JP2004088993A - Alternator for vehicle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To realize the alternator for vehicles coping with a small size and to a high output further to a low cost. <P>SOLUTION: A stator core 32 is provided with two star connection three-phase windings. Electrical conductors are arranged so as to radially form four layers in one slot. The winding of one phase has a plurality of turn parts 33c1 connecting between first/second layers and a plurality of turn parts 33c2 connecting between third/fourth layers. These turn parts 33c1, 33c2 are arranged systematically. The winding of one phase has one turn part 33a1 of the same layer connecting the first layers. The winding of one phase has two turn parts 33b1, 33b2 positioned adjacent radially to the turn part 33a1 of the same layer to connect the second/third layers. Further, the winding of one phase has output lines 3111, 3112. As a result, the winding of each phase is provided by one continuous line arranged so as to make two circumferential turns around the stator core 32. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a vehicle alternator mounted on a passenger car, truck, or the like and driven by an engine.
[0002]
[Prior art]
2. Description of the Related Art In recent years, as a countermeasure against environmental problems, a reduction in the weight of a vehicle engine body has been required to improve fuel efficiency. On the other hand, an increase in engine drive torque is required to improve drivability. As a result of these requests and their countermeasures, engine vibration tends to increase even with the same displacement. On the other hand, the vehicle alternator driven by the engine is directly attached to the engine body via a bracket or the like, so that vibration from the engine is easily transmitted. For this reason, it is necessary to improve the vibration resistance. In response to demands such as a reduction in the idling speed of the vehicle and a reduction in the size of the engine room for securing the cabin space, in addition to improvements such as higher output, smaller size and higher efficiency, There is also a need for improved heat resistance against temperature rise in the engine room. In addition, there is also a need to reduce the noise of vehicle alternators from the social demands for noise reduction outside the vehicle and the aim of improving product commerciality by improving the quietness of the vehicle interior. Therefore, it is required to provide the above various performance improvements at low cost.
[0003]
On the other hand, Japanese Patent Application Laid-Open No. H11-155270 (Patent Document 1) discloses that a stator winding is formed by a plurality of conductor segments, and conductor segments of different layers from different slots are connected to each other to achieve a high space occupation. A small, high-output, low-noise automotive alternator is shown by forming a low-resistance, low-resistance winding and arranging two three-phase windings on one stator. However, the connection between segments requires welding, and as the number of segments in a slot increases, the number of processing machines for welding, the number of welding processes, and the number of insulation processes increase. is there. Further, as the number of segments in the slot increases, the distance between the welded portions becomes shorter, so that there is a problem that the welded portions are likely to be short-circuited.
[0004]
Japanese Patent No. 3155534 (Patent Document 2) discloses a vehicle AC generator in which a plurality of windings having a length corresponding to one circumference of a stator core are arranged and joined to each other to form a winding for one phase. The stator is shown. One phase of this winding has the arrangement shown in FIG. 16 and has three welding points WELD per phase. However, the cost is increased due to a processing machine for welding, a welding process, an insulation process, and the like. Also, the coil end becomes high due to the welded portion, which hinders miniaturization.
[0005]
[Patent Document 1] JP-A-11-155270
[0006]
[Patent Document 2] Japanese Patent No. 3155534
[0007]
[Problems to be solved by the invention]
The conventional technique described above has a problem that a large number of welded joints are still required. In addition, there is also a problem that as a result of the joining portions being densely arranged in a predetermined range, the joining becomes difficult.
[0008]
In view of the above problems, an object of the present invention is to provide an inexpensive, high-output, small-sized, low-noise stator winding in an automotive alternator.
[0009]
Another object of the present invention is to provide a small-sized, high-output, and low-cost AC alternator for a vehicle, in which conductors of different layers from different slots are formed of continuous wire windings to eliminate segment welding. It is to realize a vehicle alternator.
[0010]
Still another object of the present invention is to improve the heat resistance by devising the shape of the coil end.
