Classifications

• • 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
  • H02K3/51—Fastening of winding heads, equalising connectors, or connections thereto applicable to rotors only
• • 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 invention relates to a rotor with salient poles comprising flanges for holding winding coils and associated holding flanges.
• the invention finds a particularly advantageous application in the field of rotating electrical machines such as alternators, alternator-starters and electromagnetic retarders.
• WO 2003/019748 relates to a system and a method for retaining the terminal turn of the cables on a generator rotor designed for high speed applications such as aeronautical applications.
• This rotor comprises a shaft, fins, supports and cable winding coils and at least one cover.
• the fins extend radially outwardly from the shaft and each support is placed on a corresponding fin.
• Each winding is installed around the support and the corresponding fin.
• Each cap comes to mate with one end of the corresponding fin so as to prevent the radial displacement of the windings outwardly during rotation of the rotor.
• Each support is coupled with the corresponding cover and comprises on its inner radial edge a flange extending in a direction opposite to the respective fin.
• WO 2007/003835 discloses a protruding pole rotor for a rotating electrical machine including an alternator or alternator-starter for a motor vehicle.
• an alternator / starter is a rotating electrical machine able to work in a reversible manner, on the one hand, as an electric generator in alternator function and, on the other hand, as an electric motor in particular for starting the engine. of the motor vehicle.
• This machine essentially comprises a housing and, inside thereof, a rotor fixed in rotation with a central rotor shaft and an annular stator which surrounds the rotor coaxially with the shaft.
• the stator comprises a body in the form of a pack of sheets with notches, for example of the semi-closed type, for mounting a stator winding having a plurality of windings.
• This stator winding comprises for example a set of three-phase star or delta windings, the outputs of which are connected to a rectifier bridge comprising rectifying elements.
• the alternator is of the polyphase type and the rectifier bridge or bridges make it possible in particular to rectify the alternating current produced in the stator windings in a direct current, in particular for charging the battery of the motor vehicle and supplying the electric loads and consumers of the on-board network of the motor vehicle.
• the housing is in at least two parts, namely a front bearing and a rear bearing.
• the bearings are hollow in shape and each carries a central ball bearing respectively for the rotational mounting of the rotor shaft.
• the housing has an intermediate portion internally bearing the body of the stator. This intermediate portion is interposed axially between the bearings each having a plurality of openings for internal ventilation of the machine with at least one fan secured to one of the axial ends of the rotor.
• This fan has blades integral with a flange as described below.
• the rotor shaft carries at its front end a pulley which is arranged outside the housing.
• the pulley belongs to a motion transmission device via at least one belt between the alternator and the engine of the motor vehicle.
• a package of sheets is mounted coaxially on the rotor shaft in the housing, inside the stator.
• This bundle of sheets is formed of an axial stack of sheets which extend in a radial plane perpendicular to the axis of the rotor shaft.
• This bundle of plates comprises here a cylindrical central core and a circumferential distribution of arms projecting radially from the core.
• the sheets of the sheet package all have an identical contour.
• the outline of the sheets is cut into a generally circular shape and having salient poles, which are regularly distributed in a radial direction and projecting from the shaft towards the outer periphery.
• the sheet package has at least two poles.
• Each pole consists of an arm which, starting from the core, extends radially towards the outer periphery in the direction of the stator.
• the free end of the pole ends with a return protruding circumferentially on either side of the arm.
• An annular gap exists between the free end of the poles and the inner periphery of the stator body.
• the excitation windings are electrically powered by a collector, which has slip rings, which are arranged around a rear end of the shaft.
• This collector is for example made by overmolding electrically insulating material on electrically conductive elements connecting the rings to a ring electrically connected by wire links to the ends of the rotor or excitation coils.
• the slip rings are electrically powered by means of brushes which belong to a brush holder and which are arranged so as to rub on the slip rings.
• the brush holder is generally arranged in the housing and is electrically connected to a voltage regulator.
• Each excitation coil is wound around the radially oriented arm of each pole so that axial end portions of the excitation coil project axially with respect to each radial face of the external axial end of the package. of sheets. These protruding portions will subsequently be called "buns".
• Each pole thus comprises an excitation winding which itself comprises two opposite buns.
• a first front flange and a second rear flange are mounted coaxially to the shaft so as to axially clamp the sheet of paper to keep the sheets stacked in a package.
• Each flange generally has the shape of a disk extending in a radial plane perpendicular to the axis of the shaft.
• Each flange has a central hole for coaxial mounting on the shaft.
• the flanges are arranged axially on either side of the package of sheets so that the internal radial faces of the flanges are in bearing against the outer axial radial end faces of the sheet package.
• Each flange has four holes to allow the passage of four tie rods.
• the arms of the plate bundle have holes so that the tie rods can axially traverse the bundle of sheets from the front flange to the rear flange.
• the flanges are heat conductive material, for example metal.
• the outer peripheral edge of the flanges vis-à-vis the stator has axial grooves which are open in the radial inner and outer faces of the flanges. These grooves make it possible to renew the air which is included radially between the stator and the rotor.
• Each flange also has housings that are made in their inner radial face. These accommodations are intended to receive the salient buns. At least one of the housing of at least one flange has a contact surface with the outer radial face of the associated bun. Thus, when the buns are heated, their heat is transmitted to the flasks including conduction.
• the bun is in contact with the bottom of the housing via a heat conductive substance and non-electrically conductive, which protects the wires of the excitation winding.
