Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/08—Forming windings by laying conductors into or around core parts
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K3/00—Details of windings
  • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
  • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K3/00—Details of windings
  • H02K3/46—Fastening of windings on the stator or rotor structure
  • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
  • H02K3/505—Fastening of winding heads, equalising connectors, or connections thereto for large machine windings, e.g. bar windings
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K9/00—Arrangements for cooling or ventilating
  • H02K9/02—Arrangements for cooling or ventilating by ambient air flowing through the machine
  • H02K9/04—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
  • H02K9/06—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft

Definitions

• the present invention relates generally to alternators for motor vehicles.
• the invention relates to alternators for motor vehicles comprising a stator, a claw rotor with N pairs of poles disposed inside the stator and carrying an excitation coil provided with an input wire and an output wire,
• the stator comprising a cylindrical body, several phases each formed by a plurality of electrically conductive elements mounted in series along the periphery of the stator between an input and an output, the cylindrical body comprising in its radially internal face radial notches for receiving at least four phase conductive elements which are juxtaposed in the notch in the radial direction to form at least four layers of conductive elements, each conductive element having the shape of a pin extending between two notches and- comprising a first branch which is placed in a notch in a predetermined layer and a second branch available sée in another notch in a predetermined layer and, between the two branches, on an axial side of the stator body, a head forming a U seen in the peripheral direction, while on the other side of the body a free end of
• Each notch in their stators contains four conductors, two first conductors joining this notch to the same second notch, and two other conductors joining this notch to the same third notch.
• the two conductors of the first pair overlap so that their heads form concentric unequal U's.
• the stators of these alternators require for their manufacture at least two pin forming stations equipped with different tools, one per size of U.
• pins with a small radius of curvature present a risk of alteration of the enamel pin protection in the area of the stronger U.
• the insertion of the conductive elements into the body must be done in at least two steps, one step for each layer of concentric pins.
• the object of the present invention is therefore to overcome the difficulties described above.
• the invention is mainly characterized in that at least first and second conductive elements of said half are such that the radial deviation of the layers to which the two branches of said first conductive element belong is the same as 1 radial deviation of the layers to which the two branches of said second conductive element belong and that the radii of curvature of the U of the two conductive elements are identical.
• said four conductive elements are grouped in pairs of adjacent conductors, the aforementioned radial difference being the same for the two conductive elements of the same pair, and the radii of curvature of the U of the two conductive elements of the same pair are substantially identical.
• the aforementioned radial deviation of the conductive elements of one of the two pairs is different from the aforementioned radial deviation of the conductive elements of
• the other pair and the radii of curvature of the U of the conductive elements of the two pairs are different.
• the aforementioned radial deviation of the conductive elements of one of the two pairs is the same as the aforementioned radial deviation of the conductive elements of the other pair and the radii of curvature of the U of the two pairs are substantially identical.
• two of said conductive elements are adjacent and have the same aforementioned radial deviation, the radii of curvature of the two U of the two elements conductors being substantially identical.
• the phase inputs are connected to branches of conductive elements in layer C1, the corresponding outputs being connected to branches of conductive elements in layer C4.
• the phase inputs are connected to branches of conductive elements in layer C, the corresponding outputs being connected to branches ' of conductive elements in layer C1.
• the phase inputs are connected to branches of conductive elements in layer C2, the corresponding outputs being connected to branches of conductive elements in layer C3.
• the phase inputs are connected to branches of conductive elements in layer C3, the corresponding outputs being connected to branches of conductive elements in layer C2.
• at least part of the free end of the branches located in layers C1 and C4 is inclined in a first direction, at least part of the free end of the branches located in layers C2 and C3 being inclined in a second direction symmetrical to the first with respect to the Aadial plane in which the notch is located.
• At least part of the free end of the branches located in layers C1 and C3 is inclined in a first direction, at least part of the free end of the branches located in layers C2 and C4 being inclined in a second direction symmetrical with the first with respect to the radial plane in which the notch is located.
• phase inputs are electrically connected to form a neutral point.
• the rotor comprises 6, 7, 8 or 9 pairs of poles.
• the stator has three phases.
• the stator comprises two times three phases electrically offset by 30 °.
• the rotor comprises 7 pairs of poles, the external diameter of the cylindrical body of the stator being between 132 mm and 138 mm.
• the rotor comprises 6 pairs of poles, the outside diameter of the stator cylindrical body being between 137 mm and 142 mm.
• the outputs of the stator phases are connected to a current rectification device with at least 12 diodes.
• the rotor comprises two front and rear pole wheels secured to a shaft, each carrying at their periphery seven axial teeth oriented towards the other pole wheel, the axial teeth of the same wheel forming grooves between them, the wire d input of the rotor coil extending radially between the shaft and a first of said grooves of the rear pole wheel, the lead extending radially between the shaft and a second groove, this second groove being one of the two said grooves diametrically opposite to the first groove.
• the lead extends radially substantially between the shaft and the groove diametrically opposite the first groove and angularly offset in the normal direction of rotation of the rotor.