[0011]
Another object of the present invention is to prevent a short circuit at a coil end even when the number of conductors in a slot increases.
[0012]
Still another object of the present invention is to provide a stator winding capable of realizing high output and miniaturization at low cost by making the connection of the output line only the connection between the phases of the polyphase winding. .
[0013]
Yet another object of the present invention is to reduce noise by using stator windings that are out of phase.
[0014]
[Means for Solving the Problems]
In order to achieve the above object, according to the first aspect, a field rotor having a plurality of claw-shaped magnetic poles alternately forming NS poles along a rotational circumferential direction, and a fixed member arranged to face the rotor. An alternator for a vehicle having a stator core and a stator having a multi-phase stator winding provided in a plurality of layers at a plurality of radial depths of a plurality of slots formed in the stator core. Each phase winding of the stator winding is formed of a continuous line, and each phase winding is connected to the same layer in a slot spaced apart in correspondence with the magnetic pole pitch of the NS pole of the rotor. And a crossover portion for connecting in series different layers in slots separated according to the magnetic pole pitch of the NS pole of the rotor, and coil ends on both axial sides of the stator core. Is formed. Thus, since there is no joint at the coil end transition portion, it is possible to contribute to a reduction in manufacturing cost.
[0015]
According to claim 2, in the vehicle alternator according to claim 1, the crossover portion includes a skew portion and a turn portion, and except for the crossover portion of the same layer, the skew portion of an adjacent layer is different from the crossover portion. The skew directions are opposite to each other, and the turn portion of the crossover portion radially adjacent to the crossover portion of the same layer is different in the radial depth of the slot by one layer from the turn portions of the other crossover portions. The skewed portions are connected in series at different positions. As a result, the cooling air flowing along the surface of the sloping portion of the cross section flows toward the output line, and the cooling performance of the output line connected to the rectifying element can be improved. It can contribute to improvement of the performance.
[0016]
According to a third aspect, in the vehicle alternator according to the first aspect, a transition portion radially adjacent to a transition portion between the same layers is an output line. Thus, the cooling air flowing along the surface of the sloping portion of the transition portion can improve the cooling performance of the output line connected to the rectifying element, thereby reducing the thermal effect on the element and contributing to the improvement of heat resistance. .
[0017]
According to a fourth aspect, in the vehicle alternator according to any one of the first to third aspects, the turn portion of the crossover portion between the layers has a substantially annular shape in a radial direction. As a result, it is possible to prevent interference between the same-layer crossing portions that occur when performing multi-phase winding and reduce the coil end height, thereby reducing the electric resistance of the coil end and contributing to downsizing and high output. it can.
[0018]
According to claim 5, in the vehicle alternator according to any one of claims 1 to 4, the output line of each phase of the stator winding is drawn from the same layer of an adjacent slot. Features. As a result, the distance between the output lines is shortened, the interphase connection of the multi-phase winding on the output line is facilitated, and the manufacturing cost can be reduced. Further, since it is not necessary to crawl the output line, vibration resistance can be improved.
[0019]
According to claim 6, in the vehicle alternator according to any one of claims 1 to 5, the substantially U-shaped conductor has a barbed portion at a transition portion between the same layers, and is twisted into a coil spring shape to be a predetermined. Are arranged in slots spaced apart from each other by a magnetic pole pitch. As a result, as compared with a method in which a wire is bent and formed in a lightning shape as shown in Japanese Patent No. 3155534 and folded in a perpendicular direction with a jig, coil forming becomes easier and the manufacturing cost can be reduced.
[0020]
According to claim 7, in the vehicle alternator according to any one of claims 1 to 6, the slots are separated from a first slot group corresponding to a magnetic pole pitch of the NS pole, and A second slot group adjacent to the slot group and shifted by an electrical angle of 30 degrees, a first polyphase winding is arranged in the first slot group, and a second polyphase winding is arranged in the second slot group The output is extracted from each of the first and second polyphase windings. Thereby, the vibration resistance can be improved by increasing the rigidity of the coil end, and the magnetic noise associated with power generation can be reduced by disposing the two polyphase windings at an electrical angle of 30 degrees.