• the substance is here a coating of impregnation conductive heat and electrical insulation. This varnish cures by polymerization.
• One of the flanges has filling holes which each open into the bottom of an associated housing. These filling holes are intended to allow the impregnation of the liquid varnish around the excitation winding associated with said housing, and more particularly around the two bunches of the excitation winding.
• each flange comprises blades forming a fan.
• Each blade extends axially outwardly from the outer radial face of the associated flange.
• the object of the invention is notably to propose an improved projecting pole rotor enabling improved cooling without necessarily having to carry out a varnish impregnation step between the coils and the sheet package.
• the invention relates to a rotating electric machine rotor comprising:
• a rotor shaft intended to be rotatably mounted about its axis
• this bundle of plates comprising at least eight radially projecting poles
• each holding flange comprises:
• each flange comprises a first series of through holes located around the main opening, these openings having an opening angle at least equal to the angle between two successive salient poles.
• the orifices of the first series of orifices are wider circumferentially than high radially.
• each flange comprises a second series of through holes implanted outside the first series.
• the size of the first set of orifices and / or the second set of orifices is different from one flange to the other.
• the orifices of the series of through orifices are higher radially than circumferentially wide.
• the said radially higher than circumferentially wide openings are generally vis-à-vis at least a portion of an inter-rewinding space.
• the radial height of some of the orifices generally vis-à-vis at least a portion of an inter-rewinding space is generally equal to the radial height of the inter-rewinding space.
• the radial height of some of the orifices generally vis-à-vis at least a portion of an inter-rewinding space is less than the radial height of the inter-rewinding space.
• the circumferential width of some of the orifices vis-à-vis globally of at least a portion of an inter-rewinding space is generally equal to the circumferential width of an inter-winding space.
• the circumferential width of some of the orifices vis-à-vis globally of at least a portion of an inter-winding space is greater than the circumferential width of an inter-winding space.
• the circumferential width of some of the orifices vis-à-vis globally of at least a portion of an inter-rewinding space is less than the circumferential width of an inter-winding space.
• each flange comprises a series of orifices radially higher than wide circumferentially and the second series of orifices.
• At least one flange door blades positioned on a first side of the wall facing outwardly of the rotor.
• the blades belong to a separate fan attached to fixing on the flange for example by spot welding, screwing or riveting.
• each flange comprises a second series of orifices, each orifice of the second series being positioned between two successive blades.
• the rotor further comprises two insulating elements positioned on either side of the sheet package, ensuring the insulation of buns.
• each flange has on its inner face facing the rotor at least one sector extending axially to the sheet package, - each insulating member has at least one recessed portion within which is inserted the sector. of one of the flasks.
• each insulating element comprises:
• caps located at one end of the arms extending circumferentially on either side of the arm, these caps being positioned between the winding head and the annular rim of a flange so as to participate in the retention of the buns.
• each flange comprises at least one centering pin intended to cooperate with axial openings formed in the salient poles.
• each flange comprises at least two orifices, the orifices of the flanges and the axial openings of the poles ensuring the passage of tie rods to assemble the flanges around the package of sheets.
• the rotor comprises at least one magnet positioned between two adjacent salient poles.
• the flanges are made of non-magnetic material, such as aluminum or plastic material advantageously reinforced by fibers.
• the invention furthermore relates to a set of flanges for holding a bundle of sheets and coils of windings arranged axially on either side of the laminations of a rotor of a rotating electrical machine having at least eight salient poles with formation of inter-winding spaces between two successive windings each wrapped around a projecting pole, characterized in that each holding flange comprises:
• annular flange extending over the entire outer periphery of the radial wall and extending axially in the direction of the rotor, this annular flange having a face bearing on the outer radial end faces of the sheet bundle in order to maintain place the buns despite the centrifugal force caused by the rotation of the rotor acting on said buns,
• the total surface of the series of orifices being greater than 0.3 times the total surface area of the inter-winding spaces.
• Figure 1 an axial sectional view of a rotary electric machine provided with a rotor according to the invention
• Figure 2 is an exploded perspective view of a rotor according to the invention which is not wound;
• Figures 3a and 3b perspective views of a wound rotor according to the invention without the flanges or the resolver;
• Figures 4a and 4b views respectively of the top and bottom of a rotor according to the invention without the flanges or the resolver;
• Figures 5a-5b perspective views of a wound rotor according to the invention provided with its holding flanges
• Figure 6a-6b views respectively of the top and bottom of a rotor according to the invention provided with its holding flanges with a first and a second series of orifices
• Figure 7 a sectional view of a rotor according to the invention having an alternative opening for attachment to the shaft.
• Figure 8 a view of one of the flanges with a lower number of second orifices.
• Figure 9 a partial view of one of the flanges having a series of orifices implanted vis-à-vis an inter-rewinding space.
• the invention relates to a rotor 30 with salient poles for a rotating electrical machine 10, in particular an alternator or an alternator-starter.
• This machine 10 is preferably intended to be implemented in a motor vehicle.
• an alternator / starter is a rotating electrical machine able to work in a reversible manner, on the one hand, as an electric generator in alternator function and, on the other hand, as an electric motor, in particular for starting the engine. of the motor vehicle.
• alternator-starter is described for example in the document WO-A-01/69762 to which reference will be made for more details.
• This machine essentially comprises a casing January 1 and, inside thereof, a rotor 30 integral in rotation with a central shaft of rotor and an annular stator 12 which surrounds the rotor 30 coaxially with the shaft 35 of axis B also constituting the axis of the rotor 30.
