by improving the stator winding without losing the effect due to the loss on the stator side.

Preferably, the plurality of conductor segments in the coil end adopt a configuration in which almost all of their surfaces are exposed to the cooling air.
According to this configuration, high cooling performance can be achieved for all conductor segments.
It can be uniformly exerted against the instrument. In addition,
Such a configuration is a configuration in which conductor segments are arranged only in the radial direction in a slot, a configuration in which conductor segments are bare wires and are insulated by spatially separating them, or a configuration in which a rectangular conductor segment is employed outside the slot. Under the combination of the above, the advantage of manufacturing that it can be realized relatively easily and the advantage that it can realize higher cooling performance are exhibited.

The coil end groups are formed at both ends of the stator core, respectively, and two cooling air passages are formed in the frame corresponding to the respective coil end groups. It is desirable to adopt a configuration in which According to such a configuration, the two coil end groups are reliably cooled by the respective ventilation paths. In addition, since the electric conductors in the coil end group are cooled by the cooling air passing therethrough, the cooling reduces the loss and efficiency problems due to heat, and further reduces noise problems. Reduce. In addition, it is desirable to provide a blower for generating cooling air in the frame.

With this configuration, the flow of the cooling air can be reliably generated in the frame, and the coil end can be reliably cooled. In addition, as the blowing means,
In addition to providing a dedicated cooling fan, a configuration utilizing the shape of a Randell-type field rotor can be employed. Further, in the configuration employing the blowing means, it is desirable to adopt a configuration in which the frame has ventilation holes for cooling air flowing across the conductor segments , corresponding to the coil ends.

According to such a configuration, the cooling air flowing across the conductor segments can be flowed efficiently. In this configuration, when the coil end groups are formed on both sides of the stator core, it is desirable that ventilation holes are provided corresponding to the respective coil end groups. Further, the blowing means is provided at an axial end of the field rotor, blows outward in a centrifugal direction by rotation of the field rotor, and blows the plurality of conductor segments at the coil end. It is desirable to employ a configuration including a blowing means for generating a cooling wind flowing across.

According to this configuration, the air blowing means is arranged close to the inside of the coil end group of the stator, and the cooling air flowing outward in the centrifugal direction is formed on the frame after flowing across the inside of the coil end group. Since the air is exhausted from the vent hole, a powerful and large amount of cooling air can be provided to the coil end group. Moreover, within the coil end group
Since the shape of the conductor segment is improved, high cooling performance and high heat radiation performance with low noise can be obtained. In addition, the “blowing toward the outside in the centrifugal direction” here may be a blast including some axial components in addition to the blast using only the centrifugal components. The setting of such a blowing direction can be appropriately selected according to a request such as cooling of the field rotor.

Further, it is desirable to adopt a configuration in which the blower is provided at both axial ends of the field rotor. According to such a configuration, cooling air can be obtained on both axial sides of the field rotor. In addition,
When used in combination with the configuration in which the coil end groups are formed on both sides of the stator, each of the two coil end groups can be cooled by the corresponding blowing means. Further, it is possible to adopt a configuration in which the blower includes a blower fan having a plurality of blades.

According to this configuration, the cooling air can be reliably obtained. Further, a configuration may be adopted in which the blowing means is provided by a shape of the Landel-type core formed corresponding to the plurality of claw-shaped magnetic poles. According to this configuration, cooling air can be obtained by a shape corresponding to the plurality of claw-shaped magnetic poles inherently included in the Landel-type iron core. In addition, in such a configuration, when a configuration in which air is blown only by the rundle type iron core is employed, a dedicated blower fan can be omitted, and the number of parts and the number of processing steps can be reduced. In addition, when a configuration in which air is blown jointly in combination with a blowing fan is employed, the amount of blowing air can be increased.

It is to be noted that a configuration may be adopted in which the axial end of the Landel-type iron core and the inner wall surface of the frame are disposed so as to be close to and opposed to each other. According to such a configuration, the inner wall surface of the frame can function as a shroud, and air can be blown using the shape of the axial end of the Lundell-type core. The inner wall surface of the frame as the shroud may be a component mounted on the frame in addition to the inner wall surface of the metal member as the frame.

The frame is formed with an air inlet for the air blowing means facing the mounting end of the pulley for driving the field rotor, and the outermost diameter of the air inlet is set at the air inlet. A configuration that is smaller than the outermost diameter of the pulley to be performed can be adopted. Even when such a large-diameter pulley is adopted, a practical vehicle alternator can be provided. That is, in order to reduce the size and increase the output, there is a problem that the life of the belt is reduced due to an increase in the torque. Therefore, it is necessary to reduce the stress applied to the belt by increasing the diameter of the pulley. However, in such a configuration, the pulley blocks the suction hole of the frame, and the ventilation resistance increases, so that the cooling air flow decreases. However, in the present invention, since the cooling performance is improved by improving the stator, the coil end can be cooled even if the amount of cooling air is reduced, and the miniaturization and high output can be achieved while securing the life of the belt.

Further, the coil end is spaced apart from a first electric conductor disposed as a predetermined layer in a first slot, in correspondence with a magnetic pole pitch of NS poles of the field rotor from the first slot. It is preferable to adopt a configuration in which the second electric conductor is formed by a connection pattern for connecting in series the second electric conductor arranged as a layer different from the first electric conductor in the second slot.

According to this, the arrangement of the coil ends on the side surfaces in the axial direction of the stator core is in the same direction, so that interference between the coil ends of different phases can be avoided. Therefore, the conductor can be inserted to the depth of the slot, and the output can be improved by improving the space factor. In addition, since the coil end has no irregularities and a uniform repetitive pattern is formed, noise generated between the coil end and the cooling air can be reduced.

Further, the coil end includes an end of the first electric conductor extending from the first slot, and an end of the second electric conductor.
An end of the second electric conductor extending from the slot is joined to the first electric conductor, and the first electric conductor and the second electric conductor are provided by separate conductor segments. Of the electric conductor may have an angle and a length at least half a distance of the magnetic pole pitch.

According to this, the coil end is formed by arranging the segment so as to extend from the inside of the slot and joining the other segment. The coil end formed by such joining is cooled by cooling air flowing across the coil end. By adopting a configuration involving such joining, segments can be employed. In addition, joining is
Electrical connection by ultrasonic welding, arc welding, brazing, etc.

The segment is a U-shaped segment formed by continuously connecting two electric conductors at one end of the stator core by a turn portion. The end of the first U-shaped segment as the end of the second U-shaped segment and the end of the second U-shaped segment as the end of the second electric conductor are connected to the coil end as the connection pattern. It is desirable to adopt a configuration in which is formed.

According to this configuration, the number of conductor parts and the number of joints can be reduced by half, and the manufacturing process can be facilitated. In addition, since the joints are aligned with one side of the stator in the axial direction, there is an effect that the production process is facilitated. Also, the segment is
A segment having two ends protruding from both sides of the slot, wherein at one end of the stator core, one end of a first segment as an end of the first electric conductor; (2) One coil end is formed as the connection pattern with one end of the second segment as the end of the electric conductor, and the other end of the stator core is connected to the first electric conductor at the other end. The other coil end is formed as the connection pattern by joining the other end of the first segment as an end and the other end of the third segment as an end of the other second electric conductor. May be adopted.

[0058] According to this, since the conductor segments can be in a simple shape extending in one direction, which facilitates the manufacturing process of the conductor segments themselves. In addition, a preformed conductor cell
Since segment can be a push from the radially inner side to the slot, the manufacturing process machining of the coil end portion is not required can be easily compared with the case of inserting the axial direction, it is possible to further high space factor of .

Further, it is desirable to adopt a configuration in which the total of the lap lengths of both ends of the conductor segment corresponds to the magnetic pole pitch. According to this, it is possible to form the stator winding that circulates on the stator by using the segments of a fixed shape. Thus, integrated conductor segments <br/> shape, can be reduced type can be less expensive manufacturing facilities such as press molds for making conductor segments.
In addition, by arranging the joints on both side surfaces of the stator core and having the same shape, the production process of the joints is facilitated.

Further, at least a part of the tooth tip of the iron core located on both sides of the slot is plastically deformed so that the width of the opening on the inner peripheral side of the slot is formed smaller than the distance between the inner walls in the slot. It is desirable to adopt a configuration. According to this, at the time of plastic deformation of the iron core tip portion, the electric conductor in the slot is further pushed from the radially inner peripheral side to the back of the slot, so that a higher space factor can be achieved. Further, since the teeth of the stator core can be sufficiently fixed, the rigidity of the core increases and the vibration of the stator core can be suppressed, so that the magnetic noise can be reduced. Further, by making the entrance portion narrower than the distance between the inner walls, a locking member such as a wedge can be eliminated, so that the cost can be reduced. Further, since the tooth tip portion is hardened by plastic working, it does not protrude radially inward even if a highly rigid electric conductor is used. Such a configuration can be adopted regardless of the cross-sectional shape in the slot. However, it is desirable that the cross-sectional shape of the slot be a parallel slot having a constant width in the depth direction.
Thereby, even if the shape of the inner layer conductor and the shape of the outer layer conductor are the same, the gap in the slot does not become uneven, and a high space factor can be achieved.

