JP2002171705A - Manufacturing methods for alternating-current generator for vehicle and its stator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide manufacturing methods for an alternating-current generator and for its stator, wherein a high space factor of stator winding is attained and the generator and the stator are manufactured with ease. SOLUTION: The stator of the alternating-current generator for vehicle includes a stator core and stator winding formed by winding six winding strands. The stator is manufactured by forming a strip-shaped home coil by spirally winding six winding strands and also forming the home coil into a ring shape with overlapping bath ends of the coil, and inserting it into the slots in the stator core.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an alternator for a vehicle mounted on a passenger car, a truck and the like, and a method of manufacturing a stator thereof.

[0002]

2. Description of the Related Art In recent vehicles, the engine room has become narrow due to the need for slant nose to reduce running resistance and the need to secure a cabin interior space, so that the on-board space for an AC generator for a vehicle is not sufficient. Is coming. In addition, the rotational speed of the engine is reduced to improve fuel efficiency, and the rotational speed of the vehicle alternator is also reduced. However, on the other hand, electric loads of safety control devices and the like are increasing, and improvement in power generation capacity is desired. From the above, recently,
There is a need to provide a small, high-output vehicle alternator at low cost.

In addition, the popularity of small cars has been increasing in accordance with the end-users' tendency to conserve energy and the like. In recent years, there has been an increasing variety of demands for small generators and high voltage generators for reasons such as reduced wiring weight. There is a need for a generator with specifications. Conventionally, stator windings generally required for automotive alternators have adopted a structure in which a continuous wire is attached to a stator core.Using such a stator winding, miniaturization, high output, Various improvements have been proposed to reduce noise and the like.

For example, Japanese Patent Laid-Open Publication No. Sho 54-66406 discloses that concentrated windings are inserted in order from the outer layer in order to prevent the coil ends of the stator windings from crossing and becoming longer outside the slots. A disclosed alternator is disclosed.
Also, Japanese Patent Publication No. 2927288 discloses a vehicle technology using a segment technology that improves the space factor of a stator winding in a slot and secures high cooling performance by cooperation with a rotor outside the slot. An alternator is disclosed.

Further, Japanese Unexamined Patent Application Publication No. 11-299153 discloses an automotive alternator in which an equivalent winding structure is realized using continuous wires in order to avoid segment joining.

[0006]

By the way, in the AC machine disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 54-66406,
Insertion of the windings in order from the outer layer to the inner layer eliminates the intersection of the coil ends, but even in the slot, the winding corresponding to the coil end of the outer layer is arranged on the outer layer of the slot and corresponds to the coil end of the inner layer Since the winding is disposed in the inner layer of the slot, there is a problem that a wasteful space in which the winding is not inserted into the slot is generated, and the space factor is reduced. Conversely, if an attempt is made to increase the space factor by eliminating useless space in the slot, the coil ends will eventually cross.

Further, the above-mentioned Patent Publication No. 2927288 is disclosed.
In the vehicle alternator disclosed in the above publication, a step of joining a plurality of segments constituting the stator winding is required, so that there is a problem that manufacturing is not easy. In addition, in order to support a variety of applications such as a small, low-output generator, a high-voltage output generator, or a generator that can obtain sufficient output current at low speed rotation, the stator winding is usually used. A technique of increasing the number of windings is used. However, in order to cope with such an increase in the number of windings, it is necessary to increase the number of segments, and the segment forming after the segments are mounted on the stator core becomes complicated, and the joining operation of each segment becomes complicated. There was a problem.

The above-mentioned Japanese Patent Application Laid-Open No. 11-299153 has been disclosed.
However, the winding process is complicated when considering a process of manufacturing a stator winding by actually winding a continuous wire around a stator core. As a result, there is a problem that the production is not easy.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and has as its object to realize a vehicle alternator which can realize a high space factor of a stator winding and is easy to manufacture. And a method for manufacturing the stator.

[0010]

In order to solve the above-mentioned problems, a stator winding of an automotive alternator according to the present invention is accommodated in a plurality of slots having openings on the inner peripheral side of a stator core. And a coil end portion extending from an axial end face of the stator core. Further, the slot portion has a unique number of slots accommodated in the same number of continuous slots as the number of phases of the stator winding. It consists of a slot part and other normal slot parts. At least a part of the plurality of winding wires included in the normal slot portion is connected to one of the winding elements included in each of the other two slot portions accommodated in the other two different slots via the coil end portion. Connected to the wire. Further, each of the plurality of winding strands included in the singular slot portion is connected to one of the winding strands included in the slot portion accommodated in the other one slot via the coil end portion. In addition, the winding wire of each phase of the stator winding is wound in parallel with a corresponding portion of the winding wire of another phase and inseparable from each other.