• the stator 12 comprises a body in the form of a pack of sheets with notches, for example of the semi-closed type, for mounting a stator winding 13 having a plurality of windings.
• This stator winding 13 comprises, for example, a set of three-phase star or delta windings, the outputs of which are connected to a rectifier bridge (not shown) comprising rectifier elements comprising rectifying elements such as diodes or transistors of the type MOSFET, especially when the machine 10 is of the reversible type and consists of an alternator-starter as described for example in the document FR-A-2,745,445 (US-A-6,002,219).
• the windings of the stator winding 13 are obtained using a continuous, electrically conductive wire coated with an insulating layer and mounted in the relevant notches of the stator body 12.
• the windings 13 are made using bar-shaped conductors, such as pins, interconnected for example by welding.
• the stator winding 13 comprises two sets of three-phase windings to form a device of composite stator windings 12, the windings being offset thirty electric degrees as described for example in US-A1-2002/0175589, EP-0,454,039 and FR-A-2,784,248. In this case, two rectifier bridges are provided and all combinations of three-phase star and / or delta windings are possible.
• the alternator is of the polyphase type and the rectifier bridge makes it possible in particular to rectify the alternating current produced in the stator windings 12 into a direct current, in particular to charge the battery (not represented) of the motor vehicle and feed electric loads and consumers of the on-board network of the motor vehicle.
• the shaft 35 of the rotor 30 is rotatably mounted about its axially oriented axis B in the stator 12 of the machine 10.
• the housing 1 1 is in at least two parts, namely a front bearing 14 and a rear bearing 15.
• the bearings 14, 15 are of hollow form and each bear a ball bearing respectively 16 and 17 for the rotational mounting of the shaft 35 of the rotor 30.
• the housing 1 1 has an intermediate portion (not referenced) internally bearing the body of the stator. This intermediate portion is interposed axially between the bearings 14, 15 each having a plurality of openings one of which (not referenced) is visible in Figure 1 for internal ventilation of the machine using a fan described in more detail below.
• the shaft 35 of the rotor 30 carries at its front end a pulley 18 which is arranged outside the housing 1 January.
• the pulley 18 belongs to a device for transmitting movements through at least one belt (not shown) between the alternator and the engine of the motor vehicle.
• Figure 2 shows the rotor 30 having the shaft 35, a bundle 36 of metal plates coaxially mounted on the shaft 35, this bundle 36 of sheets having at least eight poles 44 radially projecting.
• the rotor may have ten poles or 12 poles as shown in the figures. 4a and 4b.
• the poles may be distributed circumferentially in a regular manner.
• the rotor 30 further comprises an excitation winding 50 (see FIGS. 3a-3b) wound around each pole 44, so that portions 51 of axial end of the winding 50, referred to as "buns", protrude axially relative to each other. at each face 40, 41 of the outer radial end of the pack 36 of sheets.
• Flanges 55, 56 for holding the package 36 of sheets and buns 51 of the coils 50 are arranged axially on either side of the package 36 of sheets.
• the package 36 of sheets is mounted coaxially on the rotor shaft 30 in the housing 1 1, inside the stator 12.
• the package 36 of sheets is mounted to rotate with the shaft 35.
• the bundle 36 of plates comprises a central axial orifice 37 which is force-fitted on a knurled section of the shaft 35.
• the core of the bundle 36 of sheets has an opening 38 provided with recesses regularly distributed circumferentially around the opening 38 for cooperating with tabs of corresponding shape belonging to the shaft 35 (see Figure 7). In an exemplary embodiment, these recesses have a top view in a circular shape.
• the pack 36 of sheets is formed of an axial stack of sheets which extend in a radial plane perpendicular to the axis B of the shaft 35.
• the pack 36 of sheets forms the body of the rotor 30 and is in ferromagnetic material.
• This bundle 36 of plates here comprises a central cylindrical core and poles 44 projecting radially from the core. These poles 44 are in one embodiment in one piece with the soul.
• the poles 44 are attached to the core, for example by a tenon-mortise type connection as described in document FR 2 856 532.
• One pole on every two or all of the poles 44 are attached to the core in such a way that to facilitate assembly and disassembly of the poles 44.
• a return 45 projecting from a pole 44 on two or 45 salient return of all the poles 44 is reported with respect to a corresponding arm 39.
• radial faces oriented towards the middle of the pack 36 of sheets will be described as internal faces while the radial faces oriented in an opposite direction will be described as external faces. It is also considered that the rear side of the rotor 30 is located on the resolver 100 side while the front side is on the opposite side.
• the bundle 36 of metal sheets is delimited axially by the first outer radial face 40 of the front end and the second opposite outer radial face 41 of the rear end.
• the sheets of the pack 36 of sheets all have an identical contour.
• the outline of the sheets is cut in a generally circular shape and comprises the salient poles 44, which are regularly distributed in a radial direction and projections of the shaft 35 to the outer periphery, as shown in Figures 4a-4b.
• the bundle 36 of plates has at least eight poles 44 and in the example shown in the figures, it comprises twelve poles 44.
• Each pole 44 as best seen in FIG. 7, consists of an arm 39 and a salient return.
• the arm 39 extends radially from the core towards the outer periphery in the direction of the stator 12.
• the free end of the pole 44 terminates in the return 45 protruding circumferentially on either side of the arm 39.
• An annular air gap exists between the free end of the poles 44 and the inner periphery of the stator body 12.