[0021]
According to claim 8, a vehicle alternator includes a rotor having a plurality of claw-shaped magnetic poles, a stator core having a plurality of slots, and a plurality of phase windings supported in a plurality of layers in the slots. And a stator winding forming a multi-phase winding including: each of the phase windings is formed by a continuous line, and forms coil ends at both ends of the stator core, and is spaced apart from the magnetic pole pitch. A crossover portion connecting layers stored in different slots, wherein the crossover portion includes only one same-layer connection crossover portion connecting the same layer stored in different ones of the slots, and a different layer stored in different ones of the slots. And another crossover part connecting the two. According to this configuration, the phase winding can be provided by a continuous line.
[0022]
According to the ninth aspect, each of the crossover portions has a pair of skewing portions extending inclining in opposite directions to each other, and a turn portion connecting the skewing portions. The adjacent intermediate connection bridging part connects a pair of layers different by one layer from a pair of layers connected by the bridging part other than the same-layer connecting bridging part. According to this configuration, the phase winding can be provided by a continuous line.
[0023]
According to claim 10, the same-layer connection bridging part connects between first layers located at one radial end of the slot, and the intermediate connection bridging part radially adjacent to the same-layer connection bridging part, A second group connecting the first layer and the second layer, and a second group connecting the third layer and the fourth layer; And a transition portion. According to this configuration, a four-turn phase winding can be provided by a continuous wire.
[0024]
According to the eleventh aspect, the skewed portion of the same-layer connection transition portion and the skewed portion of the intermediate connection transition portion radially adjacent to the same-layer connection transition portion are arranged in parallel.
[0025]
According to the twelfth aspect, the same-layer connection bridging portion and another bridging portion form a gap extending therebetween toward the axial end.
[0026]
According to a thirteenth aspect, each of the phase windings has an output line disposed radially inside or outside the same-layer connection transition portion.
[0027]
According to a fourteenth aspect, the same-layer transition portion is formed in a substantially circular shape.
[0028]
According to claim 15, each of the phase windings has an output line derived from the same layer of adjacent slots.
[0029]
According to claim 16, the continuous line has a substantially U-shaped line with a turn for the same-layer connection transition, and the continuous line is formed as a laminated wave winding. .
[0030]
According to claim 17, the slot comprises a plurality of slots forming a first group, and a plurality of slots forming a second group which is shifted from the first group by an electrical angle of 30 degrees. Has a first polyphase winding housed in the first group of slots and a second polyphase winding housed in the second group of slots.
[0031]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an embodiment of an AC generator to which the present invention is applied will be described. In the following embodiments, the present invention is applied to a vehicle alternator. The vehicle alternator is driven by a vehicle engine.
[0032]
(First embodiment)
1 to 14 show a first embodiment of the present invention. In FIG. 1, the vehicle alternator 1 has a frame 4. The frame 4 is attached to the engine. The vehicle alternator 1 includes a pulley 20. A belt (not shown) is set on the pulley 20 to transmit the rotation of the engine. The pulley 20 is fixed to a shaft of the rotor 2. The rotor 2 is rotatably supported by the frame 4. As a result, the rotor 2 is rotationally driven by the engine.
[0033]
The rotor 2 has a field winding 8. The field winding 8 is connected to slip rings 9 and 10. The slip rings 9 and 10 are connected to a brush device, and the brush device is connected to a circuit that controls a field current. The field current control circuit is also a voltage control device that controls the output voltage of the output terminal 6. An exciting current flows through the field winding 8 via slip rings 9 and 10. The rotor 2 has a pair of Rundel-type pole cores 71 and 72. The pole cores 71 and 72 have a plurality of claw-shaped magnetic poles. When the field winding 8 is energized, the magnetic poles of the pole cores 71 and 72 are excited to N and S poles. Cooling fans 11 and 12 are fixed to both axial ends of the pole cores 71 and 72, respectively. When the rotor 2 rotates, the cooling fans 11 and 12 generate cooling air flowing in the radial direction. As a result, in the frame 4, the flow of the cooling air which is taken into the frame 4 from the opening 41 formed in the axial end face and discharged outside through the opening 42 formed in the radially outer face. Then, the ventilation path is formed.