[0011] In particular, it is desirable to provide such a unique slot portion so that the stator windings can be separated from each other in the circumferential direction. As described above, by forming the stator winding, which has conventionally been formed in an annular shape inseparable along the circumferential direction, so as to be separable at any position along the circumferential direction, the winding element wire is formed. After winding in a belt shape, the stator can be housed in each slot of the stator core to manufacture the stator, and the winding process can be simplified. Further, interference between the coil ends of each phase of the stator winding can be suppressed, a high space factor of the stator winding can be realized, and the output can be improved.

In the case where the above-mentioned slot portion is classified into an inner layer and an outer layer, each of the plurality of winding wires usually included in the slot portion is inserted into each of the other two different slots. And a plurality of winding strands included in the singular slot portion are respectively connected in series to winding strands of different layers, and winding strands of different layers of the slot portion accommodated in another slot. It is desirable to connect them in series. By connecting the slot portion of the stator winding accommodated in one slot and the slot portion of the stator winding accommodated in another slot in different layers in series, each phase of the stator winding is Can be suppressed, the space factor of the stator windings can be increased, and the output can be improved. In addition, since each slot portion accommodated in a different slot is connected via the coil end portion, the cooling air crosses the coil end portion, and compared with the coil end of the conventional stator winding. The effective surface area contributing to cooling increases, and the cooling efficiency of the stator winding can be significantly improved. Also,
Since the interference of the coil end portions is eliminated, the coil end portions and the slot portions can be regularly arranged, so that the length of each winding element wire, leakage inductance, etc. are made uniform over the entire stator winding, and the stator The current flowing through the windings and the heating value of the winding wires of each phase are also the same. Therefore, it is possible to prevent heat generation and unbalance of magnetomotive force in the entire stator winding, and it is possible to reduce temperature and reduce noise. Further, a uniform pattern is formed by the regularly arranged coil end portions, and the cooling wind crosses the coil end portions, so that noise generated by the cooling wind can be reduced.

In the case where the above-described stator includes a plurality of stator windings, each of the plurality of stator windings is formed as a plurality of layers which can be radially separated in a slot. It is desirable to arrange. By including a plurality of stator windings, a multi-voltage generator can be easily configured. Further, the stator can be easily manufactured simply by inserting the stator windings separately from the stator core and inserting the stator windings into the slots of the stator core for each layer.

In the case where the above-described stator includes a plurality of stator windings, one of the plurality of stator windings is included in the other in a cross section along the radial direction. It is desirable to configure. By including a plurality of stator windings, a multi-voltage generator can be easily configured. Also, when winding each stator winding in a state separated from the stator core, since one stator winding can be wound and then another fixed winding can be wound from above,
The stator can be manufactured only by inserting the stator winding once into each slot of the stator core.

It is desirable that the above-mentioned stator core is separable by a slit formed at least at one circumferential position. A stator can be manufactured by inserting a stator winding into a stator core having a non-annular shape and then forming the stator core into an annular shape.
In particular, since the stator winding can be inserted into the stator core from one direction, restrictions on equipment space and work space are reduced, and work efficiency can be improved.

Further, the method for manufacturing a stator of an automotive alternator according to the present invention comprises a first step of winding winding wires in a strip shape around a non-annular winding frame so as not to cross each other. A second step of extracting the bobbin from the band-shaped winding element wire formed in this way, a third step of forming the band-shaped winding element wire after the bobbin is removed into an annular shape, And a fourth step of inserting the winding wire formed into the plurality of slots into a plurality of slots formed in the stator core. After winding the winding wire in a strip shape around the winding frame, the winding frame is extracted to form a home coil, and the home coil is inserted into each slot of the stator core, whereby the stator can be manufactured. Therefore, the manufacturing process can be greatly simplified as compared with the case where the stator is manufactured by directly winding the winding wire around each slot.

Further, instead of the third and fourth steps described above, after inserting the strip-shaped winding element wire formed in the second step into a slot formed in the non-annular stator core, And a fifth step of forming the stator core into an annular shape together with the band-shaped winding wire. This allows
Since a winding element wound in a belt shape from one direction of a stator core having a non-annular shape (for example, a linear shape) can be inserted, the manufacturing process can be further simplified.

[0018]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A vehicle AC generator according to an embodiment of the present invention will be described below in detail with reference to the drawings. [First Embodiment] FIG. 1 is a diagram showing an overall configuration of an automotive alternator according to a first embodiment. The automotive alternator 1 shown in FIG. 1 includes a stator 2, a rotor 3, a frame 4, a rectifier 5, and the like.

