GB2347276A - Vehicle alternator and method of manufacture - Google Patents

Vehicle alternator and method of manufacture Download PDF

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Publication number
GB2347276A
GB2347276A GB0011548A GB0011548A GB2347276A GB 2347276 A GB2347276 A GB 2347276A GB 0011548 A GB0011548 A GB 0011548A GB 0011548 A GB0011548 A GB 0011548A GB 2347276 A GB2347276 A GB 2347276A
Authority
GB
United Kingdom
Prior art keywords
fan
resin
vehicle alternator
disposed
disks
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB0011548A
Other versions
GB0011548D0 (en
GB2347276B (en
Inventor
Nobuatsu Yoshioka
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mitsubishi Electric Corp
Original Assignee
Mitsubishi Electric Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP25281898A external-priority patent/JP3435075B2/en
Application filed by Mitsubishi Electric Corp filed Critical Mitsubishi Electric Corp
Publication of GB0011548D0 publication Critical patent/GB0011548D0/en
Publication of GB2347276A publication Critical patent/GB2347276A/en
Application granted granted Critical
Publication of GB2347276B publication Critical patent/GB2347276B/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/02—Selection of particular materials
    • F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/28—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps
    • F04D29/281—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps for fans or blowers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/66—Combating cavitation, whirls, noise, vibration or the like; Balancing
    • F04D29/661—Combating cavitation, whirls, noise, vibration or the like; Balancing especially adapted for elastic fluid pumps
    • F04D29/666—Combating cavitation, whirls, noise, vibration or the like; Balancing especially adapted for elastic fluid pumps by means of rotor construction or layout, e.g. unequal distribution of blades or vanes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
    • F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/40—Organic materials
    • F05D2300/43—Synthetic polymers, e.g. plastics; Rubber

Abstract

A resin fan 233 for a vehicle alternator is provided with a plurality of metal disks 233c which allows the fan to be secured to an end surface of a polar core by welding. The disks 233c are disposed in a circle concentric to the fan and are insertion moulded into the fan. Spherical protrusions 233e which protrude through cylindrical aperture 233d are provided for electrical resistance welding to the polar core.