Further, a rectifier is provided, and the conductor segment is provided.
A configuration in which part of the instrument is directly connected to the electrode of the rectifying element of the rectifier may be employed. According to this, a joining member such as a terminal block for forming a rectifier circuit is unnecessary, and a low-cost, small-sized rectifier having a simple configuration can be provided. Note that the segments for direct connection to such rectifying element, such as longer than the other segments, are preferably different shape from the other segments repeatedly joined a predetermined connection pattern.

[0062] The conductor segment connected to the electrode of the rectifying element may have a portion which is easily deformed between the stator and the rectifying element electrode. According to this, vibrations and the like can be absorbed by deformation of the conductor segments , and damage to the rectifying element can be prevented, so that high reliability can be realized. In addition, as the portion that is easily deformed, a shape in which a part of the conductor segment is made thin or the like can be adopted.

Further, a rectifier may be further provided, wherein the rectifier is arranged on the turn portion side of the U-shaped segment and connected to the winding end of the stator winding. According to such a configuration, when joining the ends of the U-shaped segments to form the winding, the conductor connected to the electrode of the rectifying element does not interfere, and the same pattern can be repeatedly joined. Therefore, the manufacturing process is facilitated, and the cost can be reduced.

Further, a rectifier is further provided, and the rectifier adopts a configuration in which the rectifier is arranged on the side opposite to the turn portion of the U-shaped segment and connected to the winding end of the stator winding. Is also good. According to this configuration, the turn shape of the U-shaped segment can be made the same, so that the man-hour for manufacturing the segment can be reduced, and the cost can be reduced. Further, it is possible to adopt a configuration in which the stator has a lead-out wiring which is short-circuited to each other to form a neutral point.

According to this configuration, a neutral point connection can be realized on the stator. It is desirable that the electric conductors are extended and laid, and a plurality of electric conductors are directly connected to obtain a neutral point connection. In particular, when an electric conductor having a rectangular cross-sectional shape is employed, sufficient strength can be obtained, and the electric conductor can be laid while securing a space between the electric conductor and other coil ends. Further, the heat radiation area can be increased, and the cooling performance of the stator coil can be improved.

In the structure described above, the conductor segments of the inner layer and the outer layer may be paired.
With this configuration, the number of steps for assembling the conductor to the stator can be reduced, and the gap can be easily secured because the number of coil ends is small. Further, since the number of conductors and the number of electrical connection points are small, the manufacturing process can be facilitated.
Further, the inner layer and the outer layer may have two or more pairs of conductor segments .

According to this configuration, the number of conductor segments can be set to four or more in the slot while suppressing the interference of the coil end. Even when the number of revolutions further decreases, it is possible to output from the generator. In the case where two or more pairs of the inner conductor segment and the outer conductor segment are arranged, the plurality of conductor segments accommodated in one slot are arranged in the depth direction of the slot. The plurality of conductor segments are joined to other conductor segments in the coil end group to form a plurality of joints, and the plurality of joints are arranged in a multiple annular shape. It is preferable that a configuration is adopted in which the coils are arranged apart from each other in the circumferential direction and the radial direction in the coil end group.

According to such a configuration, the joint is formed by a plurality of conductors.
In accordance with the arrangement of the body segments , that is, the arrangement of the slots, they are arranged annularly along the circumferential direction. In addition, since a plurality of conductor segments are arranged and accommodated in the slot only in the radial direction, the annular arrangement of the joints can be arranged in a concentric multiple manner. For this reason, the plurality of joints can be arranged so as to be separated from each other in the circumferential direction and the radial direction, and a gap can be reliably formed between the plurality of joints.
Also, shorting between the joints can be easily avoided, thereby providing advantages in the joining process.

The above object is to provide a field rotor that alternately forms NS poles in the circumferential direction of rotation, a stator disposed to face the outer periphery of the rotor, a frame that supports the rotor and the stator, In a vehicle AC generator having a rectifier that rectifies AC power derived from the stator into DC power, the stator includes a stacked stator core having a plurality of slots,
A plurality of electrical conductors housed in the slot, wherein the electrical conductor includes a plurality of segments, each segment corresponding to an NS pole pitch of the rotor.
A substantially U-shaped segment having two straight portions accommodated in spaced apart slots, and the turn portions of the plurality of U-shaped segments are formed as a coil end from one end face side of the stator iron core. The first and second slots are arranged so as to protrude in the same direction and are spaced apart from each other to form a first coil end group.
Multiple slots separated by one
The first slot consisting of a multi-phase slot group
And a predetermined electrical angle from the first slot set.
A second slot set, wherein the first slot
The plurality of cells accommodated in the group of slots included in the set
The first winding is formed by the
The plurality of the slots accommodated in the slot group included in the group
The second winding is formed by the segment, and the first slot
The number of slots accommodated in the plurality of slot groups included in the
The output of the first winding of a phase and included in the second set of slots
The second phase of the polyphase accommodated in the plurality of slot groups
The ends of the plurality of U-shaped segments are arranged so as to protrude in the axial direction from the other end face side to form a coil end of the winding. These coil ends are joined in a predetermined connection pattern, and these coil ends are arranged so as to be separated from each other to form a second coil end group. The field rotor has a plurality of claws for providing the N pole and the S pole. A runner-type iron core having a magnetic pole, and the field rotor further includes a ventilation path through which air flows radially across the first coil end group on both axial sides of the field rotor. This is achieved by providing a ventilation path through which air flows radially across the second coil end group.

According to such a configuration, coil ends having excellent cooling properties are formed at both ends of the stator, and furthermore, the field rotors provide ventilation paths for flowing air across the respective coil end groups. Therefore, it is possible to provide a small-sized, high-output vehicle alternator. The compound
The number of slots corresponds to the pole pitch of the field rotor.
A plurality of slots separated from each other as a group of slots for one phase
And a first slot set including a multi-phase slot group,
And a second electrical angle shifted from the first slot set by a predetermined electrical angle.
And a set of slots, wherein the polyphase stator windings
The slot group contained in the first slot group
A plurality of said segments form a first winding;
The slot group contained in the second slot set contains
A plurality of said segments form a second winding.
A plurality of the slots included in the first slot set
An output of the first winding of the multi-phase housed in the group;
Housed in the plurality of slots included in the slot set
And the output of the multi-phase second winding.
In this way, the common-mode electromotive force
High output by connecting induced segments in series
Can be secured. Furthermore, it is included in the first slot set.
The multi-phase first winding housed in the plurality of slot groups
And the plurality of slots included in the second slot set.
The combination with the output of the second phase winding of the polyphase accommodated in the lot group
Because the output is a composite value, each of the first winding and the second winding
Even if each output is relatively small, high output can be secured.
You. For example, the first winding and the second winding may be directly connected in series or
Can be connected in parallel to combine their outputs,
After rectifying the outputs of the winding and the second winding separately,
Or connect them in parallel and combine their outputs.
Can be In addition, it is preferable that the field rotor is provided with a blowing means for blowing air toward the coil end group at an axial end thereof.

Thus, a large amount of air can be strongly blown toward the coil end group. Further, it is preferable that the frame has ventilation holes as outlets of the ventilation path both on the outer peripheral side of the first coil end group and on the outer peripheral side of the second coil end group.

Thus, a ventilation path is provided from the blowing means, which passes through the coil end group and is further discharged from the ventilation port. Preferably, the U-shaped segment is formed of an electric conductor having a rectangular cross section, and the coil end is desirably arranged such that the longitudinal direction of the cross section is radially arranged. By adopting such a configuration, the ventilation resistance of the coil end group can be reduced, and noise can be reduced. In addition, as a rectangular cross-sectional shape, in addition to a rectangle, a shape in which the short side of the rectangle is a curved surface,
An oblong shape or the like can be used.

Further, in one slot, a plurality of pairs of the linear portions having a pair of an inner layer and an outer layer are accommodated in a manner arranged only in the depth direction of the slot. Are joined in the second coil end group and are arranged in a multiplex ring, and the plurality of joints are arranged apart from each other in the circumferential direction and the radial direction. Configuration can be adopted.

According to such a configuration, when a plurality of pairs of linear portions are accommodated in one slot, the joints can be surely arranged in the second coil end group at an interval, which is advantageous in the manufacturing process. Can be provided .