The stator 2 includes a stator core 22, a stator winding 23 formed by a continuous wire, and an insulator 2 for electrically insulating between the stator core 22 and the stator winding 23.
4 is included. The stator core 22 has a laminated type in which thin steel plates are stacked, and has a plurality of slots 25 having openings in the inner peripheral surface thereof. For example, in the stator winding 23 of the present embodiment, the wire diameter is 1.3.
Assuming that two sets of the covered conductors of 1 mm are used, eight sets (16) of covered conductors are accommodated in one slot. The stator windings 23 have six types (Z
1, Y1, X1, Z2, Y2, X2) Winding element wire 230
It is comprised including. X1 and X2 winding wires 23
0 have electrical angles that differ from each other by 180 °. Similarly, each of the winding strands 230 of Y1 and Y2 has an electrical angle different from each other by 180 °. Each winding element wire 2 of Z1 and Z2
30 have electric angles different from each other by 180 °.

FIG. 2 is a diagram showing the relationship between the six types of winding strands 230. The direction of each winding strand 230 corresponds to an electrical angle. The winding element wire 230 of X1 is Z1 or Y
Each of the winding wires 230 is formed at a position different from the winding wire 230 by an electrical angle of 60 °. Further, the winding wire 230 of X2 is formed at a position different from the winding wire 230 of X1 by 180 ° in electrical angle. In FIG. 2, Z1, X1, Y
1, Z2, X2, and Y2 each have six types of winding wire 2
30 corresponding to the beginning of each volume, Z1 ', X
Each of 1 ′, Y1 ′, Z2 ′, X2 ′ and Y2 ′ is 6
It corresponds to the end of each winding of the type winding element wire 230.

The rotor 3 rotates integrally with the shaft 6, and includes a set of a Landel-type pole core 7, a field coil 8, slip rings 9 and 10, a mixed flow fan 11 for cooling, and a centrifugal fan. 12 and the like. The shaft 6 is connected to a pulley 20 and is rotationally driven by a traveling engine (not shown) mounted on the vehicle.

The rundle type pole core 7 is formed by combining a pair of cores. Each core is
A cylindrical boss portion 71 assembled to the shaft 6, a disk portion 72 extending radially from one axial end surface of the boss portion 71, and a boss portion 71 extending from the outer peripheral portion of the disk portion 72 along the axial direction. It is constituted by a plurality of claw-shaped magnetic pole portions 73 extending. Each core has its own claw-shaped magnetic pole portion 7
3 are assembled so that they face each other alternately. The field coil 8 is connected to the pole core 7 via the insulating paper 81.
Of the claw-shaped magnetic pole portion 73 with an appropriate compressive force. The insulating paper 81 is made of a sheet impregnated with a resin, surrounds the field coil 8, fixes the field coil 8 by heat treatment, and performs electric insulation between the pole core 7 and the field coil 8. ing.

A mixed flow fan 11 for cooling is fixed to an end face of the disk portion 72 of the pole core 7 arranged on the pulley 20 side by welding or the like. The centrifugal fan 12 is fixed to the end face of the disk portion 72 of the pole core 7 disposed on the side opposite to the pulley 20 (slip ring side) by welding or the like. The projected area of the mixed flow fan 11 (the area of the blade projected in the rotation direction) is set smaller than the projected area of the blade of the centrifugal fan 12.

The frame 4 accommodates the stator 2 and the rotor 3, and the rotor 3 is supported rotatably around a shaft 6, and is provided on the outer peripheral side of the pole core 7 of the rotor 3. Stator 2 arranged via a predetermined gap
Has been fixed. Frame 4 is front frame 4
A and a rear frame 4B, which are fastened by a plurality of fastening bolts (not shown) to support the above-described stator 2 and the like. Further, the frame 4 is provided with a cooling wind discharge window 41 at a portion facing the stator winding 23 protruding from the axial end face of the stator core 22, and a suction window 42 at the axial end face.

A rectifying device 5 is provided outside the rear frame 4B.
And a voltage adjusting device 51 and a brush device 52 are attached,
A rear cover 53 is attached so as to cover these.
The rectifier 5 is connected to a lead extending from the stator winding 23 and converts the applied three-phase AC voltage into a three-phase full-wave rectified DC voltage.

Vehicle alternator 1 having the above-described structure
When a rotational force from an engine (not shown) is transmitted to the pulley 20 via a belt or the like, the rotor 3 rotates in a predetermined direction. In this state, by applying an excitation voltage to the field coil 8 of the rotor 3 from the outside, the respective claw-shaped magnetic pole portions 73 of the pole core 7 are excited, and a three-phase AC voltage is generated in the stator winding 23. A predetermined DC power is taken out from the output terminal of the rectifier 5.

Next, details of the stator 2 will be described.
As described above, the slots 25 formed in the stator core 22 accommodate eight sets of sixteen covered conductors,
The contents are classified into four sets of eight inner-layer covered conductors arranged closer to the inner periphery and four sets of eight outer-layer covered conductors arranged closer to the outer periphery. Focusing on one slot 25, two types of winding strands 230 whose electric angles are different from each other by 180 ° are combined.
As the set of covered conductors, the other winding wire 230 is accommodated in one slot 25 as four sets of covered conductors closer to the inner periphery.