Description

VEHICLE ALTERNATOR AND METHOD OF MANUFACTURE The present invention relates to a vehicle alternator and to a method of manufacture therefor, and in particular to a construction for securing resin fans to polar cores.
The vehicle alternator disclosed in Japanese Patent Laid-Open No.
(HEI) 5-30707, shown in Figure 6, is a known example of a conventional vehicle alternator.
In the center of Figure 6,, there are disposed: polar cores 5,6 of opposite polarity, whose polar tooth portions project alternately in the axial direction around a circumference; a magnetizing coil 7 held between the polar cores 5,6; a revolving shaft 8 to which the polar cores 5,6 are secured; and a rotor 4 having a pair of slip rings 9, which are secured to the revolving shaft by means of an insulated sleeve. A stator 1 comprising a stator core 2 and a stator coil 3 is disposed outside the rotor 4.
A front bracket 12 and a rear bracket 13 are disposed outside the stator 1, and the front bracket 12, the rear bracket 13, and the stator core 2 are secured by fastening bolts 14. Air intake openings 12a and air discharge openings 12b are disposed in the front bracket 12 for ventilation, and air intake openings 13a and air discharge openings 13b are disposed in the front bracket 13 also for ventilation, and ventilation occurs in each as shown by the arrows in the figure. The rotating shaft 8 of the rotor 4 is supported in the front bracket 12 and the rear bracket 13 by means of bearings 15,16. A pulley 17 is secured to one end of the rotating shaft 8, and the revolutions of an engine (not shown) are transmitted to the pulley 17 by means of a belt (not shown), rotating the rotor 4.
A commutator 8, which converts an alternating current resulting from an alternating voltage induced by the stator coil 3 to a direct current, and a voltage regulator 19, which regulates the terminal voltage of the vehicle alternator at a fixed value by measuring the generated voltage and controlling the magnetizing current, are disposed radially outwards from the slip rings 9. Brushes 21, which are held by brush holders 20, are pushed into contact with the slip rings 9.
Resin fans 33 with resin blades 33a formed integrally in one side thereof are disposed on end surfaces of the polar cores 5,6. Details of the mounted construction of the resin fans 33 are shown in Figure 7, which is a cross-section of a side elevation of a circumferential portion of a resin fan 33, and in Figure 8, which is a front elevation of the circumferential portion of the resin fan 33.
An annular protrusion 33b is formed integrally on an inner circumferential edge of the resin fan 33. Apertures 33c for bolts are disposed radially outwards from the annular protrusion 33b so that the resin fan 33 can be mounted on the end surface of the polar core 5. An annular recess 5b is disposed in the end surface of the polar core 5, and the annular protrusion 33b of the resin fan 33 is inserted therein. Metal braces 34 composed of bent sheet metal are placed axially outwards on the inner circumferential edge of the resin fan 33, the metal braces 34 are secured to the resin fan 33 by bolts 35, and the resin fan 33 is mounted on the end surface of the polar core 5 by bolts 32.
In a vehicle alternator of this kind, when the rotor 4 is rotated, an alternating voltage is induced in the stator coil 3, power is supplied, and heat is generated. The ventilation resulting from the rotation of the resin fans 33 cools the stator 1 and the rotor 4.
On the front bracket 12 side, a cooling ventilation generated by the rotation of the resin fan 33 is taken in through the air intake openings 12a in the front bracket 12, cools the stator 1, and is expelled through the air discharge openings 12b. On the rear bracket side, the cooling ventilation is taken in through the air intake openings 13a in the front bracket 13, cools the commutator 18, the voltage regulator 19, and the stator 1, and is expelled through the air discharge openings 13b. Resin fans 33 are used here because, compared to sheet metal fans, their shape can be modified easily to improve performance and reduce noise, and their parts are lighter.
However, resin fans suffer from the following problems: because they are made of resin, welding such as electric resistance welding etc., cannot be used to secure resin fans to the polar cores of the rotor as it can be with sheet metal fans, and the same welding equipment used to secure sheet metal fans therefore cannot be used on resin fans; braces and bolts are required, which increases the number of parts; and since the braces have to be fastened with bolts, productivity decreases.
The present invention aims to solve the above problems and to provide a vehicle alternator in which the same welding equipment used to secure sheet metal fans can be used, the number of parts during assembly is small, and productivity does not decrease because no bolt fastening is required.
The present invention provides a vehicle alternator comprising: a rotor having polar cores which hold a magnetizing coil which is secured to a rotating shaft ; a resin fan disposed on an end surface of one of the polar cores; and a plurality of metal disks disposed in a circle concentric to the resin fan, the disks being insertion molded into the resin fan and being secured to the said end surface by welding so as to secure the resin fan to the said end surface.
Each disk may be provided with a protrusion to allow the resin fan to be secured to the polar core by electric resistance welding.
A method of manufacture for a vehicle alternator according to the present invention includes securing the disks in the resin fan by insertion molding and securing the disks to the polar core by welding.