[0075]

[0076]

[0077]

[0078]

In order to achieve the above object, a field rotor which alternately forms NS poles in the circumferential direction of rotation, a stator core arranged opposite to the rotor, and a stator core mounted on the stator core In a vehicle alternator having a stator having a multi-phase stator winding and a frame supporting the rotor and the stator, the stator core includes the multi-phase stator winding. A plurality of slots for accommodating are formed, and the plurality of slots are formed from a plurality of slots corresponding to the magnetic pole pitch of the field rotor as a group of slots for one phase, and a group of slots for multiple phases. A first slot set, and a second slot set further shifted by a predetermined electrical angle from the first slot set, wherein the multiphase stator winding is configured by joining a plurality of conductor segments. Yes,
In the slot, the plurality of conductor segments are arranged as one or more pairs as an inner layer and an outer layer in the depth direction of the slot, and are housed in the slot insulated from each other. , A plurality of coil ends that extend in the end face side of the stator core and are connected in series to different layers in slots that are separated according to the magnetic pole pitch of the field rotor. And the multi-phase stator winding is connected to the first slot.
The plurality of the slots accommodated in the slot group included in the group
A first winding formed by the conductor segments;
A plurality of slots accommodated in the slot group included in the slot set
A second winding is formed by the conductor segments of the first and second slots, and the output of the multiphase first winding housed in the plurality of slots included in the first slot set is included in the second slot set. The outputs of the multi-phase second windings accommodated in the plurality of slot groups are connected so as to be combined with each other. Further, the coil ends substantially reduce the number of windings of all the slot groups. Technical means of a vehicle alternator characterized by having a surface area contributing to heat radiation equal to the following.

With this configuration, two sets of multiphase windings are obtained and their outputs are combined, so that output characteristics or generated power quality according to the specifications required of the generator can be obtained. Moreover, despite the fact that two sets of polyphase windings are mounted on one stator core, the conductor segments housed in the slots as the inner layer and the outer layer are connected at the coil ends to form the windings. Therefore, the surface area for heat dissipation of the winding formed in one slot group is substantially equal to the surface area for heat dissipation of the winding formed in the other slot group. There is no variation in the heat radiation properties. As a result, while having excellent output characteristics due to having substantially twice the phase, excellent quality of the generated power, and further reducing the electromagnetic noise, it is possible to obtain an excellent effect without reducing those effects. Heat dissipation can be realized.

In connecting the two sets of polyphase windings, each of them is connected in a star or ring connection as a polyphase winding, and each output is rectified by a separate rectifier, and then rectified in series or as a DC output. They may be connected in parallel.
Alternatively, two sets of multi-phase windings whose electrical phases are close to each other may be connected in series or in parallel, and may be connected in a star or ring connection as one multi-phase winding.

The two sets of multi-phase windings can be two sets of three-phase windings whose electrical angles are shifted by 30 degrees. Note that a plurality of the conductor segments at the coil end are further provided.
DOO, the disposed so as to extend to intersect the air flow direction of the cooling air in the frame, adopts the technical means that the structure is provided that the cooling wind flows across the plurality of the conductor segments in said coil end Is also good. According to such a configuration, more excellent heat dissipation and low noise can be realized at the coil end.

[0083] Also, the conductor segment pairs in one of said slots, are accommodated only are arranged in the depth direction of the slot, the plurality of the conductor segments
DOO are each other conductor segment in said coil end group
Is placement and bonding forms a plurality of joints, a plurality of the joints are arranged in a multiple ring, they are spaced apart from each other with respect to the circumferential direction and radial direction in the coil end in the group May be adopted.

[0084]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, an automotive alternator to which the present invention is applied will be described based on an embodiment shown in the drawings. (Configuration of First Embodiment) FIGS. 1 to 8 show a first embodiment of the present invention. FIG. 1 shows a main part of a vehicular alternator particularly adapted for an automobile. FIG.
8 are explanatory diagrams of the stator of this embodiment.

This AC generator 1 for a vehicle is generated in a stator 2 serving as an armature, a rotor 3 serving as a magnetic field, a frame 4 supporting the rotor 3 and the stator 2, and a stator 2. It has a rectifier 5 for converting AC power to DC power. The output of this rectifier 5 is connected to a 12V battery. The rotor 3 rotates integrally with the shaft 6 and includes a pair of Landel pole cores 7, a cooling fan 11, field coils 8, slip rings 9, 10, and 16 permanent magnets 51. I have. The permanent magnets 51 are connected by a magnet holder (not shown).

Permanent magnet 51 interposed between pole core claws
Uses a rectangular parallelepiped ferrite magnet. The dimensions are set such that the width between magnetic poles is 8 mm, the length in the axial direction is 24 mm, and the length in the radial direction is 9 mm. The field coil uses a rectangular conductor, and has a resistance of 1.8Ω and a turn (T) number of 330T. As the permanent magnet 51, a wet anisotropic magnet is used, and a magnet material that can suppress the demagnetization characteristic to 5% or less when fully excited at −30 ° C. is used.

The diameter of the boss of the pole core is φ50 m.
m, and the diameter of the shaft 6 is set to φ17 mm. The magnetic pole cross-sectional areas are set to be substantially the same on the basis of the cross-sectional area obtained by subtracting the cross-sectional area of the shaft 6 from the cross-sectional area of the boss portion of the pole core divided by the number of pole pairs. A pulley is fixed to an end of the shaft 6.
The pulley is rotationally driven by a traveling engine (not shown) mounted on an automobile.

The Landel type core 7 is composed of a pair of pole cores. The core 7 has a boss 71 attached to the shaft 6, two disk portions 72 extending radially from both ends of the boss, and 16 claw-shaped magnetic poles 73 arranged at the tip of the disk portion 72. The frame 4 is provided with cooling air suction holes 41 and 42 at both ends in the axial direction. Further, the frame 4 has, on its outer peripheral portion,
Cooling air discharge holes 43 and 44 are provided. The discharge holes 43 and 44 are arranged in two rows in an annular shape facing the coil end 31. The outer diameter of the pulley is set to be larger than the outer diameter of the suction hole 41 on the axial end face of the frame 4.

The stator 2 includes a stator core 32, a plurality of conductor segments 33 constituting a stator winding, and an insulator 34 for electrically insulating the stator core 32 and the conductor segments 33 from each other. Supported by the system 4. The stator core 32 is of a laminated type in which thin steel plates are stacked, and a plurality of slots 35 are formed on the inner peripheral surface thereof.

In one slot 35, two rectangular electric conductors are inserted as an inner conductor and an outer conductor. These electrical conductors are provided by conductor segments 33. The conductor segment 33 has a shape that can be called a U-shape or a V-shape. The stator winding is constituted by a number of electrically connected conductor segments 33. The turn portion 33c of the conductor segment 33 is disposed on one of the axial end surfaces of the stator core 32, and the joint portion 33d is disposed on the other side. The joint 33d is formed by connecting the ends of the different conductor segments 33. The conductor segments 33 project from both ends of the stator core 32,
Each forms a coil end 31. Then, as a result of the plurality of conductor segments 33 being annularly arranged on the stator core 32, an annular coil end group is formed.

[0091] Of the conductor segments 33, the stator core 3
The ridge 33e extending from 2 is inclined in the opposite direction in the outer layer and the inner layer. A predetermined gap that can ensure electrical insulation is provided between adjacent conductor segments 33 in the coil end group. The disk end 72 of the pole core 7 of the rotor 3 faces the coil end 31.

Note that the conductor segment 33 may or may not have an insulating film. As shown in FIG. 4, the insulators 34 are arranged in an S shape so as to insulate between the stator core 32 and the conductor segments 33 and between the electric conductors in the slots. The tip teeth of the stator core 32 may be used when the stator core 32 is manufactured or when the conductor segments 3 are used.
3. Work hardening is applied by pressing and bending after insertion.

The stator winding has three phase windings of X, Y and Z. One winding end 33f of each phase extends in the axial direction, and is electrically connected directly to the electrode portion 53 of the rectifying element 52 provided in the rectifier 5 by fusing welding or the like. A portion 33g having a reduced cross-sectional area is formed at the winding end 33f to absorb vibration and reduce transmission of stress.

The other winding end of each phase is electrically connected as a neutral point 33k directly or via a conductor as shown in FIG. The manufacturing process of the stator winding will be described. As shown in FIG. 3, the U-shaped conductor segment 33 includes an inner-layer conductor 33a, an outer-layer conductor 33b, and a turn 33c. The segment 33 is formed by bending a copper plate and pressing the same.

The plurality of conductor segments 33 are stacked so that the plurality of turn portions 33c are aligned on the same side of the axial end face of the stator core 32. Then, as shown in FIG. 4, the outer-layer-side conductor portion 33 b is inserted so as to be located on the far side in the depth direction of the slot 35, and the inner-layer-side conductor portion 33 a is located on the near side in the depth direction of the slot 35. As a result, both sides of the electric conductor are placed on the side walls of the substantially parallel slot 35 by the insulator 34.
Are press-fitted to face each other.

On the other hand, on the other end side of the stator core 32, the ends of the plurality of conductor segments 33 are arranged so as to protrude as an inner layer and an outer layer. Then, as shown in FIG. 5, the inner layer and the outer layer are bent in opposite directions in the circumferential direction. The inner layer and the outer layer are bent by a predetermined number of slots. After that, the ends of the different conductor segments 33 of the different layers are joined together to form a joint 33d. As this joint 33d,
Ultrasonic welding, arc welding, brazing, etc. can be adopted so as to provide electrical conduction.