• the lead extends radially substantially between the shaft and the groove diametrically opposite the first groove and angularly offset in the opposite direction from the normal rotation of the rotor.
• a capstan is arranged in each of the first and second grooves, the input and output wires respectively making at least one turn of the capstan located in the first and second grooves.
• the capstans each comprise a radial rod fixed to the rotor and a block fixed to a free end of the radial rod.
• the two neutral points are straightened.
• the electrical network of the motor vehicle will receive more current.
• the ratio of the thickness of the cylinder head to the width L1 of the notches must have a value between 0.51 and 0.57.
• Figure 1 is a half sectional view of an alternator according to the invention
• - Figure 2 is a perspective view of the stator of Figure 1, with conductive elements removed to show the notches of the body
• Figure 3 is a schematic representation of an example of connection of the phase windings
• - Figure 4 is a cross-sectional view showing the arrangement of the conductive elements in a notch in a first embodiment of the invention
• Figure 5 is a top view of the stator according to the first embodiment of the invention
• Figure 6 is a perspective view of the arrangement of four conductive elements of the same notch of the stator of Figure 5
• Figure 7 is a schematic representation showing the location of the conductive elements of Figure 6 in two consecutive notches of the same phase
• Figure 8 is a schematic view in a peripheral direction of the heads of two elements Figure 6 conductors
• Figure 9 is a schematic representation showing the layout of three conductive elements in two consecutive notches of the same phase in a second embodiment of the invention
• - Figure 10 is a schematic view according to
• FIG. 11 is a schematic representation showing the implantation of four conductive elements in two consecutive notches of the same phase in a third embodiment of the invention
• Figure 12 is a schematic view in a peripheral direction of the heads of the four conductive elements of Figure 11
• Figure 13 is a schematic representation showing one implantation of four conductive elements in two consecutive notches of the same phase in a fourth mode of embodiment of the invention
• FIG. 14 is a diagrammatic view in a peripheral direction of the heads of the four conducting elements of FIG. 13
• FIG. 15 is a figure similar to FIG.
• Figure 16 is a figure similar to Figure 15, in another embodiment, Figure 17 is a schematic representation of the free ends of the branches of the conductive elements of Figure 7 ,
• Figure 18 is a figure similar to Figure 17, in another alternative embodiment,
• Figure 19 is a perspective view corresponding to Figure 18,
• FIG. 20 is a rear view of an embodiment of the rotor of the alternator of Figure 1
• - Figure 21 is a top view with partial section of the rotor of the alternator of Figure 20
• Figure 22 is a curve comparing the electrical currents produced by three alternators in accordance with FIGS. 3 to 8, of stators with an outside diameter of 135 mm, comprising 6, 7 and 8 pairs of poles, respectively
• FIG. 23 is a figure similar to FIG. 22 for three alternators of stators with outside diameter 140 mm.
• FIG. 24 is a perspective view of the electrically conductive elements of FIG. 5. Description of preferred embodiments
• the alternator comprises, going from left to right of f.igure 1, that is to say from front to back, a drive pulley 1 secured to the front end of a shaft 2, of which the rear end carries slip rings (not referenced) belonging to a manifold 3.
• the axis of the shaft 2 constitutes the axis of rotation of the machine.
• the shaft 2 centrally carries the rotor 4 with an excitation winding 5, the ends of which are connected by connections to the collector 3.
• the rotor 4 is here a Lundell-type claw rotor and therefore has two wheels front and rear poles 6, 7 each carrying a front 8 and rear fan respectively 9.
• Each wheel 6, 7 has a flange perpendicular to the axis of the shaft 2.
• At the outer periphery of the flanges are made of material of the teeth s 'extending axially.
• the teeth have a trapezoidal shape and have chamfers.
• the teeth of one of the wheels are directed towards the other wheel while being angularly offset with respect to the teeth of this other wheel.
• each pole wheel then comprising respectively N North poles and N South poles formed by the teeth.
• the teeth of the pole wheels having laterally each at least one anti-noise chamfer.
• the fans 8, 9 comprise for example two series of blades or blades 90 and 91, as visible in FIG. 20, which provide ventilation channels between them.
• the blades are produced by cutting and folding a fixed flange, for example by welding 92 or any other means such as crimping, on the pole wheel 6, 7 concerned; each wheel having, as mentioned above, axial teeth directed towards the other wheel with nesting of the teeth from one wheel to the other for the formation of magnetic poles when the winding 5 is activated by means of the collector rings of the collector 3 each in contact with a brush (not referenced) carried by a brush holder 10 also serving as a support for a voltage regulator (not visible) electrically connected to the brushes.
• the regulator is connected to a current rectifying device 11, such as a diode bridge (two of which are visible in FIG. 1) itself connected to the outputs of the phases provided with windings, which comprises the stator 12 of the 'alternator.
• a current rectifying device 11 such as a diode bridge (two of which are visible in FIG. 1) itself connected to the outputs of the phases provided with windings, which comprises the stator 12 of the 'alternator.
• These fans 8, 9 extend in the vicinity respectively of a front bearing 13 and a rear bearing 14.
