JP2002335660A - Brushless alternator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To firmly fix a magnet for increasing output onto a rotor core assembly in a brushless alternator in which the rotor core assembly formed by combining a first rotor core having a plurality of first claw poles at regular intervals in the peripheral direction with a second core having a plurality of second claw poles disposed between the plurality of first claw poles at regular intervals in the peripheral direction is rotatably supported on a rotating shaft by a pair of brackets which clamp a stator therebetween. SOLUTION: A synthetic resin filler 40 which fills a section between the first and the second claw poles 32a, 33a continuously across the whole periphery of the rotor core assembly 31a is integrally molded at the rotor core assembly 31A, and a plurality of magnets 38 disposed between the first and the second claw poles 32a, 33a embedded in the filler 40.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a first rotor core having a plurality of first claw poles at equal intervals in a circumferential direction, and a plurality of second claw poles disposed between the plurality of first claw poles in a circumferential direction. The present invention relates to a brushless alternator fixed to a rotating shaft rotatably supported by a pair of brackets sandwiching a stator, wherein the rotor core assembly is formed by coupling second rotor cores having equal intervals to each other.

[0002]

2. Description of the Related Art Conventionally, such a brushless alternator is known, for example, from Japanese Patent Application Laid-Open No. 61-85045. In this case, the first and second claw poles of a rotor core assembly are required to improve the output. A magnet is placed between them.

[0003]

However, in the prior art described above, the magnet is bonded to the rotor core assembly. The magnet withstands the centrifugal force acting on the magnet by the rotation of the rotor core assembly, and the magnet is attached to the rotor core assembly. It is necessary to adhere the magnet to the three-dimensional body, and it is desired that the magnet be more firmly fixed to the rotor core assembly.

The present invention has been made in view of such circumstances, and provides a brushless alternator in which a magnet for increasing output can be firmly fixed to a rotor core assembly so as to withstand centrifugal force. The purpose is to do.

[0005]

In order to achieve the above object, according to the present invention, a first rotor core having a plurality of first claw poles at equal intervals in a circumferential direction, and a plurality of the first claw poles are provided. A rotor core assembly formed by coupling a second rotor core having a plurality of second claw poles disposed therebetween at equal circumferential intervals,
In a brushless alternator fixed to a rotating shaft rotatably supported by a pair of brackets sandwiching a stator between the first and second claws, the rotor core assembly is connected to the entire circumference of the rotor core assembly. A filler made of a synthetic resin filling the gap is integrally molded and joined, and a plurality of magnets arranged between the first and second claw poles are embedded in the filler.

According to the first aspect of the present invention, the filler made of a synthetic resin extends over the entire circumference of the rotor core assembly and fills the gap between the first and second claw poles. Even if a centrifugal force acts on the filler due to the rotation of the three-dimensional structure, the filler does not separate from the rotor core assembly, and the magnet is embedded in the filler. The magnet can be firmly fixed to the rotor core assembly.

According to a second aspect of the present invention, there are provided a first rotor core having a plurality of first claw poles at equal intervals in a circumferential direction, and a plurality of second claw poles disposed between the plurality of first claw poles. In a brushless alternator fixed to a rotating shaft rotatably supported by a pair of brackets sandwiching a stator, a rotor core assembly formed by coupling a second rotor core having equal intervals in a direction is provided. A plurality of magnets disposed between the two claw poles contact the magnets from the outer side along the radial direction of the rotor core assembly to be in a first position.
And a plurality of holders having contact support plates disposed between the second claw poles, and each holder is engaged with the first and second claw poles at least from the radially inner side of the rotor core assembly. It is characterized by being mounted on the rotor core assembly together.

According to the configuration of the invention described in claim 2, the holder having the contact support plate disposed between the first and second claw poles is at least from the radially inner side of the rotor core assembly. Since the first and second claw poles are engaged with each other, even if a centrifugal force acts on the holder due to the rotation of the rotor core assembly, the holder does not separate from the rotor core assembly. Since the rotor comes into contact with the contact support plate provided from the radially inner side of the rotor core assembly, even if a centrifugal force acts on the magnet, the magnet can be securely held by the holder, so that it can withstand the centrifugal force. Each magnet can be firmly fixed to the rotor core assembly.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described based on embodiments of the present invention shown in the accompanying drawings.