In this embodiment, the number of magnetic poles of the rotor 3 is set to 16, the number of slots of the stator core 32 is set to 96, and the stator winding forms a three-phase winding. The outer diameter of the stator is 130 mm and the inner diameter is 102 mm. The thickness of the stator core 23 is 34 mm,
An SPCC material having a thickness of 0.5 mm is laminated and fixed by laser welding or the like. The slots are set at equal intervals at a 3.75 ° pitch corresponding to a 30 ° electrical angle pitch. The shape is a substantially rectangular shape with parallel sides, and the side width is set to 1.8 mm, the depth is set to 10 mm, the back thickness is set to 3.5 mm, and the opening width is set to 0.8 mm. The radial thickness of the tip of the tip is set to 0.5 mm.

The electric conductor inserted into this slot is
The thickness is 1.6 mm and the width is 4.5 mm.
R below mm is taken. An insulator 34 having a thickness of about 100 μm is interposed between the slot and the electric conductor. Specific connection examples will be described with reference to FIGS. 6, 7, and 8. FIG. The lower crossover portion in FIGS. 6 and 7 is the turn portion 33c of the segment, and the upper side is the joint portion 33d. In the figure, the solid line shows the inner layer electric conductor, and the dashed line shows the outer layer electric conductor.

First, the X phase of the three-phase winding will be described. The first to fourth slot numbers from slot number 94 to number 94 (numbers 4, 10, 16,..., 94) form a first slot group. From No. 5 adjacent to these to No. 95 every 6 slots (No. 5, No. 11, No. 17 ... 95)
No.) form a second slot group. The first winding formed by the plurality of conductor segments 33 accommodated in the first slot group includes two wave windings. Also,
A plurality of conductor segments 33 accommodated in the second slot group
The second winding formed by the above includes two wave windings.

The first winding and the second winding are connected in series via two connection portions 102 and one connection portion 103. The two winding windings of the second winding are connected to the connection 1
03 and connected in series. Then, a wave winding of the first winding is connected in series to each of both ends by a connection portion 102. Then, two ends of the first winding are drawn out as a winding end X and a winding end X ′.

The connection portion 102 connects the inner layer electric conductor and the outer layer electric conductor accommodated in slots separated by 5 slots. The connection portion 103 connects electric conductors of the same layer housed in slots separated by 6 slots. As a result, the X phase is configured by connecting the first winding and the second winding, which are out of phase by 30 ° in electrical angle, in series. Since the first winding is 2T and the second winding is 2T,
A 4T stator winding is configured. Similarly, electrical angle 1
A Y-phase and a Z-phase are formed at a pitch of 20 °, and these three phases are star-connected as shown in FIG.

In the above embodiment, the X-phase first slot group, the Y-phase first slot group, and the Z-phase first slot group belong to the first slot group, and the X-phase second slot group. When,
The Y-phase second slot group and the Z-phase second slot group belong to a second slot group. All of the windings provided in these slot sets are uniformly exposed to the outside at the coil ends, and are uniformly exposed to the cooling air. Then, two windings electrically adjacent to each other are connected in series and synthesized as an alternating current, and the six windings provided by the two sets of slots are connected in three phases. Further, since these windings have a gap between the coil ends, even the coil ends disposed on the leeward side are sufficiently exposed to the wind. For this reason, there is almost no difference in surface area that contributes to heat radiation for each winding. In other words, as a three-phase polyphase alternator,
Despite including windings corresponding to six phases, which is twice the number of phases, all windings are placed under uniform cooling conditions.

In the stator windings shown in FIGS. 5, 6, and 7, the turn portions 33c of the conductor segments 33 are arranged on one end face side of the stator core 32, and are connected to the rectifier 5. A wire end 33f is drawn out from the other end face side of the stator core 32. (Effects of Embodiment) With the above configuration, the inclination direction of the ridge portions 33e of the plurality of conductor segments 33 located in the inner layer can be made the same direction, and the plurality of conductor segments 33 located in the outer layer can be inclined. The inclination direction of the ridge line portion 33e can be the same direction. Therefore, the multi-phase stator winding can be arranged at the coil end without interference. Therefore, the space factor of the electric conductor in the slot can be improved to increase the output. In addition, a gap is provided between adjacent electric conductors at the coil end so that electrical insulation can be ensured, so that a rise in temperature is greatly suppressed. In particular, in the present embodiment, a cooling fan 11 as an internal fan is provided at an axial end of the rundle type rotor, and discharge holes 43 and 44 as vent holes are formed in the frame 4 corresponding to the outer peripheral side of the coil end 31.
Is provided, the ventilation resistance of the cooling air passing through the coil end group toward the outer peripheral portion of the frame can be extremely reduced, and the cooling performance can be greatly improved.

Further, by connecting the windings of adjacent slots in series to form a stator winding, the number of electric conductors per slot is reduced, and a gap between the conductors at the coil end is secured. The number of T required for the power generator can be obtained. In the case of the conventional method in which the stator is designed with three times the number of magnetic poles of the rotor, the number of T
You can't get numbers. In general, a vehicular alternator having a rating of 0.5 to 2.5 kw is used. In order to realize such an output under a limitation of a predetermined physique that can be mounted on a vehicle and a limitation of an engine speed, at least 3T or more of the stator winding is necessary. When a smaller T number is set, as shown by the broken line in FIG. 9, no output is generated at low speed rotation, and only at high speed, the output is large, resulting in unsuitable characteristics as a vehicle AC generator.

For example, the number of slots is set to 3 of the number of magnetic poles of the rotor.
The output characteristics of a comparative example in which the number of electric conductors per slot is two, the number of T of the stator winding is 2T, and the output characteristics of the present embodiment are shown by a broken line and a solid line in FIG. In the conventional method, the decrease near the idling speed of the vehicle having a high rotation frequency is remarkable and cannot be realized as a vehicle generator. Inevitably, the number of electrical conductors per slot must be increased. However, as long as the cross-sectional area of one electric conductor is the same, there is a problem that the ventilation property is deteriorated and the cooling property is deteriorated due to the reduced gap between the coil ends. In addition, there is a problem that the manufacturing cost is increased due to an increase in the number of steps for assembling the electric conductor. Conversely, if the number of T's is increased by reducing the cross-sectional area of one electric conductor, the impedance of the windings will increase, making it impossible to increase the output.

On the other hand, in this embodiment, the number of slots is three times or more the number of poles, and a portion for connecting conductors of adjacent slots in series is provided. Therefore, the number of conductors per slot is the minimum. It can be a book. In particular,
With respect to the number of magnetic poles of 16 poles, not only 48 slots, which is three times the number required for a three-phase generator, but also 96 slots, which is twice as large. For example, 3 for 12 poles
A phase may employ 72 slots. As a result, a gap can be formed in the coil end to ensure cooling by ventilation, the space factor in the slot can be improved without increasing the manufacturing cost, and the output characteristics required for the vehicle from low rotation can be obtained. .

Further, the first winding and the second winding whose electric angles are shifted by 30 °
Since the winding and the winding are connected in series, the magnetomotive force can be reduced, so that there is an effect that the magnetic noise can be greatly reduced. Moreover, the first winding and the second winding are uniformly exposed to the outside at the coil end, and are uniformly exposed to the cooling air. In addition, since a gap is provided between the coil ends to allow air to pass therethrough, high cooling performance can be obtained. This relationship is realized for all six windings housed in the six slot groups, and all windings are cooled evenly.

In the connection method shown in FIGS. 6 and 7, since the two-layer inner conductors and the outer conductors are alternately connected, the length of the crossover portion of each phase is the same as a result. Therefore, the electric resistance value of each phase winding becomes uniform.
In addition, the inductance of the stator winding differs depending on the position in the slot, but in this embodiment, the number of the inner-layer electric conductors and the number of the outer-layer electric conductors are the same in each phase, so that the inductances are substantially the same. be able to. That is, since the impedance can be made uniform, local heat generation can be prevented.

Further, the axial height of the coil end can also be remarkably reduced, and as a result, the resistance value can be substantially halved compared to the conventional stator winding. As a result, it is possible to achieve a small size and high output by lowering the impedance, and it is also possible to achieve a temperature reduction and a higher efficiency by reducing a heat generation amount. Furthermore, the axial length of the stator 2 can be reduced with a reduction in the coil end height. As a result, the roundness of the corners of the frame 4 can be increased. As a result, a vehicle alternator having a round physique can be configured, and mechanical rigidity can be improved. further,
When mounted on a vehicle, there is an effect that interference with other components can be avoided.

Further, since the cooling performance of the coil end is greatly improved, the fan can be downsized. further,
As the coil end group, the unevenness of the surface is smoothed, a uniform repetitive pattern is formed, and the cooling wind crosses the coil end, greatly reducing fan noise generated between the coil end and the cooling wind. Can be reduced. Further, since the winding end 33f is taken out of the conductor segment 33 from the side opposite to the turn portion 33c, the turn portion 33c can have the same shape. For this reason, the length of the straight portion other than the turn portion 33c is changed to change the winding end 33f and the connection portion 102,
103 can be formed. Therefore, the conductor segments 33 having only the length of the straight portion need only be manufactured, so that the number of production steps can be greatly reduced, and the cost can be reduced by using inexpensive equipment.