• each pole 44 The function of the protruding return 45 of each pole 44 is to retain in the radial direction an electrically conductive excitation coil 50, which is wound around the radial arm 39 of each pole 44 as described below, against the centrifugal force experienced by the excitation winding 50 during the rotation of the rotor 30.
• the excitation coils 50 of each pole 44 are electrically interconnected by connecting son, for example in series alternately in parallel.
• the connecting son and windings 50 may be copper son covered with enamel.
• These excitation windings 50 are electrically powered by a collector 101, which has slip rings 102, which are arranged around a rear end of the shaft 35.
• This collector 101 is for example made by overmolding electrically insulating material on electrically conductive elements (not visible) connecting the rings 102 to a ring (not referenced) electrically connected by wire links to the ends of the or coils 50 of excitation of the rotor 30.
• the slip rings 102 are electrically powered by means of brushes (not shown) which belong to a brush holder and which are arranged so as to rub on the slip rings 102.
• the brush holder is generally arranged in the housing 1 1 and is electrically connected to a voltage regulator (see Figure 1).
• the rotor 30 further comprises magnets referenced 105 in Figures 4a-4b in a number equal to the number of poles (in this case twelve).
• the magnets 105 extend axially in the vicinity of the outer periphery of the rotor 30.
• the magnets 105 are arranged regularly around the shaft 35 alternately with the poles 44.
• each magnet 105 is positioned between two poles 44.
• the same notch may contain one or a plurality of magnets 105, for example two magnets 105 including a rare earth and a ferrite.
• the rotor 30 comprises at least eight poles 44 distributed in pairs of diametrically opposed poles.
• Figures 4a-4b there is provided a circumferential alternation of twelve poles 44 and twelve magnets 105.
• the number of poles 44 and the number of magnets 105 are variable depending on the application. An embodiment without magnets 105 may be provided. In another embodiment, the number of magnets 105 is smaller than the number of poles as can be seen in FIG. 7. All these provisions allow the power of the machine to be increased as desired. .
• the poles 44 and the magnets 105 are distributed circumferentially in a regular manner.
• the magnets 105 are mounted between the projecting returns 45 of two salient poles 44, said returns 45 having notches in the form of U-shaped profile grooves, as described for example in the document FR 2 784 248.
• the mounting of the magnets in at least one groove can therefore be achieved using a blade and interposition of a glue softer than the magnet.
• the magnets are mounted in the grooves with the aid of springs.
• a small gap In general, a small gap, called air gap, exists between the outer periphery of the poles 44 and the inner periphery of the stator body 12.
• the rotor 30 further comprises a device 80 for electrical insulation of the coils 50 with respect to the sheet package 36.
• This device 80 comprises two insulating elements 81, 82.
• the first insulating element 81 referred to as the front element 81
• the second insulating element 82 referred to as the rear element 82
• the winding isolation device 80 further comprises notch insulators 83 ensuring the electrical insulation of the axial portions of the windings 50.
• each insulating element 81, 82 comprises a central radial wall 85 provided with a main opening 86 allowing the passage of the shaft 35.
• Each element 81, 82 comprises arms 88 extending radially from outer edge of the wall 85 radially outwardly of each element 81, 82.
• Each of these arms 88 has at its free end a cap 89 extending circumferentially on either side of the arm 88.
• the cap 89 is also extends axially in the opposite direction to the sheet package 36 and to the inner periphery of the returns 45.
• the arms 88 of the insulating elements 81, 82 preferably have, on their outer face, grooves ensuring radial retention of the turns of the windings 50.
• the grooves of the arms 88 of the front insulating element 81 are inclined in order to facilitate the change of rank during the winding operation of winding a conductive wire around the different poles to obtain the coils 50.
• Guide pins 95 are positioned on an outer face of the radial wall 85 of the element 82. These pins 95 which have side faces on which the son bear so allow to guide the son during the operation These pins 95 also make it possible to keep the wires of the windings 50 in position in a fixed position after the winding operation is complete. These guide pins 95 are distributed on the outer face of the radial wall 85 in a manner adapted to the desired winding configuration.
• Each radial wall 85 further comprises two recessed portions 91 intended to receive internal sectors 79 of one of the flanges 55, 56 for holding.
• the recessed portions 91 are diametrically opposed.
• the number and shape of the recessed portions 91 in particular the opening angle and the annular gap between two recessed portions 91, may be adapted according to the number and shape of the corresponding sectors 79.
• the recessed portions 91 and the main aperture 86 are interconnected, the internal walls delimiting the orifice being intended to bear locally on the outer circumference of the shaft 35.
• the insulating element 82 rear comprises an annular flange 96 defining the main opening 86.
• This annular rim 96 extends axially from the outer face of the insulating element 82 towards the outside of the rotor 30.
• the rim 96 is situated between the collector 101 and a shoulder of the shaft 35. of the rotor 30.
• the elements 81, 82 insulators each comprise two devices 98 snap (clipping) for cooperating by snapping (clipping) with corresponding openings provided on each radial end face of the core of the package 36 of plates (see Figures 5a-5b, 6a-6b).
• the notch insulators 83 take the form of a thin membrane, made of an electrically insulating and heat conducting material, for example an aramid material of the so-called Nomex (registered trademark) type, this thin membrane being folded in such a manner each notch insulator 83 is pressed against the axial inner walls of the plate package 36 between two adjacent poles 44.
• the notch insulation 83 has five parts 1 10 -1 14, each part 1 10-1 14 being folded with respect to an adjacent part along a folding segment substantially parallel to the axis B of the rotor 30 A first portion 10 located toward the center of the rotor 30 is pressed against a portion of the outer circumference of the core located between two adjacent poles 44.