[0034]
The stator 3 is fixed to the frame 4 so as to face the magnetic poles of the rotor 2. The stator 3 has a stator winding 31 and a stator core 32. The stator core 32 is formed by laminating silicon steel plates in multiple layers facing in the axial direction. The stator core 32 can be formed by rolling a series of strip-shaped materials. The stator core 32 may be formed by laminating a plurality of annular materials. The stator core 32 is formed in a cylindrical shape. In FIG. 6, the stator core 32 has a plurality of slots arranged at substantially equal intervals. In this embodiment, 96 slots are provided. Each slot has an end opening that opens at both ends in the axial direction and extends in the radial direction, and an elongated radial opening that opens in the radial direction inside the stator core 32 and extends in the axial direction. The radial opening may be machined so that the circumferential width of the opening is reduced after the stator winding 31 is mounted. Further, the stator core 32 may be formed in an annular shape by winding a laminated flat plate in a C shape.
[0035]
The plurality of slots can be classified into a plurality of groups, each group including a plurality of slots. In this embodiment, a first group and a second group are configured. The second group is arranged at an electrical angle of 30 degrees from the first group.
[0036]
The stator winding 31 is mounted on a slot of the stator core 32 via an insulator 34. As shown in FIG. 1, the stator winding 31 has an accommodation portion accommodated in a plurality of layers in a slot, a crossover portion connecting between the two slots, and an output line. At both ends in the axial direction of the stator core 32, a plurality of crossover portions and an output wire are arranged so as to protrude as coil end portions. At one axial end of the stator core 32, a first coil end portion 31a on which an output line is disposed is disposed. At the other end of the stator core 32, a second coil end portion 31b is arranged. The crossover portion has two skewed portions that extend from the slot in the circumferential direction toward the axial direction, and a turn portion that connects between the skewed portions.
[0037]
As shown in FIGS. 5 and 6, the first coil end portion 31 a has a crossover portion that is regularly arranged inside and outside over a C-shaped range that occupies most of the entire annular shape. Have been. In these regular arrangement ranges, a turn portion 33c1 connecting the first layer and the second layer and a turn portion 33c2 connecting the third layer and the fourth layer are arranged. The numbers indicating the layers are shown in the order from the inner side to the outer side in the radial direction. The first coil end portion 31a has a crossover portion having a complicated shape and an output line 311 in a part of the range. These complex, irregularly shaped transitions are shown as turns 33a, 33b. The turn part 33a connects the first layer to the first layer. Therefore, the turn portion 33a is called a turn portion of the transition portion of the same layer as a turn portion connecting the transition portion of the same layer. FIG. 6 shows one phase of the windings for six phases. The turn portion 33a1 connects the first layer to the first layer. A turn portion 33b is arranged radially adjacent to the crossover portion of the same layer. The turn part 33b connects the second layer and the third layer. The turn portion 33b connects the oblique portions in series at a position where the radial depth of the slot differs by one layer from the turn portion 33c of the other regular crossover portion. The output line 311 has two output lines 3111 and 3112 corresponding to both ends of a one-phase winding. The two output lines 3111 and 3112 for one phase are arranged in the fourth layer and are circumferentially separated by one pitch, that is, six slots. In FIG. 6, the winding for one phase has two intermediate connection turn parts 33b1 and 33b2. These intermediate connection turn portions 33b1 and 33b2 are circumferentially separated by one pitch, that is, by six slots, and are located between the same layer connection turn portion 33a1 and the output lines 3111 and 3112 in the radial direction. I have.