1 to 3 show a first embodiment of the present invention. FIG. 1 is a longitudinal sectional side view of a brushless alternator, FIG. 2 is an enlarged sectional view taken along line 2-2 of FIG. 1, and FIG. 1 of 3
FIG. 3 is an enlarged sectional view taken along line -3.

First, referring to FIG. 1, a stator 1 of a brushless alternator 11A mounted on an automobile such as a truck.
Reference numeral 2 denotes a stator core 13 wound around a stator core 13 formed by laminating a plurality of annular core plates, and the stator core 13 includes a first and a second bracket 1.
It is sandwiched between 5 and 16. Moreover, the first and second brackets 15, 16 are fastened to each other by a plurality of through bolts 17,..., And the stator 12 is sandwiched between the first and second brackets 15, 16.

At the center of the first and second brackets 15 and 16, cylindrical bosses 15a and 16a are provided coaxially. One end of a rotary shaft 18 is mounted on the boss 15a of the first bracket 15 as a bearing. It is rotatably supported via 19. The other end of the rotating shaft 18 penetrates through the boss 16a of the second bracket 16 and projects outward.
A bearing 20 is provided between a and the rotating shaft 18.

A cooling fan 21 is fixed to the rotating shaft 18 outside the second bracket 16, and a pulley 22 is fixed to the other end of the rotating shaft 18 outside the cooling fan 21. An endless belt (not shown) for transmitting the power is wound around the pulley 22.

A cover 24 is attached to the first bracket 15 such that a storage chamber 23 is formed between the first bracket 15 and the outer surface of the first bracket 15. A pair of heat sinks 25 and 26 fixed to the first bracket 15 at a distance from each other, and the heat sinks 25 and
26, a plurality of diodes 27 ..., 28 ...
And a regulator 30 fixed to the first bracket 15 and the like.

A rotor core assembly 31A is disposed between the first and second brackets 15, 16 so as to be surrounded by the stator 12. This rotor core assembly 31A
Are provided with a first rotor core 32A having a plurality of, for example, eight first claw poles 32a at equal intervals in a circumferential direction, and a plurality of, for example, eight, second claw poles 33a arranged between the plurality of first claw poles 32a. Are provided at equal circumferential intervals in the second rotor core 33A.
Are connected to each other via a ring body 34 formed of a non-magnetic metal such as stainless steel and sandwiched between the rotor cores 32A, 33A.
Is fixed to the rotating shaft 18. Thus, the first rotor core 32
The A and the ring body 34 are fixed to each other by press fitting or welding, and the second rotor core 33A and the ring body 34 are fixed to each other by press fitting or welding.

Referring also to FIG. 2, the first bracket 1
A cylindrical exciting core 35 inserted into the rotor core assembly 31A is fixed to the inner surface of the rotor 5 with a plurality of bolts 36. An exciting coil 37 is wound around the exciting core 35.

Such a brushless alternator 11A
Then, an AC electromotive force is generated in the stator coil 14 in accordance with the rotation of the rotating shaft 18, the AC electromotive force is rectified to DC by the rectifier 29, and the DC power whose voltage is adjusted by the regulator 30 is, for example, the charging power of the battery. Is output from the brushless alternator 11A.

In the rotor core assembly 31A, a plurality of, for example, eight first and second claw poles 32a,
Magnets 38 for improving the output of the brushless alternator 11A are arranged between the first and second claw poles 32a, 33a, for example, at equal intervals in the circumferential direction among the 33a.

Referring also to FIG. 3, the rotor core assembly 31A has a first claw pole 32a... And a second claw pole 33 connected continuously over the entire circumference of the rotor core assembly 31A.
The fillers 40 made of synthetic resin that fill the spaces a are integrally joined by injection molding or the like, and the magnets 38 are embedded in the fillers 40.

According to the first embodiment, the filler 40 made of synthetic resin is continuous over the entire circumference of the rotor core assembly 31A and fills the space between the first and second claw poles 32a and 33a. And rotor core assembly 3
Even if a centrifugal force acts on the filler 40 due to the rotation of 1A, the filler 40 does not separate from the rotor core assembly 31A.