Figure 1 is a front elevation showing a construction of a resin fan for use in a vehicle alternator not in accordance with the present invention; Figure 2 is a cross-section taken along line 2-2 in Figure 1; Figure 3 is a cross-section showing the construction of the vehicle alternator; Figure 4 is a front elevation showing a construction of a resin fan for use in a vehicle alternator according to the present invention; Figure 5 is a cross-section taken along line 5-5 in Figure 4; Figure 6 is a cross-section showing a construction of a conventional vehicle alternator; Figure 7 is a partial cross-section of a side elevation showing a mounted construction of a resin fan for use in the conventional vehicle alternator; and Figure 8 is a partial front elevation showing the mounted construction of the resin fan for use in the conventional vehicle alternator.
Figures 1 and 2 show a construction of a resin fan 133 for a vehicle alternator not in accordance with the present invention. Figure 3 is a crosssection showing the construction of the vehicle alternator.
The shape of a resin fan 133 in Figures 1 to 3 is different from the resin fan 33 in Figure 6. Moreover, parts and components which are the same as or equivalent to those in Figure 6 will be given identical numerals and duplicate explanations will be omitted.
In the resin fan 133 in Figures 1 and 2, resin blades 133a are disposed with unequal spacing on one flat surface portion of a fan main body portion 133b comprising a flat hollow cylindrical resin plate in a circle concentric to the fan main body portion 133b. A flat annular metal plate 133c is disposed on the other flat surface portion of the fan main body portion 133b, that is to say, the flat portion 133g which is on the opposite side from the flat portion on which the blades 133a are disposed. Spherical protrusions 133e for electric resistance welding are disposed on one side of the metal plate 133c, and truncated cone-shaped recess portions 133f are disposed on the opposite side coaxial to the protrusions 133e. The protrusion-side flat surface portion 133h, which is the surface on which the protrusions 133e are disposed, is arranged with the protrusions 133e facing outwards so that the protrusion-side flat surface portion 133h lies in the same plane as the flat surface portion 133g of the fan main body portion 133b.
Cylindrical apertures 133d are disposed in the fan main body portion 133b so that they are positioned adjacent to the recess portion-side flat surface portion 133j of the metal plate 133c, on which the recess portions 133f are disposed to allow an electric resistance welder (not shown) to come into contact with the metal plate 133c. The sheet metal plate 133c of the resin fan 133, in which the protrusions 133e are disposed by pressing, is formed integrally with the resin fan main body 133b and blades 133a by insertion molding.
In Figure 3, resin fans 133 are secured by electric resistance welding to end surfaces 5a, 5b of polar cores 5,6 of a rotor 4, in which the polar cores 5,6 hold a magnetizing coil 7 secured to a rotating shaft 8.
Moreover, the means for securing the resin fans provided with metal plates insertion molded therein to the polar cores 5,6 need not be limited to electric resistance welding, and beam welding or laser welding may be used.
Figure 4 is a front elevation showing a construction of a resin fan 233 for a vehicle alternator according to an embodiment of the present invention. Figure 5 is a cross-section taken along line 5-5 in Figure 4.
The shape of metal disks 233c in Figures 4 to 5 is different from the metal plate 133c in Figures 1 to 3.
In the resin fan 233 in Figures 4 and 5, resin blades 233a are disposed with unequal spacing on one flat surface portion of a fan main body portion 233b comprising a flat hollow cylindrical resin plate in a circle concentric to the fan main body portion 233b, as with the resin fan 133 in Figures 1 and 2. The difference from Figures 1 and 2 is that metal disks 233c, which are disposed on the other flat surface portion of the fan main body portion 233b, that is to say, the flat portion 233g which is on the opposite side from the flat portion on which the blades 233a are disposed, are disks. A spherical protrusion 233e is disposed on one side of each of the metal disks 233c, a truncated cone-shaped recess portion 233f is disposed on the opposite side coaxial to the protrusion 233e, and the protrusion-side flat surface portion 233h, which is the surface on which-the protrusion 233e is disposed, is arranged with the protrusion 233e facing outwards so that the protrusion-side flat surface portion 233h lies in the same plane as the flat surface portion 233g of the fan main body portion 233b. Cylindrical apertures 233d are disposed in the fan main body portion 233b so that they are adjacent to the recess portion-side flat surface portions 233j of the metal disks 233c on which the recess portions 233f are disposed to allow an electric resistance welder (not shown) to come into contact with the metal disks 233c.
The concentrically-disposed metal di s ks 233c of the resin fan 233 are formed integrally with the resin fan main body 233b and blades 233a by insertion molding.
The metal zlisks 233c may be disposed in a circle of different diameter depending on the size of the fan. Consequently, the same metal dises 233c can be used, for example, in various resin fans of different diameter.
A plurality of disks disposed in a circle concentric to the resin fan enables use of the same disks in various resin fans of different diameter, and also reduces the number of parts during assembly and avoids decreased productivity because no bolt fastening is required.
Providing each metal disk with a protrusion, to allow the resin fan to be secured to the polar core by electric resistance welding, enables the resin fan to be secured to the polar core by welding of the metal disks and also enables use of the same welding equipment used to secure a sheet metal fan to a polar core.
The method of manufacture includes the step of securing the metal disks to the resin fan by insertion molding, and therefore the metal disks are already insertion molded into the resin fan, thereby reducing the number of parts during assembly and avoiding decreased productivity because no bolt fastening is required. The method of manufacture also includes the step of securing the metal disks to the polar core by welding, thereby enabling use of the same welding equipment used to secure a sheet metal fan to a polar core.