• the bearings 13, 14 are perforated for internal ventilation of the alternator via the fans 8, 9 when the fan assembly 8, 9 - rotor 4 - shaft 2 is rotated by the pulley 1 connected to the engine of the motor vehicle by a transmission device comprising. at least one belt in engagement with the pulley 1.
• This ventilation makes it possible to cool the windings of the stator 12 and the winding 5 as well as the brush holder 10 with its generator and the straightening device 11.
• the arrows represent the Figure 1 the path followed by the cooling fluid, here air, through the different openings of the bearings 13, 14 and inside the machine.
• the brush holder 10 As well as a perforated protective cover (not referenced) are carried by fixing by the bearing 14 so that the rear fan 9 is more powerful than the front fan 8.
• the bearings 13, 14 are interconnected, here using screws or, in a variant, non-visible tie rods, to form a casing or support intended to be mounted on a fixed part of the vehicle.
• the bearings 13, 14 each carry a ball bearing 15, 16 centrally to rotationally support the front and rear ends of the shaft 2 passing through the bearings to carry the pulley 1 and the collector rings 3.
• the blades of the fans 8, 9 extend radially above the housings presented by the bearings 13, 14 for mounting the bearings 15 and 16 which are thus ventilated. These blades define between them divergent channels towards the outside.
• the fans here are of the type described in application FR 2,811,156 to which reference will be made for more details.
• At least some of the blades are of decreasing height from their internal periphery to their external periphery, and at least some of the blades are provided, overhanging relative to the bottoms of the channels, with means preventing secondary recirculation. fluid above these so-called first blades.
• the fluid flow speed is as constant and regular as possible.
• This arrangement also makes it possible to reduce the axial size at the level of the external periphery of the rotor of the electric machine.
• the efficiency of the fan and the stability of the flow of the cooling fluid are increased, while preventing secondary recirculation of the fluid above the blades concerned, and having blades of reduced thickness.
• the means avoiding secondary recirculation of the cooling fluid may consist of fins, bridges and / or a cover.
• the fan in order to reduce the noise of the fan while improving the ventilation thereof, it is proposed to provide the fan with a second series of blades, called second blades, on the one hand, shorter than those of the other series of blades called first series of blades, and on the other hand, located radially above the internal periphery of the first series of blades in at least one channel delimited by two first consecutive blades, so that at least one second blade is interposed between two consecutive blades of the first series of blades.
• second blades on the one hand, shorter than those of the other series of blades called first series of blades, and on the other hand, located radially above the internal periphery of the first series of blades in at least one channel delimited by two first consecutive blades, so that at least one second blade is interposed between two consecutive blades of the first series of blades.
• the risks of detachment of the cooling fluid stream from the blades, called the first blades, of the first series of blades framing the second blade are reduced. If this fluid takes off from the first blades, in particular when the fluid penetrates with shock between the first blades, the second blade will allow the fluid to be bonded to the first blades framing the second blade.
• one of the fans can be eliminated due to the improvement in performance of the remaining fan.
• the two fans are of identical size because, because of a better performance of the rear fan, it is possible to reduce the size of the latter, knowing that the front fan is more powerful than that of the prior art.
• the fan described in the aforementioned application FR 2,811,156 due to better performance are particularly well suited to the stator 12, which has at least one circumferential connection piece of neutral points carried by one of the chignon and creating a pressure drop .
• the or the connecting points of the neutral points are located at the outer periphery of one of the buns to interfere as little as possible with the ventilation of this bun.
• the body of the stator 12 is advantageously not in direct contact with the support 13, 14; elastic means acting between the body of the stator 12 and the external periphery of the support or casing 13, 14.
• elastomeric pads 100, 101 are interposed axially and radially between the axial ends of the body 17 of the stator 12 and the free ends of the axially oriented parts 102, 103 of the bearings 13, 14 belonging to the support.
• the pads 100, 101 have an annular shape and have a square shape in section so that they partially cover the external periphery of the body 17.
• the free ends of the parts 102, 103 are for this purpose internally stepped in diameter for formation of a shoulder and marry externally the shape of the pads 100, 101.
• These buffers constitute elastic damping means with radial and axial action to effect mechanical decoupling of the body 17 of the stator 12 relative to the casing constituted by the bearings 13, 14.
• the neutral point connection part and its welds with the phase inputs are provided, as well as the welds of the pins as described below.
• the elastic damping means intervene at the notches between the edges thereof and the electrically conductive elements, described below, mounted in these as described in the document FR-A-2 803 128.
• the elastically deformable thermally conductive resin is interposed radially between the outer periphery of the body 14 and the inner periphery of one of the bearings, such as the front bearing, as described in document FR 00 13527 filed on
• the winding 5 of the rotor 4 can be formed from a conductive element wound and coated with a bonding layer, for example of the thermosetting type, as described in the document FR-A- 2
• the coil 5 gives off more heat which is dissipated by the thermally conductive resin.
• the body 14 is mounted directly on the bearings.
• the rotor has salient poles as described in document FR 01 00122 filed on
• the alternator is cooled by a coolant, such as the cooling water of the internal combustion engine of the motor vehicle; the rear bearing comprising channels as described for example in document DE-A-100 19 914 to which reference will be made for more details.