• the number of notching insulators 83 depends on the number of poles 44, to which it is equal. Here, the number of notch insulators 83 is twelve.
• Each excitation winding 50 comprises turns wound around the radially oriented arm 39 of each pole 44 covered with notch insulators 83 and the two arms 88 of the insulating elements 81, 82 each located at one end of this pole 44, so that the buns 51 of the excitation winding 50 project axially relative to each face 40, 41 of the outer radial end of the package 36 of sheets, as shown in Figures 3a-3b. More particularly, the outer radial face of each bun 51 is offset axially outwards with respect to the associated outer radial face 40, 41 of the sheet package 36.
• Each pole 44 thus comprises an excitation winding 50 which itself comprises two opposing buns 51. As seen in Figures 4a, 4b a space 200 exists between two adjacent coils 50.
• This space 200 will be called thereafter interbobinage space.
• Each space 200 is delimited at its outer periphery by the magnets 105 implanted between two successive returns 45 and at its inner periphery by the outer edge of the central radial wall 85.
• Each space is delimited laterally by the two successive coils 50.
• the radial height of this space 200 is greater than its circumferential width.
• Each space 200 thus has a surface S, which also takes into account the thickness of the caps 89. When there is no magnet this space is delimited by the virtual extension of the outer periphery of the caps 89.
• Each space 200 delimits a passage through the pack of sheets 36. It will be noted that the width of the buns 51 and the coils 50 is in this decreasing embodiment per layer from the outer periphery to the outer periphery of the bun 51 and the coils 50.
• each bun 51 bears against the axial face of the cap 89 turned towards the bun 51.
• the cap 89 is held stationary relative to the pole 44 through the associated arms 88 pressed between a radial face of the pole 44 and the son of the windings.
• the cap 89 in combination with the rim 75 of the flange thus allows to retain the buns 51 despite the centrifugal force caused by the rotation of the rotor 30 exerted on said buns 51.
• the first flange 55 for holding the sheet package 36, said flange 55 before and the second flange 56 for holding the sheet package 36, said flange 56 back, are mounted coaxially with the shaft 35 so as to grip axially the elements 81, 82 insulators and the packet 36 of plates.
• These flanges 55, 56 are of non-magnetic material being advantageously metallic to better evacuate the heat.
• Each flange 55, 56 comprises a radial wall 59 extending in a radial plane perpendicular to the axis B of the shaft 35. This radial wall 59 is provided with a main opening 60 allowing the passage of the 35.
• the rear flange 56 has two recesses 61 diametrically opposed opening towards the opening 60.
• the pins 95 have a rectangular section with chamfered corners so as not to hurt the portions of connecting son between two consecutive windings 50.
• the other pins 95 are implanted globally on the same circumference and the ends of each winding 50 are in contact with the relevant lateral edges of two consecutive pins for a continuous connection of the coils 50.
• the lower longitudinal edges of the guide pins 95 radially retain the connecting wire between two consecutive windings. The assembly has thus a good behavior despite the action of the centrifugal force. Of course when the windings 50 are mounted in series two lower pins 95 are sufficient.
• the aforementioned solution with pins 95 ensures continuity between the different windings 50, which are all at the same potential.
• the windings can be made using a centrally hollow needle for passage of the wire and which moves circumferentially, axially and radially. This needle switches to move from one 95 to another.
• the internal pins can be removed and the ends of the wires can be fixed directly to the tabs 198.
• each flange 55, 56 has an annular flange 75 extending over the entire outer periphery of the radial wall 59 and extending axially towards the center of the rotor 30.
• This annular flange 75 has bearing face on the outer radial end faces of the poles 44 so that the caps 89 of the insulating elements 81, 82 are sandwiched between an inner annular face of the flange 75 and the buns 51.
• Such a configuration allows the flanges 55, 56 to participate with the caps 89 in maintaining the buns 51 despite the centrifugal force caused by the rotation of the rotor 30.
• each flange 55, 56 comprises integrally blades 70 forming a fan.
• Each blade 70 extends axially outwardly of the rotor 30 from the outer radial face of the flange 55, 56 associated.
• the blades 70 are made integral with the flange 55, 56 associated.
• the blades 70 are arranged at the periphery of the outer radial face of the flange 55, 56 asymmetrically with respect to the axis B of the shaft 35 to increase the ventilation performance and reduce the noise when the rotor 30 turned.
• the blades 70 belong to a separate fan flange 55, 56.
• the use of flanges 55, 56 and separate fans allows to easily adapt the fans according to the power of the machine 10 targeted.
• the flange 55, 56 and the fan are then fixed together by means of a fixing device formed for example by fixing elements associated with the flanges 55, 56 cooperating with the orifices of the fan.
• This attachment can be made using screws as in Figure 16 of US 6,784,586, alternatively by riveting or spot welding.
• Each flange 55, 56 further comprises a first series of orifices through 72 to ensure a flow of air inside the rotor between two salient poles 44.
• These orifices 72 are located around the opening 60 main and have an opening angle at least equal to the angle between two successive poles 44 salient. They are wider circumferentially and lower radially.
• this first series of orifices 72 comprises four orifices 72 having the same opening angle.
• the orifices 72 are facing at least the base (the inner periphery) of a space 200 between two successive coils 50 to ensure a circulation of air inside the rotor between the two salient poles 44 concerned.
• the applications it depends on the applications.