FIG. 3 is a partial cross section of the stator 2.
As shown in FIG. 3, eight sets of 16 winding element wires 230 are accommodated in each slot 25. Further, in each slot 25, four sets of eight winding strands 230 arranged near the outer periphery and four sets of eight winding strands 2 arranged near the outer periphery.
3 are hatched in FIG. 3 in different directions.

FIG. 4 is a winding specification diagram of the stator 2. FIG. 5 shows a stator winding 2 satisfying the winding specifications shown in FIG.
FIG. 9 is a diagram showing a winding order of winding element wires 230 when forming No. 3; As shown in FIG. 4, each winding element wire 230 such as Z 1, Y 1, X 1, etc., has 36 sets of coil end portions 23 </ b> D protruding from the pulley side end surface of the stator core 22, It has 36 sets of coil end portions 23R protruding from the pulley side end surface, and 36 sets of slot portions accommodated in each slot 25 of the stator core 22. Also,
Each slot 25 has eight winding strands 230 arranged closer to the inner periphery and eight winding strands 2 arranged closer to the outer periphery.
The slot portion of each winding element wire 230 can be considered as being divided into a slot inner layer portion 23SN closer to the inner periphery and a slot outer layer portion 23SG closer to the outer periphery.

In FIG. 5, the coil end portions 23D on the pulley side are numbered in the order of arrangement from "1" to "36", and the coil end portions 23D corresponding to the respective numbers are denoted by D1 to D36. It is written. Similarly,
"1" to "3" are set in the coil end 23R on the side opposite to the pulley.
Numbers are assigned in the arrangement order up to “6”, and the coil end portions 23R corresponding to the respective numbers are described as R1 to R36. Each slot 2SN is stored in the slot inner layer portion 23SN and the slot outer layer portion 23SG accommodated in the slot 25.
The numbers “1” to “36” are assigned in the arrangement order of 5, and
The slot inner layer portion 23SN corresponding to each number is S
N1 to SN36 are described, and the slot outer layer portion 23SG is described as SG1 to SG36. Further, the slot 25 corresponding to the slot part number (SN ○○, SG ○○)
It shall be expressed as XX. Hereinafter, description will be made using these notations.

As shown in FIGS. 4 and 5, the winding element wire 230 of Z1 starts to be wound from SG22, and D19, SN1
It is wound in the order of 9, R16. Further, the winding wire 230 of X1 disposed adjacent to the winding wire 230 of Z1 by one slot starts winding from SG23, and D20, SN
20 and R17 are wound in this order. The winding wire 230 of Y1 disposed adjacent to the winding wire 230 of X1 by one slot starts winding from SG24, and D21, SN2
It is wound in the order of 1, R18. Winding element wire 2 of Y1
The winding element wire 230 of Z2 disposed adjacent to the slot 30 and one slot starts winding from SG25, and D22, SN22,
It is wound in the order of R19. Wound element wire 230 of Z2
And the X2 winding wire 23 arranged adjacent to one slot
0 starts winding from SG26, D23, SN23, R2
It is wound in the order of 0. X2 winding wires 230 and 1
Y2 winding strand 230 arranged adjacent to slot
Starts from SG27, D24, SN24, R21
It is wound in order.

FIG. 6 is a view schematically showing a winding start portion of the stator winding 23. As shown in FIG. As described above, Z1, X1, Y
1, Z2, X2, Y2 winding element wire 230,
After being wound so as to correspond to the position of each slot 25 shown in S22 to S27, when forming the coil end portion 23D on the pulley side, it is folded back to a position shifted by three slots and shown in S19 to S24. It is wound so as to correspond to the position of each slot 25 to be formed. In this way,
At the pulley side coil end portion 23D and the opposite pulley side coil end portion 23R, 6
Kinds of winding strands 230 are spirally wound.

Further, in this manner, the six kinds of winding wire 2
When the windings 30 are spirally wound in order and reach the slots 1 to 6 at one end, the winding direction is reversed. In the present embodiment, after reversing the winding direction, the six types of winding wire 230
Are wound in a spiral in order, and slots 1 to
6, the winding direction is also reversed, and finally, the winding wire 230 of the same slot outer layer portion 23SG and the winding wire 230 of the same slot inner layer portion 23SN are wound four times for the same slot 25. It is wound by each. Therefore, 3
Each of the six slots 25 accommodates a total of 16 sets of winding wires 230.

However, as shown in FIG. 4, there are six slots 25 indicated by S1 to S6 located at both ends, and S7 to S6.
In the other 30 slots 25, indicated at 36,
The arrangement of the winding wire 230 in the slot, that is, the inside of the slot, is different.