[0038]
Focusing on the one-phase winding of the stator winding 31, as shown in FIG. 6, the first coil end portion 31a has a slot 33a1 having a radial depth of the slot in the same layer as a crossover portion. A turn portion that is radially adjacent to the crossover portion of the same layer and that connects the inclined portions in series at a position where the radial depth of the slot differs by one layer from the turn portion of the other crossover portion. 33b1, a turn portion 33b2, a turn portion 33c of a crossover portion for connecting different layers in the separated slots in series, an output line 3111, and an output line 3112 are arranged.
[0039]
FIG. 13 is a partial perspective view of the stator 3. FIG. 14 is a wiring diagram showing an arrangement of the windings for one phase accommodated in the stator 3. FIG. 13 illustrates a range in which the same-layer transition portion, the intermediate connection transition portion, and the output line are arranged. FIG. 14 illustrates the same range as FIG. In FIGS. 13 and 14, parts related to the X phase are indicated by reference numerals. 13 and 14, a turn portion 33a1, turn portions 33b1 and 33b2, and output lines 3111 and 3112 are indicated.
[0040]
As shown in FIGS. 13 and 14, a skewed portion 33a11 connected to the turn portion 33a1 of the same-layer crossover portion, and a skewed portion 33b12 connected to the turn portion 33b1 of the intermediate connection crossover portion located radially outside thereof. Have the same inclination direction. The skew portion 33a11 and the skew portion 33b12 shown in FIGS. 13 and 14 are substantially parallel. In other ranges, two radially adjacent inclined portions have opposite inclination directions and intersect with each other. As shown in FIGS. 13 and 14, the intermediate connection bridging part connects the second layer and the third layer, so that the first bridging part 33a1 of the same layer and the last regular bridging part 33c1 are connected. A gap is formed between them. In FIG. 13, a triangular gap extending outward in the axial direction is formed between the same-layer transition portion 33a1 and the transition portion 33c1. This gap is located on the axial extension of the first layer.
[0041]
As shown in FIG. 7, in the second coil end portion 31b, the crossover portions are regularly arranged in an inner and outer doubly over the entire annular shape. As shown in FIG. 7, the second coil end portion 31b is provided with a crossover turn portion 33d for connecting different layers in the spaced slots in series. The first layer and the second layer are connected by a turn part 33d1, and the third layer and the fourth layer are connected by a turn part 33d2.
[0042]
The stator winding 31 described above includes a plurality of phase windings. In the embodiment, it is a six-phase winding. Each phase winding is a continuous wire having a length that reciprocates the stator core 32 four times in the circumferential direction. Each phase winding is arranged by arranging two arms of an electric conductor bent in a substantially U-shape around the stator core 32 while meandering in a wave-like manner in the circumferential direction. It is formed as a four-turn winding. The plurality of phase windings are connected to form a multi-phase winding. In embodiments, the plurality of phase windings form a plurality of multi-phase windings. In this embodiment, as shown in FIG. 8, they are connected as two star-connected three-phase windings. These two three-phase windings are shifted from each other by 30 degrees in electrical angle. One three-phase winding has neutral point connection terminals X1, Y1, Z1 and three output terminals X2, Y2, Z2. The other three-phase winding has neutral point connection terminals U1, V1, W1 and three output terminals U2, V2, W2. The output terminals X2, Y2, Z2, U2, V2, W2 are connected to the rectifier circuit 5.
[0043]
In this embodiment, the number of magnetic poles of the NS poles of the rotor is eight each, for a total of 16 poles. As shown in FIG. 8, the first three-phase winding constituting the stator winding 31 has an X phase, and a Y phase and a Z phase whose electric angles are different by 120 degrees. The second three-phase winding has a U-phase, a V-phase, and a W-phase at a position shifted by an electrical angle of 30 degrees from the first three-phase winding. Further, the number of slots of the stator core 32 is 96, and the slot interval corresponding to the magnetic pole pitch of the NS poles of the rotor adjacent in the circumferential direction is 6 slot pitch (6SLOTS).