Moreover, the magnets 38 ...
Since the magnets 38 are buried therein, the magnets 38 can be firmly fixed to the rotor core assembly 31A so as to withstand the centrifugal force.

4 to 7 show a second embodiment of the present invention. FIG. 4 is a longitudinal sectional side view of a brushless alternator, FIG. 5 is an enlarged sectional view taken along line 5-5 of FIG. 4, and FIG. 4 of 6
FIG. 7 is an enlarged sectional view taken along line -6, and FIG. 7 is a perspective view of the holder and the magnet.

4 to 6, a rotor core assembly 31B is disposed between the first and second brackets 15 and 16 of the brushless alternator 11B so as to be surrounded by the stator 12. This rotor core assembly 31
B includes a first rotor core 32B having a plurality of, for example, eight first claw poles 32b at equal intervals in a circumferential direction;
A second rotor core 33 having a plurality of, for example, eight second claw poles 33b arranged between the claw poles 32b at circumferentially equal intervals.
B are connected via a ring body 34.

Of the plurality of, for example, eight first and second claw poles 32b, 33b in the rotor core assembly 31B, for example, four first and second claw poles 32b, 33b at equal intervals in the circumferential direction. Between them are magnets 38 for improving the output of the brushless alternator 11B.
Are arranged, and each of the magnets 38 is formed of a non-magnetic material such as stainless steel so that the rotor core assembly 31B
Are held by holders 41.

Referring also to FIG. 7, the holder 41 includes a rectangular flat contact support plate 41a disposed between the first and second claw poles 32b and 33b, and a longitudinal direction of the contact support plate 41a. A pair of engagement support plates 41b, 41b, which are respectively provided at both ends at right angles to each other, are integrally provided.
41b is formed so as to project from both ends in the longitudinal direction of the contact support plate 41a to both sides.

The magnet 38 includes two engaging support plates 41b,
41b, the length corresponding to the distance between the two support plates 41b,
It is formed in a rectangular parallelepiped shape so as to have a width corresponding to the distance between the side ends of 41b and a height corresponding to the amount of protrusion of the two engagement support plates 41b, 41b from the contact support plate,
It is held by the holder 41 so as to be bonded with an adhesive.

On the other hand, the first and second claw poles 32b,.
b, at the outer end of the rotor core assembly 31B along the radial direction, locking flanges 42 projecting to both sides along the circumferential direction of the rotor core assembly 31B are provided. The contact support plate 4 of the combined support plates 41b, 41b
1a, the first and second claw poles 32b,..., 3 from the inner side along the radial direction of the rotor core assembly 31B.
3b are attached to the rotor core assembly 31B so as to engage with the locking flanges 42.

The magnet 38 held by the holder 41 abuts on the contact support 41a of the holder 41 on the outer end side of the rotor core assembly 31B in the radial direction, and on the inner end side of the rotor core assembly 31B in the radial direction. It comes into contact with the ring body 34. Both ends of the magnet 38 along the circumferential direction of the rotor core assembly 31B contact the first and second claw poles 32b, 33b on both sides of the magnet 38.

In the second embodiment, the contact support plate 4
As shown in FIG. 6, the magnet 38 at the portion protruding from 1a is in contact with the locking flanges 42, 42 of the first and second claw poles 32b, 33b, but may not be in contact. .

According to the second embodiment, the holder 41 having the contact support plate 41a disposed between the first and second claw poles 32b and 33b of the rotor core assembly 31B is provided in the radial direction of the rotor core assembly 31B. First and second from inside
The holder 41 engages with the locking flanges 42, 42 of the claw poles 32b, 33b, so that even if a centrifugal force acts on the holder 41 due to the rotation of the rotor core assembly 31B, the holder 41 is not rotated.
There is no separation from 1B.

In addition, the magnet 38 is attached to the contact support plate 41a of each holder 41 by the rotor core assembly 31B.
Abut on the inner side in the radial direction of the rotor 38, even if a centrifugal force acts on the magnet 38, the magnet 38 can be securely held by the holder 41. Therefore, each magnet 38 is connected to the rotor core assembly so as to withstand the centrifugal force. It can be firmly fixed to the three-dimensional body 31B.