• a coolant such as the cooling water of the internal combustion engine of the motor vehicle; the rear bearing comprising channels as described for example in document DE-A-100 19 914 to which reference will be made for more details.
• the stator is in this case mounted with the aid of pads of elastic material, for example elastomer, on the casing 13, 14 of the alternator to filter vibrations and reduce noise.
• Figures 2 and 3 show a stator 12 comprising a cylindrical body 18 of axis XX 'and two series of three phases PI to P3 and P4 to P6 constituting two series of three-phase windings offset by 30 ° electric and behaving like a hexaphase winding seen from the side of the straightening device.
• a stator 12 comprising a cylindrical body 18 of axis XX 'and two series of three phases PI to P3 and P4 to P6 constituting two series of three-phase windings offset by 30 ° electric and behaving like a hexaphase winding seen from the side of the straightening device.
• the six-phase it will include two three-phase winding series of staggered '30 ° electrical, each coil three-phase wound in a star having an independent neutral point.
• Each phase PI to P6 is each formed by a plurality of electrically conductive elements 20 mounted in series along the periphery of the stator 12 between an input, respectively El to E6, and an output, respectively SI to S6, to form at least winding phase by phase.
• the cylindrical body 18, also called a sheet bundle comprises in its radially internal face radial notches L for receiving at least four phase conductive elements 20.
• the conductive elements 20 are juxtaposed in the notch L in the radial direction to form at least four layers of conductive elements C1 to C4, as shown in FIG. 4 in the case of notches with 4 conductive elements.
• each conductive element 20 has the shape of a pin extending between two notches L and having a first branch
• the U-shaped heads 20c are generally all arranged on a first axial side 18a of the body 18, forming a first bun 24.
• the branches 20a and 20b of the conductive elements protrude from a second axial side 18b of the body 18 by free ends 20d, each free end 20d being electrically connected to a free end of a branch of another conductive element, for example by welding, thus forming the phase windings.
• the free ends 20d form the second bun 26.
• Half of the conductive elements 20 engaged by their first branches 20a in a first notch L is engaged by their ' second respective branches in the same second notch L ', each forming between the two notches L and L' the so-called U.
• the branches 20a and 20b all extend parallel to the axis XX '.
• the conductive elements 20, the El to E6 inputs and outputs SI to S6 are in the form of metal bars, typically * copper, typically of rectangular cross section, although other forms of 'section can be considered as circular sections or oval.
• the notches L extend over the entire axial length of the body 18. They are radially oblong and of semi-closed type, as can be seen in FIG. 4. These notches L are distributed circumferentially in a regular manner.
• the conductive elements 20 are mounted axially by threading in the notches L. They can also be mounted radially, the notches L then being closed by shims or by plastic deformation of the edges of the notch.
• the intermediate U-shaped portions 20c are twisted so as to be able to pass from a branch 20a situated on one layer to a branch 20b situated on a layer of different level.
• the stators are part of alternators with 6, 7, 8 or 9 pairs of poles. These stators can comprise three phases, twice three phases, 6 phases or more. Each phase can include one, two or more than two phase windings. Each notch L can include 4, 6, 8 conductive elements 20 or more. The number of notches in the body 18 depends on these four factors. For example, for an alternator with 8 pairs of poles, 6 phases, 4 windings per phase and 4 conductive elements by notches, the body 18 will comprise 96 notches marked from L1 to L96 in the order of their arrangement around the body 18.
• a first conductive element 20 comprises a first branch 20a disposed in a given notch Lk '
• the second branch 20b corresponding is arranged in a notch Lk + 6 located 6 notches further.
• the second branch 20b is connected by its free end 20d to a free end of a third branch 20a of a second conductive element 20, this third branch 20a being in a notch Lk + 12 being still 6 notches away.
• a phase winding corresponds to a set of connected conductive elements making an approximate turn of the body 18.
• a phase can include several phase windings, in series connecting the input to the output making a total of several turns of the body.
• the phase windings can in. this case be connected by special conductive elements, allowing for example to reverse the winding direction, or to offset the windings by a notch.
• the notches of the first winding are adjacent to the notches of the second winding, making an electrical offset of 30 ° between these windings for a hexaphase stator.
• the phase inputs can be electrically connected to form a neutral point.
• FIG. 3 schematically represents a hexaphase stator, the inputs El to E3 of the first three phases PI to P3 being connected and the inputs E4 to E6 of the other three phases P4 to P6 being also connected.
• the phases P4 to P6 are offset by 30 ° respectively with respect to the phases PI to P3, which represents an offset of a notch L.
• half of the conductive elements 20 engaged by their first branches 20a in a first notch L is engaged by their second respective branches in the same second notch L ', each forming between said two notches said U.
• At least one of the first and second conducting members 20 of the so-called half are as 1 gap radial layers which belong the two branches 20a and 20b of said first conductive element 20 is the same as the radial deviation of the layers to which belong the two branches 20a and 20b of said second conductive element 20.
• These first and second ' conductive elements ' are therefore arranged strictly parallel over most of their length, and it follows that the radii of curvature of the U of the first and second conductive elements 20 are substantially identical.