[0044]
FIG. 9 shows the arrangement of the housing portion of the stator winding 31 in the two slots and the arrangement of the crossover portion connecting them. The position in the radial direction of the crossover portion is shown in the order of a one-dot chain line, a broken line, a solid line, and a two-dot chain line from the radial inside. As shown in FIG. 10, the turn portion 33a1 of the transition portion of the same layer is formed to be substantially annular in the radial direction. Accordingly, when viewed along the circumferential direction, the turn portion 33a1 has a shape that can be called a circle or a P-shape. As a result, as shown in FIG. 13, a plurality of same-layer connection bridging portions can be arranged without interfering with each other. As shown in FIG. 11, the output lines 311 are arranged in the same layer of adjacent slots. In this embodiment, the output line 311 is arranged on the fourth layer.
[0045]
The stator 2 of the vehicle alternator 1 described above is manufactured by the following steps. In this embodiment, the processing of the stator windings for six phases proceeds simultaneously, but in the following description, the description will focus on one phase. In an actual manufacturing method, electrical conductors for six phases are arranged and processed at the same time.
[0046]
The stator winding 31 is manufactured through the steps shown in FIGS. 2, 3, and 4. First, as shown in FIG. 2, the electric conductor 30 having a length corresponding to one phase is bent into a substantially U-shape. The electric conductor 30 is a continuous line. The U-shaped bent portion formed at this time forms the turn portion 33a1 of the same-layer connection transition portion. The electrical conductor 30 has a rectangular cross section. Both ends of the electric conductor 30 correspond to the output lines 3111 and 3112.
[0047]
Next, the electric conductor 30 is formed into a wave coil using the jig 300. In this winding step, the two arms of the U-shaped conductor 30 are spirally wound around the jig 300. As shown in FIGS. 3 and 4, the winding process proceeds while sequentially forming the turn portions. When a strip-shaped winding having a length surrounding the stator core 32 is formed by repeating the steps of FIGS. 3 and 4, an intermediate connection bridging portion is formed. The intermediate connection bridging portion is formed by deforming the two arms of the U-shaped conductor 30 into a wave shape so as to advance one pitch on the same side surface of the jig 300 without winding the arm around the jig 300. After forming the intermediate connection bridging portion, the steps shown in FIGS. 3 and 4 are repeated again for one rotation of the stator core 32. As a result, the substantially U-shaped conductor 30 is twisted like a coil spring. The winding formed by the steps of FIGS. 2 to 4 has a shape that can also be called a wave-shaped winding. 3 and 4 has a length corresponding to two turns of the stator core 32 in the circumferential direction.
[0048]
Next, the wave belt-shaped winding is wound twice in a cylindrical shape so as to make two turns around the stator core 32. As a result, the same-layer connection turn portion 33a1 and the output lines 3111 and 3112 are arranged so as to overlap in the radial direction. The winding wound in a cylindrical shape is mounted in the slot from the radial inside of the stator core 32 and is fixed to the stator core 32. At this time, it is also possible to deform the tip end of the teeth provided between the slots of the stator core 32 to narrow the opening of the slot.