Also, by making the cross section of the electric conductor rectangular,
A high space factor can be achieved, and conductor segments can be created by pressing or the like, so that materials and processing costs can be reduced. Further, since the facing area between the electric conductor and the stator core is increased, the heat transfer is improved, and the temperature of the electric conductor can be further reduced. Further, since the rigidity of the whole stator is increased, there is also an effect of suppressing magnetic noise.
Further, since the rigidity of the electric conductor itself is increased, it is easy to manage the gap between the coils. As a result, it is possible to eliminate the insulating film of the electric conductor and the fixing material of the electric conductor, thereby providing a highly reliable and low-cost generator. In addition, since the rigidity of the winding end is increased, the rectifier 5 which is conventionally required is not required.
Can be eliminated, and it is possible to connect directly to the rectifying element 52, so that there is a further cost reduction effect.

In the slot, a single-wire electric conductor is
Since it is housed in two layers inside and outside, assembly becomes easy. Moreover, since there is only one joint in the radial direction, there is no overlap with other joints, so that the steps such as welding are easy and the productivity is improved. Therefore, a low-cost generator can be provided. Furthermore, since it can be constituted by one set of rectifiers, the electric parts can be simplified and the cost can be reduced.

Further, since it is a Rundel type rotor,
Since an iron material can be used for the cooling fan, the durability against high-speed rotation is better than that of the silent rotor. This is because the magnetic poles are arranged on the axial end face of the transparent rotor, so that a member provided on the axial end face must be made of a non-magnetic material such as aluminum or resin in order to prevent a magnetic flux short circuit. With such high speed durability, the pulley ratio can be set high, and the output can be improved by increasing the rotation speed of the rotor when the engine is idling.
Further, since the material cost and processing cost of the fan are low, and inexpensive fusing welding can be employed as a joining means with the pole core, the production cost can be reduced.

(Second Embodiment) FIGS. 10 to 12 show a second embodiment. In the first embodiment, the turn portion 33c of the conductor segment 33 is provided on one side of the end face of the stator core 32, but in the second embodiment, the conductor segment separated by the turn portion 33c is used. The difference is that joints are arranged on both sides of the stator core 32.

As shown in FIG. 11, the conductor segment 33 includes an inner conductor 33h which is a substantially linear portion inserted into the slot 35, and axially opposite sides of the stator core 32 on both sides of the inner conductor. And an outer conductor 33i which is a substantially linear portion extending to the outside. The outer conductor 33i has an angle and a length that goes around a distance of about half the magnetic pole pitch. The outer conductor 33i forms a ridge as the coil end 31, as shown in FIG. A plurality of conductor segments 33 are inserted into the slots so that the inclination of the ridges 33i of the inner layer and the outer layer is reversed. Further, as shown in FIG. 12, the stator core 32 is
It is manufactured from a semi-finished product in which 2a is U-shaped or J-shaped. After inserting the plurality of conductor segments 33 into the slot, the stator core 32 applies plastic working to the tooth tip 32a by pressing a processing jig against the tooth tip 32a from the radial direction, and the like. It is manufactured by narrowing the inner peripheral side opening. By doing so, the conductor segment 33 can be inserted from the inside in the radial direction, the conductor segment can be processed in advance to the final shape, and the assembling becomes easy.

After the conductor segment is inserted, the conductor segment is compressed from the radially inner side and deformed in accordance with the slot shape, so that a higher space factor can be obtained. In addition, since the tip of the tooth tip is hardened by the plastic working, there is also an effect that the tip of the conductor segment 33 can be prevented from being deformed by springback. Although the conductor segment 33 is processed in advance, the conductor segment 33 may be bent after being stored in the slot. (Third Embodiment) In the first and second embodiments, the number of electric conductors in the inner and outer layers is only one pair, that is, the number of electric conductors per slot is 2T. May be two or more pairs. In this case as well, as shown in FIG. 13, interference between coil ends of different phases can be avoided as in the first embodiment. Therefore, effects such as a high space factor, high cooling efficiency, and low noise can be obtained as in the above-described embodiment. Further, since the number of electric conductors per slot increases, power generation can be started from a low engine speed, and the power generation amount at low speed rotation can be increased.

FIG. 14 shows the arrangement of the insulators when two pairs of electric conductors in the inner and outer layers, that is, when the number of conductors per slot is 4T. Furthermore, by providing two or more pairs of inner and outer electric conductors, it is possible to configure an arbitrary number of T by changing the setting of the number of slots and the connection location. (Fourth Embodiment) In the first to third embodiments, the electrical angle is 30
The number of T per slot is increased by connecting the windings accommodated in two groups of slots having a phase difference of ° in series, and the sixth order component of the number of pole pairs, which is the main component of the magnetic sound, is canceled. The noise is reduced. That is, the outputs of the two windings are combined in an AC state.

On the other hand, as shown in the development diagrams of the stator windings of FIGS. 15 and 16 and the circuit diagram of FIG.
The difference is that two sets of three-phase windings having a phase difference of 0 ° are rectified by respective rectifiers and then combined and output. That is,
In a DC state, the outputs of the two windings are combined. Specific connection examples will be described with reference to FIGS. The lower crossover part in FIGS. 15 and 16 becomes the segment turn part 33c, and the upper part becomes the connection part 33d. In the figure, the solid line indicates the inner layer electric conductor, and the dashed line indicates the outer layer electric conductor.

First, the X-phase first and second windings will be described. Slot number 4 to 9 every 6 slots
No. 4 (No. 4, 10, 16,..., No. 94) constitute the first slot group. No. 5 to 6 adjacent to these
Up to 95 every slot (5th, 11th, 17th ...
No. 95) forms a second slot group. The first winding formed in the first slot group is a winding end X1 shown in FIG.
And X1 ′. The first winding has winding ends X1 and X1
2 connected in series with the inverted connection part laid between
Includes a book winding.

The second winding formed in the second slot group is:
It has a winding end X2 and X2 'shown in FIG. 16, and is formed similarly to the first winding. Further, similarly, a Y phase and a Z phase are formed at an electrical angle of 120 ° apart. A first winding and a second winding are also formed for each of these phases. These six windings are connected as shown in FIG. Three first windings of the X, Y, and Z phases are star-connected and connected to the first rectifier. Three second windings of the X, Y, and Z phases are star-connected and connected to the second rectifier. The DC output of the first rectifier and the DC output of the second rectifier are connected in parallel, and the DC outputs are combined.

As a result, the DC outputs of the 2T three-phase winding are taken out in total, so that the output shortage in the low rotation speed region can be improved. Further, in combination with the third embodiment in which two or more pairs of inner and outer electric conductors are arranged, 4T or more can be realized, and the problem of insufficient power generation in a low rotation speed region can be solved. Further, since it is not necessary to connect two windings having different electrical angles in series, the shape of the conductor segments can be made the same, and the production efficiency of the conductor segments can be further improved.
The effect that noise reduction is achieved by canceling the sixth order component of the pole pair number, which is the main component of the magnetic sound, is also obtained.

In the above embodiment, the X-phase first slot group, the Y-phase first slot group, and the Z-phase first slot group belong to the first slot group, and the X-phase second slot group. When,
The Y-phase second slot group and the Z-phase second slot group belong to a second slot group. Then, the windings provided in these slot sets are polyphase-connected as different polyphase stator windings, respectively rectified separately, and then connected in parallel as direct current and combined. (Other Embodiments) In the first embodiment, the conductor segments are joined only on one side of the end face of the stator 2, but they may be joined on both sides. For example, the turn portions of the plurality of conductor segments can be dispersedly arranged on both sides of the stator core 32. In this case, there is an effect that the interval between the joining portions can be widened and the joining process such as welding is facilitated.

The stator core 32 shown in FIG. 12 adopted in the second embodiment can be combined with the conductor segment 33 shown in FIG. 3 adopted in the first embodiment. When the stator core 32 shown in FIG. 12 is employed, the plastic working can be performed in order from the slot in which the insertion has been completed, while the conductor segments are being inserted into the slots. Thereby, the production efficiency can be dramatically improved.

As the electric conductor, an electric conductor having a rectangular cross section composed of a plurality of strands can be adopted. In the above embodiment, the electrical conductor is made of copper. Instead, aluminum, iron, or the like can be used. By selecting such a material, there is an effect that the material cost can be reduced, the conductor segment can be manufactured by casting and die casting, and the production process can be simplified. Although the cross section of the electric conductor is rectangular, it may be round. Further, a combination of a rectangle and a circle may be used. For example, the inside of the slot may be rectangular and the outside of the slot may be round. In this case, a high space factor and high cooling performance can be obtained. Conversely, if the inside of the slot is round and the outside of the slot is rectangular, a sufficient gap between the electric conductors at the coil end can be ensured, and the ventilation performance of the cooling air can be reduced to greatly improve the cooling performance. The electric conductor having a rectangular cross section has a shape that can be called a flat shape.