Specifically, in the six slots 25 indicated by the slots S1 to S6 located at the left end in FIG. 4, as shown in FIG. 5, the slot inner layer portion 23SN (SN
1 to SN6) accommodates two sets of four winding element wires 230, and the slot outer layer portions 23SG (SN1 to SN3) of three slots 25 indicated by S1 to S3 have winding element wires 23.
0 is not accommodated, and eight sets of four winding element wires 230 are accommodated in the slot outer layer portions 23SG (SG4 to SG6) of the three slots 25 indicated by S4 to S6.

On the other hand, S1 to S1 at the right end in FIG.
In the six slots 25 indicated by S6, as shown in FIG. 5, two sets of four winding element wires 230 are accommodated in the slot inner layer portion 23SN (SN1 to SN6), and three slots indicated by S4 to S6. Outer layer portion 23SG of the slots 25
(SN4 to SN6) do not accommodate the winding wire 230,
Four sets of eight winding element wires 230 are accommodated in the slot outer layer portions 23SG (SG1 to SG3) of the three slots 25 indicated by S4 to S6.

Of these, the winding wire 230 accommodated in the slot inner layer portion 23SN is connected to coil ends 23D and 23R extending in one direction along the circumferential direction.
On the other hand, in the thirty slots 25 indicated by S7 to S36, both the slot inner layer part 23SN and the slot outer layer part 23SG, each of which includes two sets of four winding strands 230, are accommodated. The coil ends 23D and 23R connected to both extend along both sides in the circumferential direction.

In this embodiment, when each winding element wire 230 included in the slot portion is connected in series only to a slot portion of a different layer accommodated in another slot 25, this slot The portion is referred to as a “singular slot portion”, and the slot portion other than the singular slot portion is referred to as a “normal slot portion”. The slot 25 in which the singular slot portion is arranged is referred to as “singular slot”, and the slot 25 in which only the normal slot portion is arranged is referred to as “normal slot”.

In this embodiment, as shown in FIG. 4, in order to realize a stator winding 23 in which singular slots are arranged at both ends and a normal slot is arranged between the slots, six winding elements are provided. The operation of spirally winding the wire 230 in one direction is repeated by folding the wire 230 when it reaches the unique slot. As a result, a band-shaped home coil in which the singular slot portions are arranged at both ends is formed. Therefore, the stator coil 23 can be formed by forming the home coil into an annular shape and overlapping the unique slot portions at both ends.

In this case, as shown in FIG.
Regarding the six unique slots 25 indicated by “1” to “6” in FIG. 7, the inner layer (N) in the home coil
The relationship between the outer layer (G) is broken, the inner layer and the outer layer are intricately arranged, and the arrangement of the coil ends 23D and 23R connected to each other is disturbed. Therefore, the effects on the above-described effects such as a high space factor, a low resistance, and an improvement in cooling performance are small.

FIG. 8 is a diagram showing a bobbin necessary for forming a band-shaped home coil and a method of manufacturing a home coil using this bobbin. FIG. 9 is a side view of the bobbin 100 shown in FIG. As shown in FIG. 8, the bobbin 100 includes a bobbin main body 110 having a predetermined thickness, a plurality of slot restricting portions 120, 122 and a coil end restricting portion 130 which are disposed so as to substantially match the interval between the slots 25. , 13
2 is included. Multiple slot restrainers 12
Numerals 0 and 122 are for shaping the shapes of the slot outer layer portion 23SG and the slot inner layer portion 23SN, and the adjacent interval A is set to a value substantially equal to the adjacent slot interval. The spacing B between one slot restraining portion 120 and the other slot restraining portion 122 is
Is set to a value equal to or slightly larger than the thickness in the axial direction. Also, one of the coil end restraining portions 1
Numeral 30 is for forming the shape of the coil end portion 23D on the pulley side, and the other coil end restraining portion 132
Is for shaping the shape of the coil end 23R on the side opposite to the pulley. The slot restraining portions 120, 1
Each of the coil 22 and the coil end restraining portions 130 and 132 is attached to the bobbin main body 110 so as to be able to be inserted and withdrawn.

By winding six types of winding strands 230 around such a winding frame 100 in a helical manner, the winding order "1" to "15" or the winding order "15" to "15" shown in FIG. "3
7 "and the like, when the winding strand 230 wound in one direction is a winding strand of the same layer, the adjacent coil end portions 23D or the coil end portions 23R do not interfere with each other due to intersection or the like. A linear shape can be realized. Note that FIG. 8 shows a case where attention is paid to the winding element wire 230 of Y2, and “33” to “4” in the winding order shown in FIG.
The state near the right end of the home coil corresponding to “1” or “77” to “85” is shown.