• FIGS 5 to 8 illustrate this advantageous characteristic for a hexaphase winding, in a first embodiment where the notches L contain four
• FIG. 5 shows a six-phase alternator stator comprising a body 18, aforementioned comprising a sheet package provided with notches L traversed by electrically conductive elements 20 called here
• the stator winding of the phases comprises on a first axial side 18a of the body 18, the first bun 24 which brings together all of the heads 20c of all the pins as well as the phase outputs SI to S3
• stator winding of the hexaphase type being composed of the two series above of
• the bun 24 also includes the phase inputs as mentioned above, also called neutral inputs as well as their connections or connections at an equipotential point.
• the neutral inputs are 6 in number and are therefore connected in two groups of three inputs corresponding to the two star windings.
• FIG. 24 shows an advantageous variant of the device for connecting the neutral point. Two first neutral inputs are connected by a pin 160. The third neutral input. is then connected to the previous pin by a single connection point produced for example in the form of a weld 162 -by electron beam. Thus it is possible to connect the equipotential neutral point with a single solder connecting only two specific conductors 161, 160 thereby increasing the reliability of the electrical connection.
• Each winding series can be made with standard pins 140, 145, three standard pins 164, 165, 166 for phase output and two specific pins for the connection of the neutral point.
• Pin 163 which allows the windings to be connected at the phase outputs and the neutral point.
• Pins 164 to 166 correspond to standard pins of the nested or wavy type, one of the branches of which is extended axially. We also see in this figure in 167 the three phase outputs of the second phase series.
• the second bun 26 On the opposite side of the bun 24 is the second bun 26 which carries all the connections / connections of the free ends 20d of the pins to form the phase windings.
• these connections are made in the form of welding by electron beams or by laser as described in application FR-0102735 filed on February 28, 2001, which allows welding without first stripping the free ends of the pins, for example by a mechanical process.
• FIG. 6 represents a set of two wavy pins 31 and 33 and two nested pins 32 and 34.
• the 4 branches 311, 321, 331 and 341 adjacent to the aforementioned four pins, are aligned radially in a notch L of the stator body as shown in FIG. 4.
• the branch 311 is placed on the airgap side of the electric machine, that is to say at the internal periphery of a notch , while the branch 341 is placed at the bottom of the notch.
• the branch 311 belongs to a pin of the wavy type while the branch 341 belongs to a pin of the nested type.
• the pin placed as close as possible to the air gap could be of the nested type.
• the tops 20e of the heads 20c of the pins at the level of the bun 24 are - located axially substantially at the same level. .
• this arrangement makes it possible to use only one type of pin for the production of pins of the wavy and nested types.
• the conductive elements shaped shaped pin are threaded through the notches axially pushing their free ends into the slots until they emerge from the other side of the stator body. Then, to form the bun 26, the free ends of the pins are bent so as to produce wavy and nested pins.
• tops 20e of the heads of the pins 20 are substantially situated axially at the same level represents an advantage since their alignment can be achieved in a single pushing operation by a suitable tool.
• Another advantage provided by the configuration of the bun 24 relates to its ventilation. Indeed, the fact that all the tops of the pin heads are located at the same level allows better ventilation because the interior of the pin heads 20c constitutes a chamber devoid of any obstacle which could interfere with good air circulation of cooling, generated for example, by the fans 8 and 9 shown in FIG. 1.
• the air easily penetrates through the blanks of the buns 24 and 26 to emerge just as easily as shown by the ventilation arrows in FIG. 1.
• the vertices 20e of the pin heads are adjacent while being here in contact with each other.
• the bun 24 is more rigid because all the pins are in contact, thus forming a mechanically rigid assembly.
• the air noise is also very reduced because there is no obstacle inside the bun 24 which could generate a harmful air noise during the operation of the electric machine at certain speeds.
• the height of the bun 24 is reduced because all the vertices 20e are at the same level.
• the phase outputs SI to S6 extend in axial projection relative to the heads 20c and to the inputs El to E6. It will also be noted that it is easily possible to adjust the axial length of the second bun 26 by pushing more or less on the heads 20c since these are located at the same level. Finally, a great standardization of pins is obtained.
• FIG. 7 schematically describes the arrangement of the conductive elements in the notches in order to obtain a hexaphase winding of the type previously described. There is shown at 35 a pin head of the corrugated type, close to the air gap and at 36 a pin head of the nested type. These two pins constitute a basic segment or pattern of a phase winding.
• the head 35 is connected to the branches A and G of the pin in question, while the head 36 is connected to the branches B and H of this second pin.
• Said branches passing axially through a notch Lk and Lk + 6 respectively.
• Lk and Lk + 6 are provided 5 notches distributed circumferentially in a regular manner for the windings of the 5 other phases.
• the hexaphase winding of our embodiment has 2 notches per pole and per phase.
• the stator will have 96 notches.
• the branch B associated with the head 36 is located in the notch Lk radially above the branch A associated with the head 35.
• the branch H associated with the head 36 is located in 1 ' notch Lk + 6 radially above the branch G associated with the head 35.