• the four orifices 72 of the front flange 55 are arranged in a regular manner around the main opening 60. It will be noted that the orifices 72 do not have the same size from one flange to the other and that axial flow is achieved in the air between the coils 50.
• the orifices 72 of the flange 55 are wider circumferentially and radially than those of the flange 55.
• the orifices 72 are vis-à-vis the base of two spaces 200, while the orifices of the flange 55 are in contact with each other. to the base of a single space 200 and a portion of the base of another space 200.
• Each flange 55, 56 further comprises a second series of orifices 73 through to ensure circulation within the rotor.
• Each orifice 73 of the second series is positioned between two successive blades 70. It is possible to provide such orifices 73 in all the zones separating two successive blades 70 or only in some of these zones depending on the desired ventilation circuit.
• These orifices 73 have an opening angle smaller than the opening angle of the orifices 72 of the first series of orifices 72.
• the second series of orifices 73 comprise fourteen orifices 73 of unequal size. This second series 72 gives access to at least a portion of a space 200 at the outer periphery of this space.
• the orifices 73 are located radially outside the orifices 72, that is to say on a mean circumference greater than that of the first orifices, and, on the one hand, in the vicinity the outer periphery of at least one space 200 and secondly, in the free zones between two blades 70 arranged asymmetrically to reduce noise.
• There is thus an asymmetry between the two flanges 55, 56 allowing axial circulation of the undisturbed air by the possible presence of the magnets 105 implanted at the outer periphery of the sheet package 36 between two returns 45 implanted outside the slots.
• the invention takes advantage of the presence of the spaces 200 and therefore the axial passages passing between two windings 50 opposite to implant the orifices 72, 73.
• the total area of the first 72 and the second series of orifices 73 is greater than 0.3 times the total surface of the interwinding spaces 200 to cool the rotor 30 well and obtain a good passage of the air while having a large number of poles 44.
• openings 72, 73 may be symmetrical or asymmetrical from one flange 55 to the other 56. It all depends on the applications.
• countersinks 68 are provided, in the image of countersinks 68 described below. These countersinks radially affect the outer periphery of the radial wall 59 and axially a portion of the flange 75. These countersinks can be located at the free spaces between two returns 45.
• orifices 73 it is possible to eliminate orifices 73 and replace them with facings. It all depends on the applications.
• the second set of orifices 73 may not have the same size from one flange to the other.
• the air coming from outside the rotor 30 will penetrate inside the rotor 30 through the orifices 72, 73 of a flange 55, 56 to then flow along the rotor 30 to the inside the spaces 200 between two successive poles 44 and then emerge on the opposite side via the orifices 72, 73 of the opposite flange 55, 56.
• the flanges 55, 56 constitute, via their blades 70, internal fans, the bearings 14, 15 having, in known manner, air inlet and outlet openings.
• the number of orifices 72, 73, and countersinks their dimensions, the number of blades 70, and their arrangement, may be adapted depending on the desired ventilation circuit while maintaining the mechanical strength of the flanges 55, 56.
• each flange 55, 56 further has on its internal face facing the sheet package 36 two inner sectors 79 extending axially to the sheet 36 of the package.
• Each sector 79 is inserted into a recessed portion 91 of a radial wall 85 of an insulating element 81, 82.
• these sectors 79 are constituted by two diametrically opposite portions of the same ring.
• the sectors constitute axial stops for the core of the plate package 36.
• each flange 55, 56 comprises two centering pins 77 intended to cooperate with axial openings 66 formed in the projecting poles 44.
• the pins 77 thus facilitate the angular positioning of the flanges 55, 56 during assembly.
• the flanges 55, 56 of non-magnetic material are made of moldable material such as aluminum to remove the heat or alternatively plastic material advantageously reinforced with fibers.
• the flanges 55, 56 are fixed to each other by tie rods 62 of axial orientation, which are here three in number.
• each flange 55, 56 comprises three orifices 65 intended to allow the passage of each tie rod 62.
• the tie rods 62 pass axially through the axial openings 66 formed in the poles, the 36 sheet metal package from the flange 55 front to the flange 56 back.
• These tie rods 62 are made of non-magnetic material, for example aluminum or stainless steel.
• each flange 55, 56 comprises countersinks 68 to accommodate the ends of each tie 62. These countersinks 68 allow passage of air
• the flanges comprise other cooling means such as at least one heat pipe implanted at a return 45.
• This heat pipe may be implanted in favor of an orifice. 65 free.
• the shaft may be a shaped shaft to form a heat pipe.
• the mounting holes 65 of the flange 55 before are tapped.
• the tie rods 62 comprise a threaded end which is screwed into the tapped holes of the front flange 55 when the rotor 30 is mounted.
• the threaded end of the tie rod 62 is self-tapping so that the associated orifice 65 of the flange 55 is smooth.
• the end of the tie rod 62 is smooth and passes through the associated orifice 65 of the flange 55, the free end of the tie rod 62 being crushed in contact with the outer face of the flange 55 for fastening by riveting.
• the tie rod 62 is replaced by a rod passing through the orifices 65 of the flanges 55, 56 and the plate pack 36, the axial ends of the rod being crushed in contact with the external faces of the flanges 55, 56 for fastening by riveting. .
• the rotor 30 includes a resolver 100 making it possible to know the rotational position of the rotor 30.
• the resolver 100 intervenes in particular when the machine 10 operates in motor mode (starter function), in order to be able to suitably adapt the voltage applied to the coils 50 of the stator 12 depending on the position of the rotor 30.