In the second embodiment, both ends of the magnet 38 along the circumferential direction of the rotor core assembly 31B are engaged with the first and second claw poles 32b, 33b from the radially inner side of the rotor core assembly 31B. The centrifugal force that abuts and engages the stopper flanges 42 and 42 and acts on the magnet 38 is applied to the contact support plate 41 a of the holder 41 and the first and second claw poles 32 b and 33 b on both sides of the magnet 38. Therefore, the load acting on the magnet 38 can be dispersed.

8 to 11 show a third embodiment of the present invention. FIG. 8 is a longitudinal sectional side view of a brushless alternator, FIG. 9 is an enlarged sectional view taken along line 9-9 of FIG. 8, and FIG. 8 is an enlarged sectional view taken along the line 10-10, and FIG. 11 is a perspective view of the holder and the magnet.

8 to 10, a rotor core assembly 31C is arranged between the first and second brackets 15 and 16 of the brushless alternator 11C so as to be surrounded by the stator 12. This rotor core assembly 3
1C includes a first rotor core 32C having a plurality of, for example, eight first claw poles 32c at equal intervals in a circumferential direction, and a plurality, for example, eight second claw poles 32c, disposed between the plurality of first claw poles 32c.
Second rotor core 3 having claw poles 33c at equal intervals in the circumferential direction
3C is connected via a ring body 34.

Of the plurality of, for example, eight first and second claw poles 32c, 33c in the rotor core assembly 31C, for example, four first and second claw poles 32c, 33c spaced at equal intervals in the circumferential direction. Between them are magnets 38 for improving the output of the brushless alternator 11C.
Are arranged, and each of the magnets 38 is formed of a non-magnetic material, for example, stainless steel, so that the rotor core assembly 31C
Are held by holders 43.

Referring also to FIG. 11, the holder 43 includes:
A rectangular flat plate-shaped contact support plate 43a disposed between the first and second claw poles 32c, 33c, and a pair of engagement supports provided at right angles to the longitudinal center portions of both ends of the contact support plate 43a. The plates 43b, 43b are integrally provided. The width of the contact support plate 43a is set to be larger than the width of both engagement support plates 43b, 43b, and the magnet 38 is held by the holder 43 so as to be bonded with an adhesive.

On the other hand, the first and second claw poles 32c,..., 3 at the outer end of the rotor core assembly 31C in the radial direction.
Are provided on both side surfaces of the holder 43 so as to extend in parallel with the axis of the rotary shaft 18.
Is used to connect the both ends of the contact support plate 43a to the locking grooves 44, 4.
4 are attached to the rotor core assembly 31C so as to engage with the rotor core assembly 31C.

The magnet 38 held by the holder 43 contacts the contact support 43a of the holder 43 on the outer end side of the rotor core assembly 31C in the radial direction, and on the inner end side of the rotor core assembly 31C in the radial direction. It comes into contact with the ring body 34. Both ends of the magnet 38 along the circumferential direction of the rotor core assembly 31C contact the first and second claw poles 32b, 33b on both sides of the magnet 38.

According to the third embodiment, the holder 43 having the contact support plate 43a disposed between the first and second claw poles 32b and 33b of the rotor core assembly 31C is provided in the radial direction of the rotor core assembly 31C. First and second from inside
The locking grooves 44 are engaged with the claw poles 32b and 33b.
Since the holder 43 is engaged with the rotor core assembly 31C, even if a centrifugal force acts on the holder 43 due to the rotation of the rotor core assembly 31C, the holder 43 does not separate from the rotor core assembly 31C.

Further, the magnet 38 is mounted on the contact support plate 43a of each holder 43 by the rotor core assembly 31C.
Abuts from the radially inner side of the rotor 38, even if a centrifugal force acts on the magnet 38, the magnet 43 can be securely held by the holder 43. Therefore, each magnet 38... It can be firmly fixed to the three-dimensional body 31C.

Although the embodiments of the present invention have been described above, the present invention is not limited to the above embodiments, and various design changes can be made without departing from the present invention described in the appended claims. It is possible.

For example, in the above embodiment, the first and second
Claw poles 32a, 33a; 32b, 33b; 32c, 33c
Are eight in each case, but four magnets 38 are arranged, but the number of magnets 38 is not limited to four.