• the branch H is adjacent to the bottom of the notch so that two branches F and E, associated with two other pin heads are located radially au- below the branches H and G.
• two branches D and C associated with two other heads of pins 1 are located radially above the branches B and A so that the heads 35 and 36 are parallel. This pattern is repeated so on.
• a notch there are two pairs of electrically conductive elements, a first pair of these elements, implanted at the external periphery of the notch being connected by heads to another pair of conductive elements implanted at the internal periphery of another consecutive notch belonging to the same phase.
• the pairs are distributed alternately from one notch to another.
• This regular pattern is interrupted at the entry and exit of the phase considered as represented according to two possible embodiments in FIGS. 15 and 16 in which the pins corresponding to the heads 35 and 36 are identical to those of FIG. 7
• the conductor D 'corresponding to the conductor D of FIG. 7 constitutes the phase output of the winding considered, while the conductor E' corresponding to the conductor E of FIG.
• the conductor C corresponding to the conductor C in FIG. 7 constitutes the phase output of the winding considered, while the conductor F 'corresponding to the conductor F in FIG. 7 constitutes the input of the neutral point of said winding.
• the conductors C and F of FIG. 15 and the conductors D and E of FIG. 16 are respectively connected to each other by a special connection pin.
• two pairs of conductive elements are mounted in superposition in each notch of the stator so that a first pair is installed above or below the second pair and this, in an alternating manner from one notch to another consecutive notch of the same phase so that the heads of the pins are parallel and the tops of these pin heads are axially substantially at the same height.
• Figure 8 shows pins 35 and 36 viewed peripherally. It is clear that the radii of curvature of the U-shaped heads of these pins are substantially equal.
• Figures 9 and 10 illustrate a second embodiment of the invention where the notches L contain six conductive elements arranged on six layers C1 to C6.
• the said three pins extend between a notch Lk and a notch Lk + 6, in the case of a hexaphase winding.
• the difference between these two notches would of course be different if the stator had a different number of phases.
• the head 37 joins a branch located on the layer C3 of the housing Lk to a branch located on the layer C5 of the housing Lk + 6.
• the head 38 joins a branch located on the layer C2 of the housing Lk to a branch located on the layer C4 of the housing Lk + 6. It will be noted that the heads 37 and 38 are parallel over most of their lengths.
• the head 39 joins a branch located on the layer C1 to a branch located on the layer C6.
• pins form the basic pattern of a phase winding, this pattern being reproduced over the entire circumference of the stator, the pin 39 being, depending on the case, of the nested type or of the wavy type.
• Figures 11 and 12 illustrate a third embodiment of the invention where the notches L contain eight conductive elements arranged on eight layers C1 to C8.
• the head of a pin of the nested type has been represented at 40, at 41 the head of a wavy type pin, 42 the head of a pin of the nested type, at 43 the head of a pin of the wavy type.
• the head 40 can belong to a pin of the wavy type, the head 41 then belonging to a pin of the nested type.
• the head 42 may belong to a pin of the wavy type, the head 43 then belonging to a pin of the nested type.
• the heads 42 and 43 pass astride the • 10 heads 40 and 41.
• Said four pins extend between a notch Lk and a notch Lk + 6, in the case of a hexaphase winding. The difference between these two notches would of course be different if the stator had a number of
• the head 40 joins a branch located on the layer C4 of the housing Lk to a branch located on the layer C6 of the housing Lk + 6. At the same time, the head 41 joins a branch located on the layer C3 of the
• the head 42 joins a branch located on the layer C2 of the housing Lk to a branch located on the 2.5 layer ' C8 of the housing Lk + 6.
• the head 43 joins a branch located on the layer C1 of the housing Lk to a branch located on the layer C7 of the housing Lk + 6. It will be noted that the heads 42 and 43 are parallel over most of their lengths.
• pins form the basic pattern of a phase winding, this pattern being reproduced over the entire circumference of the stator.
• FIG. 12 It can be seen in FIG. 12 that the U formed by the heads 40 and 41 when viewed in a peripheral direction have substantially identical radii of curvature.
• the radii of curvature of the U of heads 42 and 43 are also substantially identical, and are larger than those of heads 40 and 41.
• Figures 13 and 14 illustrate a fourth embodiment of one invention where the notches L also contain eight conductive elements arranged on eight layers C1 to C8.
• the head of a nested type pin is represented at 44, the head of a wavy type pin at 45, the head of a nested type pin at 46, the head of a wavy type pin at 47 .
• the head 44 can belong to a pin of the wavy type, the head 45 then belonging to a pin of the nested type.
• the head 46 can belong to a pin of the wavy type, the head 47 then belonging to a pin of the nested type. Heads 44 and 45 never cross heads 46 and 47.
• Said four pins extend between a notch Lk and a notch Lk + 6, in the case of a hexaphase winding. The difference between these two notches would of course be different if the stator had a different number of phases.
• the head 44 joins a branch located on layer C6 of housing Lk to a branch located on layer C8 of housing Lk + 6.
• the head 45 joins a branch located on the * layer C5 of the housing Lk to a branch located on the layer C7 of the housing Lk + 6.