The conductor segment 33 may be provided with an insulating film, and the insulator may be arranged in a U-shape along the inner wall of the slot. In this case, there is an effect that the shape of the insulator can be simplified. Further, the stator core 32 may be insulated to eliminate the insulator. In this case, when the conductor segment 33 is inserted into the slot, it is possible to prevent the insulator from shifting and causing insulation failure.

The stator winding may be a multi-phase winding of three or more phases. Even in the case of a multi-phase winding, a winding can be regularly formed on the stator core 32, and the winding shape is not complicated. With three or more phases, the output voltage can be further reduced in noise and ripple. The stator windings may be triangularly connected. This can be selected as appropriate according to the characteristics of the amount of power generated by the vehicle.

A rotor having no permanent magnet may be used as the rotor. Further, the rotor may be a rotor only by excitation of the permanent magnet. Cooling fans may be provided on both end faces of the rotor. For example, the configuration shown in FIG. 18 can be adopted. In this embodiment, a cooling fan 12 is also provided on the front end face of the rotor. According to such a configuration, good cooling characteristics can be obtained. In the Landel type rotor, since the wind is generated at the disk portion of the pole core, the required cooling performance can be obtained only with one of the cooling fans 11 shown in FIG. 1. There is an effect that the physique as an AC generator can be downsized.

The configuration shown in FIG. 19 may be employed. On the end face of the rotor 3 where the cooling fan is not installed,
The inner wall surface 45 of the outer peripheral portion of the suction hole 41 of the frame 4 is brought close to and opposed. Thereby, the inner wall surface 45 plays the role of a shroud, treating the disk portion 72 of the pole core 7 as a fan. Therefore, the blowing capacity of the disk unit 72 increases. Therefore, compared with the case where the cooling fans are provided on both sides, the same cooling performance can be achieved without increasing the number of parts and the number of processing steps, and the size can be further reduced.

As shown in FIG. 23, the winding end 33f may be provided on the same side as the turn portion 33c. Thereby, in the joining process such as welding at the joint, the winding end 33
Since f does not become an obstacle, and the same pattern is repeatedly joined, the production process is facilitated. In the embodiment described above, the number of slots is six times the number of magnetic poles of the rotor. Then, by providing a portion for connecting the electric conductors accommodated in two adjacent slots in series, the number of turns of a series of windings was set to 4T. This can be referred to as a three-phase double slot series winding. Instead, for example, the number of slots may be nine times the number of magnetic poles. By providing a portion for connecting the electric conductors housed in the three adjacent slots in series, it is possible to achieve 6T. This can be referred to as a three-phase triple slot series winding.
In addition, by providing a portion to be connected in parallel without connecting the conductors in the same slot in series, an odd number of turns such as 5T can be set. A larger number of turns may be set by increasing the number of slots.

Further, the number of slots provided in the stator core 32 may be further increased by one slot from the double slot configuration. For example, 97 slots are used for stator core 3
2 may be formed. FIG. 20 and FIG. 21 are development views illustrating the connection in this case. In the figure, the solid line is the inner layer electric conductor,
The dashed line indicates the outer layer electric conductor. According to this configuration, the shape, particularly the height, of the connection portions 104 and 105 can be the same as the other coil ends. In the connections shown in FIGS. 6 and 7, the connection portions 102 and 103 have different heights from the other coil ends, require electric conductors of different shapes, and reduce the complexity of the bonding process. Invite.

The connecting portion 104 for connecting the electric conductors forming different layers in adjacent slots has the same inclination and height as the other coil ends. For this reason, in manufacturing the U-shaped conductor segment, the length of the straight portion can be unified, and the production process of the conductor segment becomes easy. Furthermore, since the connection portions 105 for connecting the electric conductors in the same layer can be formed in the same shape as that of a normal repetition, the connection process is facilitated.

In this configuration, the winding end X shown in FIGS.
A turn portion of a U-shaped conductor segment may be arranged on the drawer side. Since all the turns are unified to six slots, there is also an effect that the production process of the segments becomes easy. Further, the stator may be coated with an insulating resin for securing electric insulation.
Such resins are also called impregnated resins. Such resin is
This is effective for improving the electrical insulation of the windings or for fixing and fixing the stator-like segments to each other. In addition, it is desirable that the resin is applied so as not to impair the air permeability into the coil end group. However, the gap between the coil ends may be somewhat closed by the resin. Even in such a configuration, since a gap is maintained between the segments in the coil end group, a large surface area contributing to heat dissipation can be secured, and high cooling performance can be obtained.

According to the embodiment described above, the interference of the coil ends can be suppressed, the space factor of the stator winding can be increased, and the output can be improved. Further, since the conductors located in the inner and outer layers of the different slots are connected in series, the conductor length and leakage inductance of each phase winding caused by the position in the slot are made uniform in each phase. For this reason, the current flowing through the coil becomes uniform, and the amount of heat generated in each phase becomes the same.
Local heat generation of the stator winding and magnetomotive force imbalance can be prevented, and temperature and noise can be reduced. In addition, by using a stator winding that connects adjacent slots in series, the number of conductors per slot is reduced, and a gap between conductors at the coil end is secured, while a low-speed rotation required for a vehicle generator is required. You can get the number of turns to get the output. In particular, in the above-described embodiment, since two sets of three-phase stator windings having electric angles different by 30 degrees are formed, the effect of suppressing electromagnetic noise is obtained, and the electric noise is substantially reduced. Since the outputs of the six windings having different phases are combined, the ripple component included in the rectified DC power is small, and high-quality power can be supplied. Moreover, the stator windings are formed using the segments, and the electric conductors are stacked and accommodated only in the depth direction in the slots. For this reason, a plurality of coil ends having a uniform shape can be uniformly arranged, and a plurality of windings having electrically different phases are uniformly exposed to the outside at the coil ends, so that the cooling air Can be evenly exposed to Moreover, at the coil end, a plurality of conductor segments are separated from each other,
A sufficient surface area for heat dissipation is secured. Furthermore, excellent heat dissipation is realized by the cooling air flowing across.
By these actions, it is possible to realize high heat dissipation and cooling while eliminating variations in cooling for each of a plurality of windings. A vehicle alternator adaptable to high output is provided.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view of a first embodiment of the present invention.

FIG. 2 is an external view of a stator according to the first embodiment.

FIG. 3 is a perspective view of a conductor segment 33 of the first embodiment.

FIG. 4 is a partial cross-sectional view of the stator according to the first embodiment.

FIG. 5 is a perspective view showing coil ends at both end surfaces of the stator of the first embodiment.

FIG. 6 is a developed view showing a connection state of a stator winding, showing first to forty-eighth slots.

FIG. 7 is a developed view showing a connection state of the stator windings, showing the 49th to 96th slots.
FIGS. 6 and 7 show a series of stator windings connected in a ring by VV and VI-VI lines.

FIG. 8 is a circuit diagram of a vehicle alternator.

FIG. 9 is a graph showing output characteristics of the automotive alternator.

FIG. 10 is a partial external view of a stator according to a second embodiment.

FIG. 11 is a perspective view of a conductor segment 33 of the second embodiment.

FIG. 12 is a partial cross-sectional view of a stator according to a second embodiment.

FIG. 13 is a perspective view showing a coil end of the stator according to the third embodiment.

FIG. 14 is a partial cross-sectional view of a stator according to a third embodiment.

FIG. 15 is a developed view showing a connection state of a stator winding of the fourth embodiment.

FIG. 16 is a developed view showing a connection state of a stator winding of the fourth embodiment. FIGS. 15 and 16 show VII-V
A series of stator windings are shown connected in a ring by lines II and VIII-VIII.

FIG. 17 is a circuit diagram of an automotive alternator according to a fourth embodiment.

FIG. 18 is a longitudinal sectional view of another embodiment.

FIG. 19 is a longitudinal sectional view of another embodiment.

FIG. 20 is a developed view showing a connection state of a stator winding of another embodiment.

FIG. 21 is a developed view showing a connection state of a stator winding of another embodiment. FIGS. 20 and 21 show that IX-IX
A series of stator windings are shown connected in a ring by lines XX.

FIG. 22 is a perspective view showing a stator winding end of the first embodiment.