• the resolver 100 is replaced by a magnetic target associated with a set of Hall effect sensors carried by a sensor holder.
• the rear flange 56 is configured to carry a target holder which is intended to allow associated sensors to detect the angular position of the rotor 30.
• the sensors are carried by a sensor holder whose position is adjustable circumferentially. Reading the target is here radial.
• the target holder with its target and the sensors integral with a sensor holder belong to means for monitoring the rotation of the rotor as described in the document WO01 / 69762, to which reference will be made for more details [0130].
• the notch isolators 83 are each installed between two successive poles 44.
• the insulating elements 81, 82 are fixed on the sheet metal package 36 by clipping (clipping) via the two devices 98. Each external radial end face of each pole 44 is then in direct contact with an arm 88 of a element 81, 82 insulator.
• the excitation coils 50 are then wound around each pole 44 covered with insulators 83 of notch and the two arms 88 of the elements 81, 82 insulators associated with this pole 44, the son of the coils 50 being guided and held by the grooves of the arms 88 and the pins 95 for guiding the elements 81, 82 insulators.
• the package 36 of plates, the elements 81, 82 insulators and the associated excitation windings 50 are mounted on the rotor shaft 30, for example by press fitting. Then the flanges 55, 56 are arranged axially on either side of the pack 36 of plates so that the centering pins 77 enter axial openings 66 formed in the projecting poles 44 and that the sectors 79 are positioned at internal portions 91 recessed 85 walls of the elements 81, 82 insulating.
• the collector 101 is positioned on the shaft 35 between the second flange 56 and the second insulating element 82.
• the annular flanges 75 of the flanges 55, 56 then have a bearing surface on the outer radial end faces of the poles 44 so that the caps 89 of the insulating elements 81, 82 are sandwiched between an inner annular face. rim 75 and buns 51.
• Such a configuration allows the flanges 55, 56 to participate with the caps 89 in maintaining the buns 51 despite the centrifugal force caused by the rotation of the rotor 30.
• the threaded rod of the tie rods 62 is then inserted axially into the orifices 65 for fixing the front flange 55.
• tie rods 62 are then screwed into the threaded fastening holes 65 of the rear flange 56 until the head of each tie rod 62 bears against the bottom of the associated countersink 68 of the front flange 55.
• the tie rods 62 make it possible to axially grip the sheet package 36 and the insulating elements 81, 82 between the two flanges 55, 56.
• a balancing operation of the flanges 55, 56 is performed.
• This operation consists for example in the drilling of holes or recesses in the periphery of the outer face of the radial wall 59 of each flange 55, 56 so that the rotor 30 does not vibrate when it is rotated. Thanks to the invention the balancing operation is facilitated by the flanges 55, 56 to reduce the number of fasteners.
• the resolver 101 is positioned around the shaft 35, on the outer face of the radial wall 59 of the second flange 56.
• the excitation coils 50 tend to heat up in view of the current flowing through them.
• the flanges 55, 56 rotate with the shaft 35 of the rotor 30.
• the heat is effectively evacuated in the surrounding air by means of the blades 70 and the orifices 72, 73.
• the surrounding air is renewed thanks to the mixing and turbulence induced by the blades 70.
• stator and rotor laminations make it possible to reduce the losses due to the eddy currents.
• the recesses of the opening 38 of FIG. 7 make it possible to reduce the stresses during force-fitting of the knurled shaft in the central orifice of the core of the sheet metal bundle 36.
• solution pole 44 in one piece with the central core of the package of plates 36 is more advantageous than a solution with poles reported because this solution has a better resistance to the centrifugal force and ensures a smaller gap between the outer periphery of the rotor 30 and the inner periphery of the stator body.
• the embodiments described above make it possible to use the collectors 101 of conventional alternators, for example of the type described in document FR 2 710 197, and also the conventional mounting of the magnets of these alternators.
• the flanges 55, 56 of hollow shape, have a flange 75 constituting a pressure element to maintain the sheet package 36 and prevent deformation, in particular a opening of it.
• the sheet package 36 is clamped between the flanges 55, 56.
• the flanges 75 configured to come into contact with the flaps 45, stiffen the flanges 55, 56 and constitute, via their inner periphery, a radial stop for the caps 89 of the elements 81. 82.
• the outer periphery of the caps 89 is allowed to cooperate with the inner periphery of the flanges 75 of the flanges 55, 56.
• flanges 55, 56 constitute, via their flange 75, a axial stop for the magnets 105 implanted between two consecutive returns 45.
• the hollow form of the flanges can accommodate the buns 51, the elements 81, 82 with their caps 89 and a portion of the collector 101. It will be appreciated that the internal sectors 79 of the flanges avoid deformation of the core of the package 36 in combination with the walls 85 of the elements 81, 82.
• the elements 81, 82 are, as mentioned above, of electrically insulating material. They may be plastic, such as PA 6.6. They are thicker and less good heat conductor than the 83 notch insulators.
• the number of orifices 73 can be reduced as can be seen in FIG. 8, one of the orifices 73 being adjacent to a countersink 68.
• the small orifices 73 of FIGS. 6a and 6b have been removed. relationship between the total surface of the orifices 72, 73 greater than 0.3 times that of the total area of the spaces 200 being always verified.
• orifices 172 depends on the location of the blades 70. In the embodiment which precedes the circumferential width of the orifices 172 is generally equal to the circumferential width of the spaces 200. As a variant, the orifices 172 are narrower or wider circumferentially than the spaces 200.