• the head 46 joins a branch located on the layer C2 of the housing Lk to a branch located on the layer C4 of the housing Lk + 6. At the same time, the head 47 joins a branch located on the layer C1 of the housing Lk with a branch located on the layer C3 of the housing Lk + 6.
• heads 44, 45, 46 and 47 are parallel over most of their lengths.
• the free ends of the branches located on the layers C4 and C1 are twisted in a peripheral direction, the free ends of the branches located on the layers C3 and C2 being twisted in an opposite peripheral direction.
• the second variant is shown in perspective in FIG. 19.
• the main criterion used for this optimization is the mass power of the alternator, that is to say the ability of the alternator to deliver current relative to the weight of its active part, essentially consisting of the winding 5 of the rotor 4 , phases P of the stator 12, the body 18 of the stator 12 and the pole wheels 6, 7 of the rotor 4.
• This criterion is particularly relevant since current motor vehicles require an available electrical power of larger and larger to supply more and more electrical consumers. However, this increase in power must not lead to an excessive increase in the external dimensions of the alternator.
• the alternator is always placed under the engine hood where, as everyone knows, the space available is very limited.
• the external size of the alternator therefore becomes a determining criterion.
• alternators comprising stators wound with round wire coils know that, when the number of pairs of rotor poles increases, then the frequency of the induced flux increases in the same proportions as well as the induced current and the losses of iron at stator level. These iron losses resulting from eddy currents tend to reduce the efficiency of the alternator.
• those skilled in the art of alternators comprising stators wound with coils of round wire increases the number of pairs of poles with the diameter of the machine. Its objective is indeed to control the losses of magnetic flux between the adjacent teeth of different magnetic polarity. This magnetic leakage flow passes directly from one tooth of the Lundell type rotor to another adjacent to it, but of different sign, without passing through the body of the stator.
• the choice of the number of pairs of poles in stators wound with round wires is mainly dictated either by considerations of process, or according to the diameter of the machine to guarantee leaks of forbidden magnetic fluxes, with or without forbidden magnets, reasonable.
• technical devices are then placed in the alternator to reduce, for example, the losses of iron which can occur, for example at the level of the stator or the rotor.
• alternators having a relatively large diameter it is necessary to take into account the problems of centrifugation at the level of the teeth of the rotor which can deviate and strike the stator.
• a folded or forged wheel will have a different behavior on centrifugation and, for a given diameter, the number of poles which ensures the best mechanical strength may be different according to one or the other method.
• Alternators wound with pins have a different geometry than those wound with round wires.
• the active part of the stator facing the rotor has an active magnetic part with a different surface because in the case of a winding produced with pins, said pins are inserted by the axial openings of the notches of the stator and not by the radial openings notches as is the case for wound stators - with conventional round wires.
• the alternator comprises a rotor 4 with seven pairs of poles and a hexaphase stator 12 with two series of three phases P offset by 30 ° electric.
• the body 18 of the stator 12 comprises notches each containing four conductive elements 20 in pins of substantially rectangular section, such as those described above, arranged in accordance with the figures
• the inputs El to E3 and E4 to E6 of the two series of three phases are connected respectively to a neutral point.
• the main dimensions of the stator are indicated below, mainly with reference to FIG. 4.
• the outside diameter Rext of the body 18 of the stator is 135 mm. It can vary from 132 mm to 138 mm without the performance of the alternator are greatly affected.
• the internal diameter Rint of this body 18 is 108 mm.
• the stator comprises 84 identical notches L arranged on the internal radial face of the body 18 in a regular pitch of 4.286 °.
• the width L1 of the notches is 2.05 mm and their depth pi is 10.3 mm.
• the radial thickness e of the solid part partially closing the opening of the notch is 0.4 mm.
• the width L2 of the branches of the conductive elements passing through the notch is 1.55 mm and their thickness p2 is 2.4 mm.
• the radius of curvature of the angles of the section of these branches is 0.5 mm.
• These branches are surrounded by a layer of insulating material 160 ⁇ m thick.
• the stator yoke is the part between the external peripheral part of the stator and the bottom of the notches. To have the optimum specific power, the ratio of the thickness of the cylinder head to the width L1 of the notches must have a value between 0.51 and 0.57.
• the curve in FIG. 22 compares the electric current I expressed in amperes supplied by 3 alternators all conforming to FIGS. 3 to 8 and of body 18 of external diameter • 135 mm, comprising respectively 6 pairs of PP poles, 7 pairs of PP poles and 8 pairs of PP poles, for two rotational speeds, 1800 rpm (curve Cl) and 6000 rpm (curve C2).
• 1800 and 6000 rpm respectively represent the idling speed of the internal combustion engine of the motor vehicle and an average speed.
• the size of the conductive elements is the same for the three alternators, and corresponds to the dimensions given above.
• the mass power varies according to the number of poles in the same way as the intensity, because the mass of an alternator varies little when we go from 6 to 8 pairs of poles.
• stator 12 has in this configuration an iron / copper distribution, ie magnetic path / electrical path, optimum.