FIG. 23 is a perspective view showing a stator winding end of another embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Vehicle alternator 2 Stator 3 Rotor 31 Coil end 32 Stator iron core 33 Conductor segment 34 Insulator 35 Slot 4 Frame 5 Rectifier 6 Shaft 7 Pole core 8 Field coil

────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP-A-9-182337 (JP, A) JP-A 8-205441 (JP, A) WO 92/6527 (WO, A1) (58) Fields surveyed (Int.Cl. ⁶ , DB name) H02K 3/00-3/52 H02K 19/00-19/38

Claims (49)

(57) [Claims] 1. A field rotor which alternately forms NS poles along a circumferential direction of rotation, a stator core arranged opposite to the rotor, and a multi-phase stator winding mounted on the stator core. In a vehicle alternator having a stator having wires and a frame supporting the rotor and the stator, the field rotor has a plurality of claw-shaped magnetic poles providing the N pole and the S pole. Wherein the stator core comprises a laminated core formed with a plurality of slots extending through the laminated plate; the polyphase stator winding comprises a plurality of conductor segments ; In the slot, the conductor segments are arranged in pairs or more as an inner layer and an outer layer in the depth direction of the slot, are housed insulated from each other in the slot, and are arranged outside the slot. In addition, the rotor is disposed so as to extend to the end face side of the stator core, and the NS magnetic pole pick-up of the rotor is provided.
A coil end is formed by a connection pattern that connects different layers in slots spaced apart in correspondence with the coil, and as a result, a coil end group mainly repeating the connection pattern is formed on the end face side of the stator core. And a plurality of the conductor segments at the coil end.
Are arranged to extend in a direction intersecting with the direction of air flow of the cooling air in the frame, and are spaced apart from each other.
And a plurality of the conductor sections at the coil end.
A cooling air flow across the segment is provided, wherein the plurality of slots are arranged at a magnetic pole pitch of the field rotor.
Slot group for one phase with multiple slots correspondingly separated
As the first slot set consisting of a group of slots for multiple phases.
And a predetermined electrical angle deviation from the first slot set.
A second slot set, wherein the multi-phase stator winding is included in the first slot set.
A plurality of the conductor segments accommodated in the slot group
First winding is formed by including the second slot group
A plurality of said conductor segments accommodated in said slot group
A second winding is formed by the first slot;
A plurality of slots contained in the set,
The output of the first winding and included in the second slot set
An alternator for a vehicle, comprising combining and outputting the outputs of the multi-phase second winding accommodated in the plurality of slot groups . 2. The automotive alternator according to claim 1, further comprising a winding end as an output of the multi-phase stator winding, wherein the stator and the rotor drive the rotor. An alternator for a vehicle, wherein the generator is set so as to output a voltage of 15 (V) or more to the winding end when the engine speed is within an idling speed range. 3. An apparatus according to claim 1 or 2 automotive alternator according vehicular AC generator and said first winding and said second winding is characterized in that it is arranged in series. 4. The alternator for a vehicle according to claim 3, wherein the first slot group includes a plurality of slots spaced apart in correspondence with the NS magnetic pole pitch of the rotor, and is adjacent to the first slot group. And a second slot group arranged in a manner that the first winding is accommodated in the first slot group.
Consists of conductor segments connected in series, said second winding which is accommodated in the second slot group
An alternator for a vehicle, comprising conductor segments connected in series. 5. The automotive alternator according to claim 1, wherein the slots are arranged at an interval of about 30 ° in electrical angle, and the conductor segments housed in the plurality of slots are arranged. Wherein the conductor segments accommodated in the respective slots of the first slot group which are separated from each other by a magnetic pole pitch.
Are electrically connected in series to each other to form a first series conductor group as the first winding, and are housed in respective slots of a second slot group adjacent to the first slot group. The conductor segments are electrically connected in series to each other to form a second series conductor group as the second winding, and the first series conductor group and the second series conductor group are connected to each other. vehicle without the three-phase windings become series, its winding end is characterized in that it is connected to a rectifier
For alternator . 6. The vehicle alternator according to claim 1, wherein the first rectifier rectifies and outputs the AC output of the first winding, and rectifies the AC output of the second winding. second and a rectifier, said automotive alternator first rectifier rectifying output and the rectified output of said second rectifier, characterized in that the output by combining the output. 7. The alternator for a vehicle according to claim 6, wherein the first group of slots includes a plurality of slots spaced apart in correspondence with an NS magnetic pole pitch of the rotor. A second slot group disposed adjacent to the first slot group, wherein the first winding is accommodated in the first slot group.
Consists of conductor segments connected in series, said second winding which is accommodated in the second slot group
An alternator for a vehicle, comprising conductor segments connected in series. 8. The method of claim 1 or 2 automotive alternator, further comprising two sets of rectifiers, the slots are arranged at intervals of approximately 30 ° in electrical angle, is housed in the plurality of slots the The conductor segments housed in respective slots of a first slot group which are separated from each other by a magnetic pole pitch among conductor segments.
Together with bets each other are electrically connected in series with each other form a first series conductor group serving as said first winding, second Ro <br/> Tsu preparative group to be adjacent to said first slot group The conductor segments housed in the respective slots are electrically connected in series to each other to form a second series conductor group as the second winding, and furthermore, the first series conductor group and the second series conductor group are connected to each other. An AC generator for vehicles , wherein two series conductor groups independently form three-phase windings, and winding ends of the three-phase windings are connected to the rectifiers. 9. The vehicle alternator according to claim 1, wherein the outer diameter of the claw-shaped magnetic pole of the Landel type iron core is L1, and the length in the rotation axis direction is L2. The ratio is L1 / L
AC generator for vehicles characterized in that 2 ≧ 1.5
Electric machine . 10. The vehicle alternator according to claim 1, wherein the plurality of conductor segments are accommodated in one slot.
The vehicle alternator is characterized in that the parts are arranged only in the depth direction of the slot. 11. The automotive alternator according to any one of claims 1 to 10, electrically all insulated front within said slot
The alternating current generator for a vehicle , wherein the conductor segments are spatially separated at coil ends formed at ends of the stator core. 12. The alternator for a vehicle according to claim 1, wherein at least a part of an iron core tip located on both sides of the slot is plastically deformed to form an inner peripheral side of the slot. An AC generator for a vehicle , characterized in that the width of the opening is smaller than the distance between the inner walls in the slot. 13. The alternator for a vehicle according to claim 1, wherein the conductor segment has a substantially rectangular cross-section in the slot along the slot shape. Vehicle alternator . 14. The alternator for a vehicle according to claim 1, wherein the plurality of conductor segments are formed of a bare metal member, and the plurality of conductor segments are disposed between the plurality of conductor segments in the slot. An electrical insulating member interposed between the plurality of conductor segments and the inner wall surface of the slot to provide electrical insulation, wherein the plurality of conductor segments are spatially separated from each other outside the slot. An alternator for a vehicle, wherein the alternator is disposed at a distance from the vehicle . 15. The automotive alternator according to any of claims 1 to 14, the conductor cell housed in the said stator core slot
The overall axial length of the stator consisting of a segment is the field
An alternator for a vehicle, wherein the alternator is equal to or less than the total axial length of the magnetic rotor . 16. A vehicle AC generator according to any of claims 1 15, vehicle, wherein at least part of a portion located outside the slot of the conductor segments are substantially flat shape
Dual-use alternator . 17. The vehicle alternator according to claim 1, wherein a magnet is interposed between the magnetic poles of the field rotor, and a magnet magnetic flux is added to the field magnetic flux to apply the magnetic flux to the stator. An alternator for a vehicle , characterized by being directed to the vehicle . 18. The method according to claim 1, wherein
In a vehicle alternator, a plurality of coils at the coil endThe conductor segment
Almost all of their surfaces are exposed to the cooling wind
IsAC generator for vehicles. 19. The vehicle alternator according to claim 1, wherein the coil end groups are formed at both ends of the stator core, respectively, and each of the coil end groups is formed in the frame. that ventilation paths of the two cooling air in response to the coil end groups are formed
Characteristic alternator for vehicles . 20. A vehicle AC generator according to any of claims 1 19, further vehicular alternator, characterized in that it comprises a blowing means for generating a cooling air within the frame. 21. A vehicle alternator according to claim 19 or 20, in correspondence with the coil end group, wherein the said frame
Characterized in that the ventilation holes of the cooling air flowing across a plurality of the conductor segments at the coil end is formed
Vehicle alternator . 22. The alternator for a vehicle according to claim 20, wherein the blower is provided at an axial end of the field rotor, and is turned outward in a centrifugal direction by rotation of the field rotor. To the plurality of conductors at the coil end.
An alternator for a vehicle, comprising: blowing means for generating cooling air flowing across a body segment . 23. A vehicle alternator according to claim 22, wherein said blowing means, vehicle AC generator, characterized in that are provided at both ends in the axial direction of the field magnet rotor. 24. A vehicle alternator according to claim 23, wherein the sending means, vehicle AC generator, characterized in that it comprises a blowing fan having a plurality of blades. 25. A vehicle alternator according to claim 23, wherein said blowing means is to be provided by the shape of the plurality of claw-shaped magnetic poles the Lundell iron core formed corresponding to the
Characteristic alternator for vehicles . 26. The alternator for a vehicle according to claim 25, wherein an axial end of the Landel-type iron core and an inner wall surface of the frame are arranged so as to be close to and opposed to each other. AC generator for vehicles . 27. The vehicle alternator according to claim 22, wherein the frame is provided with a pulley for the blowing means facing a mounting end of a pulley for driving the field rotor. An AC power generator for a vehicle , wherein an inlet is formed, and an outermost diameter of the inlet is smaller than an outermost diameter of a pulley to be mounted thereon.