[0043]

As described above, according to the first aspect of the present invention, the synthetic resin filler which fills the gap between the first and second claw poles continuously over the entire circumference of the rotor core assembly is provided with the action of centrifugal force. Therefore, the magnets are buried in the filler without being separated from the rotor core assembly, so that each magnet can be firmly fixed to the rotor core assembly so as to withstand the centrifugal force.

According to the second aspect of the present invention, since the first and second claw poles are engaged at least from the radially inner side of the rotor core assembly, the rotor core assembly is separated from the rotor core assembly by the action of centrifugal force. Since the magnet is disposed between the first and second claw poles and abuts against the abutting support plate of the holder from the radially inner side of the rotor core assembly, the magnet withstands centrifugal force. Thus, each magnet can be firmly fixed to the rotor core assembly.

[Brief description of the drawings]

FIG. 1 is a vertical sectional side view of a brushless alternator according to a first embodiment.

FIG. 2 is an enlarged sectional view taken along line 2-2 of FIG.

FIG. 3 is an enlarged sectional view taken along line 3-3 of FIG. 1;

FIG. 4 is a vertical sectional side view of a brushless alternator according to a second embodiment.

FIG. 5 is an enlarged sectional view taken along line 5-5 of FIG. 4;

FIG. 6 is an enlarged sectional view taken along line 6-6 of FIG. 4;

FIG. 7 is a perspective view of a holder and a magnet.

FIG. 8 is a vertical sectional side view of a brushless alternator according to a third embodiment.

FIG. 9 is an enlarged sectional view taken along line 9-9 of FIG.

FIG. 10 is an enlarged sectional view taken along line 10-10 of FIG. 8;

FIG. 11 is a perspective view of a holder and a magnet.

[Explanation of symbols]

 11A, 11B, 11C ... brushless alternator 12 ... stator 15, 16 ... bracket 18 ... rotating shaft 31A, 31B, 31C ... rotor core assembly 32A, 32B, 32C ... first rotor core 32a, 32b, 32c ... first claw poles 33A, 33B, 33C ... second rotor cores 33a, 33b, 33c ... second claw poles 38 ... magnets 40 ... fillers 41, 43 ..Holders 41a, 43a...

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 5H619 AA03 AA05 BB02 BB06 BB17 PP02 PP08 PP24 5H621 AA03 GA07 GA13 HH01 JK01 JK13 5H622 CA02 CA05 CA11 CB04 CB05 PP20

Claims (2)

[Claims] 1. A plurality of first claw poles (32a) having a plurality of first claw poles (32a) arranged at equal intervals in a circumferential direction, and a plurality of second claw poles disposed between the plurality of first claw poles (32a). (33
Second rotor core (33A) having a) at equal intervals in the circumferential direction
And a rotor shaft assembly (31A) rotatably supported by a pair of brackets (15, 16) sandwiching the stator (12) therebetween.
In the brushless alternator fixed to the rotor core assembly (31A), the rotor core assembly (31A) is connected to the entire circumference of the rotor core assembly (31A), and is made of synthetic resin that fills the space between the first and second claw poles (32a, 33a). The filler (40) is integrally molded, and a plurality of magnets (38) arranged between the first and second claw poles (32a, 33a) are embedded in the filler (40). And a brushless alternator. 2. A first rotor core (32B, 32C) having a plurality of first claw poles (32b, 32c) at equal circumferential intervals.
And a second rotor core (33B, 33C) having a plurality of second claw poles (33b, 33c) arranged between the plurality of first claw poles (32b, 32c) at equal circumferential intervals. The rotor core assembly (31B, 31C) formed of a pair of brackets (1) sandwiching the stator (12) therebetween.
A plurality of magnets (38) arranged between the first and second claw poles (32b, 33b; 32c, 33c) in a brushless alternator fixed to a rotating shaft (18) rotatably supported by (5, 16). ) Comes into contact with each magnet (38) from the outside along the radial direction of the rotor core assembly (31B, 31C) to contact the first and second claw poles (3).
2b, 33b; 32c, 33c), a plurality of holders (41, 43a) having contact support plates (41a, 43a).
43), and each holder (41, 43) is
First and second claw poles (32b, 33) from at least radially inner sides of the rotor core assemblies (31B, 31C).
b; 32c, 33c) to engage the rotor core assembly (3
1B, 31C).