When the above-described home coil is actually manufactured, the winding frame 100 is fixed, and the six types of winding wires 230 are wound while the winding machine is spirally rotated around the winding frame 100. , But the six types of winding wire 23
Alternatively, the drawer port 0 may be fixed, and the front and rear positions may be moved while rotating the winding frame 100.
In this case, since only the rotation operation and the movement operation of the winding frame 100 are controlled, the winding process can be simplified.
After the home coil is formed using the bobbin 100 in this manner, the slot restraining portions 120, 1
By removing the coil 22 and the coil end restraining portions 130 and 132 and further removing the reel body 110, a band-shaped home coil is formed. Thereafter, the home coil is formed into an annular shape such that the unique slots located at both ends thereof are overlapped, and then inserted into each slot 25 from the inner peripheral side of the stator core 22.

FIG. 10 is a diagram showing a connection state of the stator winding 23 of the present embodiment. The six types of winding wire 230 are:
Since the mutual electrical angles have the relationship shown in FIG. 2, by connecting them as shown in FIG. 10, the Y connection can be performed as a whole. By performing such connection, the stator winding 23 is completed.

As described above, in the automotive alternator 1 of the present embodiment, the stator winding 23 can be formed so as not to interfere with the coil end portion. In particular, a high space factor can be achieved by regularly arranging the six types of winding wires 230 in the slot 25, and the length of the coil end portion is shortened to reduce the resistance of the stator winding 23. , It is possible to increase the output.

In this embodiment, cooling fans 11 and 12 are provided as inner fan fans on the axial end surface of the rotor 3, and the cooling wind is provided at a position facing the coil end of the stator winding 23. Since the discharge window 41 is formed, the ventilation resistance of the cooling air flowing through the coil end formed in a shape that does not interfere can be extremely reduced, and the cooling performance can be greatly improved.

Further, since a continuous wire can be used as the six kinds of winding strands 230, the number of joints can be reduced as compared with the case where short segment conductors are joined, and the manufacture becomes easy. In particular, since it is easy to change the winding specification by increasing or decreasing the number of windings, various output characteristics can be realized, and it is easy to meet the demands of a small generator, a high-voltage generator, and the like.

Also, a band-shaped home coil is formed by simply winding the six types of winding wires 230 around the winding frame 100 in a spiral shape, and this is deformed into an annular shape and inserted into each slot 25 of the stator core 22. As a result, the stator winding 23 can be formed, so that a complicated winding step is not required and the manufacturing can be simplified.

In the above-described embodiment, since the home coil formed in a belt shape is annularly deformed and then inserted into each slot 25 of the stator core 22 to form the stator winding 23, the slot outer layer is not necessarily formed. It is not necessary to arrange all the slot inner layer portions 23SN on the inner peripheral side than the portion 23SG, and as shown in FIG.
They may be arranged irregularly.

In the above embodiment, the wire diameter is 1..
Although two 3 mm winding wires 230 were connected in parallel,
It is not always necessary to use two winding strands 230 connected in parallel, and it is possible to use one winding strand 230 alone or to connect three or more winding strands 230 in parallel. Good. Instead of the winding wire 230 having a circular cross section, a rectangular wire having a rectangular or square cross section may be used. In this case, the space factor in the slot 25 can be further increased by regularly arranging the winding wires 230 in the slot 25.

In this embodiment, the same number of turns is set for all of the six types of winding strands 230. However, depending on the position of the drawer for connecting to the rectifier 5, etc.
The number of turns of one of the winding wires 230 may be reduced. For example, the winding operation of the winding element wire 230 of Y2 shown in FIG.
Alternatively, the winding end portion may be pulled out from the slot 25 of No. 6.

In this embodiment, after the winding operation of the six types of winding wires 230 is completed, the winding start of each of the winding wires 230 of X1 and X2, Y1 and Y
2 and the winding starts of the respective winding strands 230 of Z1 and Z2 are joined to form the Y-connected stator winding 23 shown in FIG. However, a continuous line in which these joints are partially included in advance may be used. That is, the winding wire 230 ′ having a length approximately twice the sum of the lengths of the winding wire 230 of X1 and the winding wire 230 of X2 described above is used by bending it in half. The two conductors extending from the bent portion are connected to winding wires 23 of X1 and X2.
Used as 0. Y1 and Y2 winding strands 230 and Z
The same applies to the winding wires 230 of 1 and Z2.
Thereby, the joining process for the three joining portions performed after the winding operation is completed can be omitted, and the manufacturing process can be further simplified.

[Second Embodiment] In the vehicle alternator of the second embodiment, the winding method of the stator winding included in the vehicle alternator of the first embodiment is changed. Things. Specifically, in the above-described first embodiment, the stator winding 23 is realized by wave winding, but in the present embodiment, the stator winding is realized by concentrated winding.