Claims (5)

  1. Claims: 1. A vehicle alternator comprising: a rotor having polar cores which hold a magnetizing coil which is secured to a rotating shaft; a resin fan disposed on an end surface of one of the polar cores; and a plurality of metal disks disposed in a circle concentric to the resin fan, the disks being insertion molded into the resin fan and being secured to the said end surface by welding so as to secure the resin fan to the said end surface.
  2. 2. A vehicle alternator as claimed in claim 1, wherein each disk is provided with a protrusion to allow it to be secured to the said end surface by electric resistance welding.
  3. 3. A method of manufacturing a vehicle alternator according to claim 1 or 2, including: securing the plurality of disks in the resin fan by insertion molding; and securing the disks to the said end surface by welding.
  4. 4. A vehicle alternator substantially as described with reference to, and as shown in, Figures 4 and 5 of the accompanying drawings.
  5. 5. A method of manufacturing a vehicle alternator, substantially as described with reference to Figures 4 and 5 of the accompanying drawings.
GB0011548A 1998-09-07 1999-02-12 Vehicle alternator and method of manufacture Expired - Lifetime GB2347276B (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP25281898A JP3435075B2 (en) 1998-09-07 1998-09-07 AC generator for vehicles
GB9903306A GB2341279B (en) 1998-09-07 1999-02-12 Vehicle alternator and method of manufacture

Publications (3)

Publication Number Publication Date
GB0011548D0 GB0011548D0 (en) 2000-06-28
GB2347276A true GB2347276A (en) 2000-08-30
GB2347276B GB2347276B (en) 2000-11-01

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ID=26315131

Family Applications (1)

Application Number Title Priority Date Filing Date
GB0011548A Expired - Lifetime GB2347276B (en) 1998-09-07 1999-02-12 Vehicle alternator and method of manufacture

Country Status (1)

Country Link
GB (1) GB2347276B (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2830293A1 (en) * 2001-09-28 2003-04-04 Valeo Equip Electr Moteur FAN, PARTICULARLY FOR ROTATING ELECTRIC MACHINES SUCH AS AN ALTERNATOR

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0500442A1 (en) * 1991-02-22 1992-08-26 Valeo Equipements Electriques Moteur Fan rotor for rotating electric machines, particularly for alternators for cars

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0500442A1 (en) * 1991-02-22 1992-08-26 Valeo Equipements Electriques Moteur Fan rotor for rotating electric machines, particularly for alternators for cars

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2830293A1 (en) * 2001-09-28 2003-04-04 Valeo Equip Electr Moteur FAN, PARTICULARLY FOR ROTATING ELECTRIC MACHINES SUCH AS AN ALTERNATOR
WO2003029658A1 (en) * 2001-09-28 2003-04-10 Valeo Equipements Electriques Moteur Alternator fan
US7168923B2 (en) 2001-09-28 2007-01-30 Valeo Equipements Electriques Moteur Alternator fan

Also Published As

Publication number Publication date
GB0011548D0 (en) 2000-06-28
GB2347276B (en) 2000-11-01

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Date Code Title Description
PE20 Patent expired after termination of 20 years

Expiry date: 20190211