• the alternator comprises a rotor 4 with six pairs of poles and a six-phase stator 12 with two series of three phases P offset by 30 ° electric.
• the body 18 of the stator 12 comprises 72 notches each containing four conductive elements 20 in pins of substantially rectangular section, such as those described above, arranged in accordance with FIGS. 3 to 8.
• the outside diameter Rext of the stator body 18 is 140 mm. It can vary from 137 mm to 143 mm without the performance of the alternator is not greatly affected.
• the curve in Figure 23 compares the electrical current I expressed in amperes supplied by 3 alternators all in accordance with Figures 3 to 8 and of body 18 with an external diameter of 140 mm, comprising respectively 6 pairs of PP poles, 7 pairs of PP poles and 8 pairs of PP poles, for two rotational speeds, 1800 rpm (curve C1) and 6000 rpm (curve C2). It is clearly seen that the maximum intensity, therefore the maximum specific power, is produced by the alternator with 6 pairs of poles, which therefore represents the optimum efficiency for the outside diameter of 140 mm.
• the other dimensional characteristics of the alternator in the preferred embodiment described above result directly from the know-how of a person skilled in the art, once the number of pairs of poles and the external diameter of the body 18 are fixed. They are not shown here.
• stator notches contain 4 conductors. They can easily be adapted 'to cases where the notches contain 6 or 8 conductors.
• the first preferred embodiment of the invention described above involves an asymmetrical rotor 4 with 7 pairs of poles.
• the input 50 and output 51 wires of the winding 5 of this rotor are connected to the collector 3.
• an advantageous arrangement is provided for the invention. which will now be described with reference to FIGS. 20 and 21.
• the rotor comprises two front and rear pole wheels 6 and 7 each carrying teeth at their periphery, referenced 71 to 77 following the periphery of the rear pole wheel in the normal direction of rotation of the rotor 4 symbolized by an arrow in FIG. 20.
• Each pole wheel comprises 7 teeth since the alternator in the first preferred embodiment comprises 7 pairs of poles.
• the teeth 71 to 77 of the rear pole wheel are separated from each other by grooves 71 'to 77'.
• the rotor 4 also includes 2 . hooks 78 and 78 'carried by the rear face of the rear pole wheel 7. These hooks 78 and 78' are located near the shaft
• the input wire 50 connects the hook 78 to the coil 5. It extends radially from the hook 78 to the first groove 71 '.
• the output wire 51 connects the hook 78 ′ to the coil 5 passing through a hole made at the base of the tooth 74, that is to say in a direction exactly diametrically opposite to the first groove
• the two input and output wires 50 and 51 are symmetrical with respect to the axis of rotation of the machine and this device therefore adapts to a conventional manifold 3.
• This solution has the following drawbacks.
• the passage section of the magnetic flux is reduced by the presence of the hole, and this in the most saturated part of the rotor, which causes a degradation of the performance of the machine.
• the mounting of the coil 5 is difficult because it is necessary to pass the output wire 51 blind into the hole, which risks causing many manufacturing defects.
• the hole is located near ground, which leads to the risk of short circuit.
• the output wire 51 extends radially from the hook 78 'to a second groove, this second groove being the groove 74' or the groove 75 ', these two grooves being diametrically opposite to groove 71'.
• the output wire 51 passes through the groove 75 ', because this arrangement is more favorable for hooking to the hook 78'.
• Capstans 79 are located in gorges 71 'and 74' / 75 '. These capstans 79 each comprise a radial rod secured to the rotor at one end, and a block mounted at the opposite free end.
• the input and output wires 50 and 51 each make a tour of the capstans 79 respectively located in the first and second grooves 71 'and 74' / 75 'before joining the coil 5.
• This arrangement can obviously be used with any rotor comprising a number of pairs of odd poles.
• the rear fan 9 has clearances 93 and 94 which respectively allow the passage of the wires 50 and 51 between the flange of the rear pole wheel and the fan.
• the two neutral points are rectified.
• the electrical machine delivers more current into the electrical network while delivering an acceptable ripple rate.
• the alternator is an alternator-starter, that is to say a reversible machine constituting an alternator when the pulley is driven by the engine of the motor vehicle or a starter to drive the vehicle engine via the pulley as described for example.
• alternator-starter that is to say a reversible machine constituting an alternator when the pulley is driven by the engine of the motor vehicle or a starter to drive the vehicle engine via the pulley as described for example.
• one of the bearings 15, 16 carries at least one sensor, for example of the magnetic type, for detecting the passage of a magnetic target carried by the rotor.
• the rectifier bridge is then a rectifier and control bridge, which in a mode of
• phase outputs are then connected to a connector carried by one alternator and connected to the rectification and control device by a cable.
• the electric machine according to the invention with a connecting part is a high power machine, compact, low noise and well cooled.

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• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Synchronous Machinery (AREA)
• Windings For Motors And Generators (AREA)
• Permanent Magnet Type Synchronous Machine (AREA)
• Insulation, Fastening Of Motor, Generator Windings (AREA)
• Motor Or Generator Cooling System (AREA)
• Iron Core Of Rotating Electric Machines (AREA)

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