FIG. 11 is a winding specification diagram of the stator winding 23 of the present embodiment. FIG. 12 is a diagram showing the winding order of the winding wires when forming the stator winding 23 shown in FIG. As shown in FIG. 12, the stator winding 2 of the present embodiment is
No. 3 is formed by sequentially shifting the winding operation of performing concentrated winding four times on the same slot 25 by six slots. Specifically, for example, focusing on the winding element wire of Z1, four concentrated windings are first performed using SN1 and SN4, and then, after reaching SN7 through R4, using SN7 and SG10. Four concentrated rolls are performed. In this way, by repeating the concentrated winding four times by sequentially shifting by six slots, the winding is finally completed at SG34. The same applies to the winding wire other than Z1. Finally, the winding wire of X1 is SG35, the winding wire of Y1 is SG36, and Z
The winding wire of No. 2 is SG1, the winding wire of X2 is SG2,
The winding strands of Y2 end at SG3.

Even when the concentrated winding as described above is performed,
A singular slot portion is arranged at both ends, and a band-like home coil having a normal slot portion is formed between them. The band-shaped home coil is deformed in a ring shape and inserted into each slot 25 of the stator core 22.

FIG. 13 is a connection diagram of the stator winding of the present embodiment. Similar to the first embodiment, the six types of winding element wires have the mutual electrical angle shown in FIG. 2, and by connecting these as shown in FIG. Y connection can be performed. In particular, the singular slot S
Since the winding start of the winding element wire of 1 to Z1 and the winding end of the winding element wire of Z2 are drawn out, the winding of the winding element wire which occurs when these are joined becomes unnecessary. Similarly, the winding start of the winding wire of X1 and the winding end of the winding wire of X2 from the singular slot S2 are the winding start of the winding wire of Y1 and the winding of the winding wire of Y2 from the singular slot S3. Since the ends are respectively drawn out, it is not necessary to route the winding wires which are generated when these are joined.

As described above, in the automotive alternator according to the present embodiment, the stator winding 2
By forming 3, as in the vehicle alternator of the first embodiment, the stator coil has a high space factor, a high output,
Cooling performance can be improved. Further, since it is easy to change the winding specification by increasing or decreasing the number of windings, various output characteristics can be realized, and it is easy to meet the demands of a small generator, a high-voltage generator, and the like. In this embodiment, by employing concentrated winding, the arrangement of the coil end portions on the pulley side and the arrangement of the coil end portions on the opposite pulley side are the same on each axial end surface of the stator core 22. Because of the direction, the interference of the coil ends of different phases can be further reduced. Note that, in the present embodiment, in addition to the features of the first embodiment, only the unique slot portion is arranged in the unique slot.

The present invention is not limited to the above embodiments, and various modifications can be made within the scope of the present invention. For example, in the embodiment described above, the stator 2 is formed by using the stator core 22 having an annular shape and inserting the annularly formed home coil into each slot 25 from the inner peripheral side thereof. A belt-like platform formed to have the winding specification shown in FIG. 4 or 11 in each slot 25A of the stator core 22A having a linear shape (or a non-annular shape other than the linear shape) as shown in FIG. After the coil is inserted together with the insulator 24, the whole may be formed into an annular shape.

FIG. 15 is a view showing a partial shape of a stator which is formed into an annular shape after a belt-like home coil is inserted into a linear stator core 22A. Since the ends of the linear stator cores 22A are butted together to form a substantially C-shaped stator, a slit 231 corresponding to the butted portion of the stator core is formed in a part of this stator. You.

In each of the above embodiments, the case where the stator winding is formed by one three-phase winding has been described. However, the stator winding is formed by combining a plurality of multi-phase windings. It may be. For example, as shown in FIG. 16, in each slot 25 of the stator core 22, a first polyphase winding 233 is arranged on the outer layer side, and a second polyphase winding 234 is arranged on the inner layer side. A stator winding composed of a set of multiphase windings 233, 234 may be formed. By providing a plurality of such multi-phase windings and arranging the respective multi-phase windings separably along the radial direction of the slot 25, for example, a multi-voltage generator having a plurality of types of output voltages can be obtained. It can be easily realized.

Alternatively, as shown in FIG. 17, in each slot 25 of the stator core 22, a first multi-phase winding 23
5 and a second polyphase winding 2 wound so as to cover the outer periphery thereof
36, these two sets of polyphase windings 235, 236
May be formed. Thus, in the cross section along the radial direction of the slot 25,
By providing a plurality of multi-phase windings so that one is included in the other, it is possible to easily realize, for example, a multi-voltage generator having a plurality of types of output voltages. Further, such a stator winding is composed of the first multi-phase winding 2.
After forming the strip-shaped first home coil corresponding to 35, a strip-shaped second home coil corresponding to the second multi-phase winding 236 is formed thereon, and then the double-shaped home coil is formed. Since the first and second home coils can be formed into a ring shape and inserted into each slot 25 of the stator core 22, the stator coil can be manufactured using two types of polyphase windings. The process can be greatly simplified.