• the orifices 172 are offset circumferentially relative to the spaces 200. This is made possible by the hollow form of the flanges. Note that some of the orifices 73 are only vis-à-vis a portion of a bun 51 and that nevertheless the air can reach the spaces 220 because the buns 51 are rounded and the flanges 55, 56 are hollow. Of course we can replace a portion of the orifices 172 by orifices of the second series 73 or add (as shown in dashed lines in Figure 9) orifices of the second series 73 implanted outside the series of orifices 172. It is possible to reduce the circumferential width of the orifices 72 in order to implant orifices 172.
• tie-rods 62 namely one hole per tie 62.
• two tie-rods 62 are provided which are diametrically opposed and two heat pipes diametrically opposed, each heat pipe comprising a rod engaged in at least one hole of one of the flanges 55, 56 and at least in a section of the holes of the sheet 36 bundle and opening outwardly of the flange 55, 56 concerned.
• These heat pipes can completely cross the flanges 55, 56 and the package 36 of sheets and be configured outside the flanges 55, 56 to form fan blades 70.
• Such heat pipes are described, for example, in FIGS. 11A and 11B of the document FR 2,855,673 to which reference will be made.
• the provisions of Figures 12, 13 and 24 of this document are also applicable.
• the number of poles 44 depends in the aforementioned manner on the applications. This number is 12 in the figures. Alternatively, it may be 8 or 10 or more than 12. Compared with WO 2007/00385, the number of coils 50 is increased in all cases while having the possibility of increasing the number of magnets at will to increase the power of the rotating electrical machine with salient poles. Thus the number of magnets may be less than the number of poles 44.
• the magnets can replace the magnets with non-magnetic parts to have a continuity of material at the outer periphery of the rotor.
• Many combinations can be made.
• all the spaces between the returns 45 may be free.
• a portion of these spaces between the returns 45 may be free and the others occupied by magnet and / or non-magnetic parts.
• the magnets may be of different shade.
• some of the spaces between two returns 45 may be occupied by ferrite magnets and at least some of the other spaces may be occupied by rare earth magnets.
• at least one of the elements 81, 82 is devoid of grooves and the insulator 83 may be integral with one of the elements 81, 82, for example by molding.
• the insulation may be in two parts each in one piece with one of the elements 81, 82.
• the insulation 83 may be alternatively PA 6.6 being thinner than the elements 81, 82.
• the windings can be connected together as in WO 2007/003835 supra.
• the flanges 55, 56 are obtained by molding, or forging or injection of plastic or metal.
• the blades 70 of at least one flange 55, 56 are removed.
• the two flanges are alternatively blade-free, especially when the rotating electrical machine is cooled by water.
• the intermediate portion of the casing January 1 comprises a channel for circulating a coolant, such as the engine engine coolant and the stator body is mounted by hooping inside the intermediate portion.
• a coolant such as the engine engine coolant
• the stator body is mounted by hooping inside the intermediate portion.
• the two flanges do not have blades have more freedom to implement the second series of openings 73, which can be wider circumferentially to extend on either side of a winding .
• At least one of the series of orifices 72, 73 and / or counterbore is different from one pool to another.
• the series of orifices 72, 73 and / or countersinks are identical from one flange 55, 56 to the other.
• the housing comprises a front bearing and a rear bearing as disclosed for example in Figure 14 of US 6 784 586 in the document showing a portion of the brushes and the rectifier bridge current.
• the rotating electrical machine is alternatively an alternator devoid of resolver or any other means of monitoring the rotation of the rotor.
• the cooling of the rotor 30 is improved. Indeed, the invention increases the intrinsic aeraulic performance of the flanges 55, 56 and allows better heat dissipation at the rotor 30 by convection. In addition, it reduces the noise sound aunterlic type. This better cooling of the rotor 30 keeps the windings 50 of the rotor 30 over the operating range of 0 to 18000 revolutions per minute and increases the number of poles 44 of the rotor 30. In addition, the cost and time are reduced. of making the rotor 30 minimizing varnish impregnation operation which is time consuming and expensive. Indeed we can drop drops varnish at the level of chignons to have a better cohesion windings coils 50, and a better resistance to centrifugal force.
• the connecting wires and windings 50 may be covered with an additional bonding layer in the form of an impregnating polymer, which, by heating and polymerization, makes it possible to bond the coils of the coils together for better performance. the centrifugal force.
• one of the flanges 55, 56 of non-magnetic material is made of plastic material and the other of aluminum, of brass or magnesium.
• the plastic flange is advantageously made of plastic material reinforced with fibers.
• the embodiment of the flange made of plastic or aluminum makes it easy to obtain the blades by molding. Balancing of the plastic flange can be accomplished by adding material into at least one axial projection of the flange as described in DE 23 46 345 to which reference will be made.
• the balancing of at least one of the flanges is carried out alternatively by crimping at least one balancing mass in one of the recesses made in projections of this flange as described in the document DE 30 31 622 to which we will refer for more details.

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• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Insulation, Fastening Of Motor, Generator Windings (AREA)
• Synchronous Machinery (AREA)

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• 2011
  • 2011-12-20 FR FR1162024A patent/FR2984630B1/fr not_active Expired - Fee Related
• 2012
  • 2012-11-09 EP EP12795514.4A patent/EP2795766A2/de not_active Withdrawn
  • 2012-11-09 WO PCT/FR2012/052590 patent/WO2013093255A2/fr active Application Filing

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