Machine . 28. The vehicle alternator according to claim 1, wherein the coil end includes a first electric conductor arranged as a predetermined layer in a first slot, and the first slot. From a connection pattern for connecting in series a second electric conductor arranged as a layer different from the first electric conductor in a second slot spaced apart according to the magnetic pole pitch of the NS poles of the field rotor. AC generator for vehicles
Electric machine . 29. The vehicle alternator according to claim 28, wherein the coil end is an end of the first electric conductor extending from the first slot, and the second electric end is extending from the second slot. are formed by joining an end portion of the conductor, wherein the first electrical conductor and the second electrical conductor, the separate
A vehicle provided by a conductor segment , wherein an end of one of the electric conductors has an angle and a length that at least circles a distance of half the pole pitch.
For alternator . 30. The automotive alternator according to claim 29, wherein the conductor segment is formed by continuously connecting two electric conductors at one end of the stator core by a turn portion. A first U-shaped segment as an end of the first electrical conductor and a second U-shaped segment as an end of the second electrical conductor.
The U-shaped joining of the ends of the segments, a vehicle AC generator, wherein said coil end is formed as the connection pattern. 31. The alternator for a vehicle according to claim 29, wherein the conductor segments protrude from both sides of the slot.
A segment having two ends, at one end of the stator core, one end of a first segment as an end of the first electric conductor, and one end of the second electric conductor. One end of the coil is formed as the connection pattern by joining the one end of the second segment to the other end of the first segment as the end of the first electric conductor at the other end of the stator core. And the other end of the third segment as an end of the other second electric conductor, and the other coil end is formed as the connection pattern. Vehicle interchange
Generator . 32. The alternator for a vehicle according to claim 31, wherein a total of the orbital lengths of both ends of the conductor segment is:
For the vehicle, which corresponds to the magnetic pole pitch
Alternator . 33. The alternator for a vehicle according to claim 31, wherein at least a part of an iron core tip located on both sides of the slot is plastically deformed to reduce the width of an opening on the inner peripheral side of the slot. An alternator for a vehicle, wherein the alternator is formed to be narrower than a distance between inner walls in a slot. 34. The automotive alternator according to claim 1, further comprising a rectifying element, wherein a part of the conductor segment is directly connected to an electrode of the rectifying element. Car
Dual-use alternator . 35. The alternator for a vehicle according to claim 34.
In the above, connected to the electrode of the rectifying elementConductor segment
Is deformed between the stator and the rectifying element electrode.
Characterized by having a part that is easy to doAC power generation for vehicles
Machine. 11. 36. A vehicle alternator according to claim 30, wherein, arranged in the turn portion of the U-shaped segments, the multi
An alternator for a vehicle, comprising: a rectifier connected to a winding end of a phase stator winding. 37. The alternator for a vehicle according to claim 30, wherein a rectifier disposed on a side of the U-shaped segment opposite to a turn portion and connected to a winding end of the polyphase stator winding is provided. An alternator for a vehicle, comprising: 11. 38. A vehicle AC generator according to any of claims 1 37, wherein the stator includes an AC vehicle and having a lead-out wiring which forms a neutral point short-circuited to each other Generator . 39. The vehicle alternator according to claim 1, wherein the conductors of the inner layer and the outer layer are provided in the slot.
AC power source for vehicles characterized by a pair of segments
Electric machine . 40. The vehicle alternator according to claim 1, wherein the conductors of the inner layer and the outer layer are provided in the slot.
Vehicle exchange characterized by two or more segments
Flow generator . 41. The vehicle alternator according to claim 40, wherein the plurality of conductor cells accommodated in one of the slots are provided.
Segment, said has only been arranged in the depth direction of the slot, the plurality of the conductor segments, wherein are mutually joined with other of said conductor segments in the coil end groups forms a plurality of joints, a plurality of The vehicle is characterized in that the joints are arranged in multiple annular shapes and are spaced apart from each other in the circumferential and radial directions in the coil end group.
For alternator . 42. A field rotor that alternately forms NS poles in the circumferential direction of rotation, a stator disposed to face the outer periphery of the rotor, a frame supporting the rotor and the stator, A rectifier for rectifying AC power derived from the stator into DC power, wherein the stator includes a laminated stator core having a plurality of slots, and a plurality of electric conductors housed in the slots. Wherein the electrical conductor includes a plurality of segments, each segment corresponding to an NS pole pitch of the rotor.
A substantially U-shaped segment having two linear portions housed in slots spaced apart from each other, wherein the turn portions of the plurality of U-shaped segments are formed as coil ends from one end face side of the stator core. The first projections are arranged so as to protrude in the axial direction and are spaced apart from each other.
A coil end group is formed, and the plurality of slots are formed at a magnetic pole pitch of the field rotor.
Slot group for one phase with multiple slots correspondingly separated
As the first slot set consisting of a group of slots for multiple phases.
And a predetermined electrical angle deviation from the first slot set.
And a second set of slots included in the first set of slots.
First winding is of formed by a plurality of said segments that
In the slot group included in the second slot set.
A second winding is formed by the plurality of contained segments.
A plurality of the slots included in the first slot set.
The output of the multiphase first winding housed in the
The plurality of slots included in the two-slot set
Connected so as to combine the output of the second winding of the multi-phase.
The ends of the plurality of U-shaped segments are arranged so as to protrude in the axial direction from the other end face side, and are joined in a predetermined connection pattern so as to form a coil end of the winding. Ends are arranged so as to be spaced apart from each other to form a second coil end group, wherein the field rotator includes a Landel-type core having a plurality of claw-shaped magnetic poles providing the N pole and the S pole, The field rotator includes a ventilation path through which air flows radially across the first coil end group and a radial path across the second coil end group on both axial sides of the field rotor. An alternator for a vehicle, which provides a ventilation path through which air flows. 43. The automotive alternator according to claim 42, wherein said field rotor is provided at its axial end with air blowing means for blowing air toward said coil end group. AC generator for vehicles . 44. The alternator for a vehicle according to claim 43, wherein the frame has the ventilation path on both the outer peripheral side of the first coil end group and the outer peripheral side of the second coil end group. An alternator for vehicles , characterized by having a ventilation opening as an exit. 45. The automotive alternator according to any one of claims 42 to 44, wherein the U-shaped segment is formed of an electric conductor having a rectangular cross section, and at the coil end,
An alternator for a vehicle, wherein a longitudinal direction of the cross section is arranged in a radial direction. 46. The automotive alternator according to any one of claims 42 to 45, wherein a plurality of pairs of the linear portions having an inner layer and an outer layer as a pair are provided in one slot. A plurality of joints, which are arranged and accommodated only in the depth direction and join the ends of the U-shaped segment, are arranged in a multiple annular shape in the second coil end group. Characterized in that the joints are arranged apart from each other in the circumferential and radial directions.
Machine . 47. A field rotor which alternately forms NS poles along the circumferential direction of rotation, a stator core arranged opposite to the rotor, and a multi-phase stator winding mounted on the stator core. In a vehicle alternator having a stator having wires and a frame supporting the rotor and the stator, the stator core has a plurality of slots for accommodating the polyphase stator winding. The plurality of slots are formed as a first-phase slot group consisting of a multi-phase slot group, with the plurality of slots spaced according to the magnetic pole pitch of the field rotor as a single-phase slot group. further wherein the first slot group includes a second slot group shifted predetermined electrical angle, said polyphase stator winding is constituted by joining a plurality of conductor segments, the plurality of conductors The segment is Inside the slot, they are arranged in pairs or more as an inner layer and an outer layer in the depth direction of the slot, are housed insulated from each other in the slot, and outside the slot, the stator core A plurality of coil ends that extend in the end face side and are connected in series to different layers in slots that are separated according to the magnetic pole pitch of the field rotor; A stator winding is included in the first set of slots.
A plurality of the conductor segments accommodated in the slot group
Forming a first winding, which is included in the second slot set.
A plurality of said conductor segments accommodated in said slot group
A second winding is formed by the plurality of slots, and the multi-phase windings are accommodated in the plurality of slot groups included in the first slot set.
Wherein an output of the first winding are connected to combine the output of the second winding of the multiphase housed in a plurality of said slots group included in the second slot group, further wherein An alternator for a vehicle, wherein the coil end has substantially the same surface area that contributes to heat radiation for each winding of all the slot groups. 48. The vehicle alternator according to claim 47 , further comprising a plurality of said conductor segments at said coil end.
Placement, the disposed so as to extend to intersect the air flow direction of the cooling air in the frame, AC vehicle, characterized in that the configuration of the cooling air flows across the plurality of the conductor segments in the coil end is provided Generator. 49. The vehicle alternator according to claim 47 , wherein a plurality of pairs of said conductor segments are provided in one said slot.
DOO is, the are only housed are arranged in the depth direction of the slot, the plurality of the conductor segments, forms a plurality of joints are mutually joined with other of said conductor segments at the coil end group The vehicle according to claim 1 , wherein the plurality of joints are arranged in multiple annular shapes, and are spaced apart from each other in a circumferential direction and a radial direction in the coil end group.
For alternator .