Further, in each of the above-described embodiments, the three-phase windings whose electrical angles are shifted by 30 ° are formed using the six winding wires, but the electrical angles of each other are 30 °. The six-phase windings shifted by ° may be formed using 12 winding strands. This makes it possible to reduce the magnetic noise generated during power generation, increase the number of phases, further reduce the degree of overlap between coil ends, improve cooling performance, and facilitate various winding specifications. And the like become more remarkable.

[Brief description of the drawings]

FIG. 1 is a diagram illustrating an overall configuration of a vehicle alternator according to a first embodiment.

FIG. 2 is a diagram showing a relationship between six types of winding element wires.

FIG. 3 is a partial cross section of a stator.

FIG. 4 is a winding specification diagram of a stator.

FIG. 5 is a view showing a winding order of winding wires.

FIG. 6 is a diagram schematically illustrating a winding start portion of a stator winding.

FIG. 7 is a diagram showing a positional relationship between inner and outer layers when a home coil of a stator winding is formed.

FIG. 8 is a view showing a winding frame necessary for forming a band-shaped home coil and a method of manufacturing a home coil using the winding frame.

FIG. 9 is a side view of the bobbin shown in FIG.

FIG. 10 is a diagram illustrating a connection state of a stator winding according to the first embodiment.

FIG. 11 is a winding specification diagram of a stator winding according to a second embodiment.

FIG. 12 is a view showing a winding order of winding wires when forming the stator winding shown in FIG. 11;

FIG. 13 is a connection diagram of a stator winding of the second embodiment.

FIG. 14 is a view showing the shape of a stator core formed in a straight line.

FIG. 15 is a diagram showing a partial shape of a stator that is formed into a ring shape after inserting a band-shaped home coil into a straight stator core.

FIG. 16 is a diagram showing a winding state of a stator winding including a plurality of multiphase windings.

FIG. 17 is a diagram showing another winding state of a stator winding including a plurality of multiphase windings.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 vehicle alternator 2 stator 3 rotor 4 frame 5 rectifier 22 stator core 23 stator winding 25 slot 100 winding frame 110 winding frame main body 120, 122 slot restraining portion 130, 132 coil end restraining portion

 ──────────────────────────────────────────────────続 き Continued on front page F-term (reference) PP14

Claims (8)

[Claims] 1. A rotor having a rotor driven to rotate, a stator core disposed opposite to the rotor, and a stator having a stator winding mounted on the stator core, the rotor and the stator. A stator frame, wherein the stator winding includes a slot portion accommodated in a plurality of slots having openings on the inner peripheral side of the stator core, and a shaft of the stator core. And a coil end portion extending from the direction end face, wherein the slot portion is a singular slot portion accommodated in the same number of continuous slots as the number of phases of the stator winding, and other normal slot portions. At least one portion of the plurality of winding wires included in the normal slot portion is connected to another different two wires via the coil end portion.
Connected to one of the winding wires included in each of the slot portions accommodated in the one of the slots, and each of the plurality of winding wires included in the singular slot portion includes the coil end portion. Through one of the winding wires included in the slot portion accommodated in the other one of the slots, and the winding wires of each phase of the stator winding are connected to another winding wire. An alternator for a vehicle, wherein the alternator is wound in parallel with a corresponding part of the winding element wire of the phase so as to be inseparable from each other. 2. The slot according to claim 1, wherein the slot is classified into an inner layer and an outer layer, and each of the plurality of winding wires included in the normal slot is accommodated in two different slots. The plurality of winding wires included in the singular slot portion are connected in series with the winding wires of different layers of the respective slot portions, and the slots accommodated in another one of the slots. An alternator for a vehicle, wherein the alternator is connected in series with the winding wires of different layers. 3. The alternator for a vehicle according to claim 1, wherein the stator winding is formed in the singular slot so as to be separable from each other along a circumferential direction. 4. The stator according to claim 1, wherein the stator is configured to include a plurality of stator windings, and each of the plurality of stator windings is disposed within the slot. An automotive alternator, which is arranged as a plurality of layers separable in a radial direction. 5. The stator according to claim 1, wherein the stator includes a plurality of stator windings, and each of the plurality of stator windings extends in a radial direction. An alternator for a vehicle, characterized in that, in a cross section, one is included in the other. 6. The alternator for a vehicle according to claim 1, wherein the stator core is separable at at least one slit formed at a circumferential position. 7. A first step of winding a winding element wire in a band shape around a non-annular winding frame so as not to intersect with each other, and a step of winding the winding element wire in the first step. A second step of extracting the winding frame; a third step of forming the band-shaped winding element wire formed in the second step into an annular shape; And a fourth step of inserting the stator into a plurality of slots formed in the stator core. 8. The winding according to claim 7, wherein the stator core has a non-annular shape, and the slot-shaped winding formed in the second step is formed in the slot formed in the stator core. A vehicle AC comprising a fifth step of forming the stator core into an annular shape together with the strip-shaped winding element wire after inserting the element wire, in place of the third and fourth steps. Method of manufacturing stator for generator.