[0049]
As shown in FIG. 12, the winding jig 300 can be configured by three flat jigs 301, 302, and 303. Each of the flat jigs 301, 302, and 303 has a rectangular cross section, and has a predetermined length along the winding direction of the corrugated winding. The jigs 301, 302, and 303 are arranged in parallel with each other so that their longitudinal directions coincide with the winding direction. Gaps capable of accommodating the electric conductor 30 are provided between the jig 302 and the jig 301 and between the jig 302 and the jig 303, and these gaps correspond to the second layer and the third layer. Can be FIG. 12 shows a winding process corresponding to FIG. The winding having the turn 33c1 is formed on the jig 301 with the turn 33a1 of the same-layer connection transition portion disposed at the end. Next, the turn portions 33b1 and 33b2 of the intermediate connection transition portion are formed on the jig 302. The winding direction in which the U-shaped conductor 30 is wound around the jig 301 is opposite to the winding direction in which the U-shaped conductor 30 is wound around the jig 302 when forming the turn portions 33b1 and 33b2 of the intermediate connecting portion. Thereafter, the U-shaped conductor 30 is wound around the jig 303, and a winding having the turn portion 33c2 is formed on the jig 303. The winding direction of winding the U-shaped conductor 30 around the jig 302 and the winding direction of winding the U-shaped conductor 30 around the jig 303 when forming the turn portions 33b1 and 33b2 of the intermediate connection bridging portion are opposite to each other. Thus, in the winding step, the direction in which the electric conductor is wound around the jig is reversed before and after the jig to form a turn portion of the intermediate connection transition portion. When the jig of FIG. 12 is used as described above, the same-layer processing step for forming the turn portion 33b described with reference to FIGS. . According to this configuration, the number of conductors entering the slot can be changed by adjusting the length of the substantially U-shaped conductor. In the case of a multi-phase winding, it can be formed by twisting all phases simultaneously into a coil spring shape.
[0050]
[Operation and effect of the embodiment]
With the configuration described above, when the field winding 8 is energized when the rotor 2 rotates, a rotating magnetic field is formed, which links the stator 3. As a result, an alternating current is generated in the stator winding 31. The alternating current is taken out from the output line 311 of the stator winding 31 and rectified by the rectifier 5. As a result, DC is extracted from the output terminal 6. The output terminal 6 is connected to a vehicle-mounted electric load, a battery, and the like, and DC power is supplied to these devices.
[0051]
In the embodiment, the number of conductor joints is only the interphase connection of the multi-phase winding, and the cost for welding can be reduced. Further, since there is no welded portion other than the interphase connection of the multi-phase winding, the height of the coil end is reduced, and the electric resistance of the coil end can be reduced, thereby contributing to high output and downsizing. In addition, since the output lines are adjacent to each other and the connection between the phases of the multi-phase windings is easy, the man-hour can be reduced, and the vibration resistance can be improved since there is no need to lay the lead lines. . The cooling air flows toward the output line, and the cooling performance of the output line connected to the rectifying element can be improved, so that the heat influence on the element can be reduced and the heat resistance can be improved. By changing the length of the substantially U-shaped conductor of each phase, the length of the winding can be changed, and the number of conductors in the slot can be easily changed. Reduction can be realized. For example, by forming and arranging the stator core three times, six conductors can be arranged per slot. By forming and arranging the stator core four times, one conductor can be arranged per slot. Eight conductors can be arranged.
[0052]
(Second embodiment)
In the first embodiment, the number of slots is 96, but the number of slots may be 48 as shown in FIG. In this case, the slot interval corresponding to the magnetic pole pitch of the NS pole of the rotor adjacent in the circumferential direction is 3 slot pitch (3SLOTS). With this configuration, the same effect as in the first embodiment can be obtained.
[0053]
[Other embodiments]
Further, the number of magnetic poles of the NS pole and the number of adjacent slots connected in series can be appropriately selected according to required output characteristics and the like. Also, the winding connection may be a Ｙ connection instead of a Y connection, or a composite connection of both.
[0054]
In addition, it is also possible to arrange the same layer connection transition part in the fourth layer and arrange the output line in the first layer.
[Brief description of the drawings]
FIG. 1 is a partial cross-sectional view illustrating an overall configuration of a vehicle alternator according to a first embodiment of the present invention.
FIG. 2 is a plan view of a substantially U-shaped conductor for one phase of the stator winding according to the first embodiment of the present invention.
FIG. 3 is a perspective view showing an intermediate stage of torsion forming of a substantially U-shaped conductor for one phase of the stator winding according to the first embodiment of the present invention.
FIG. 4 is a perspective view showing an intermediate stage of torsion forming of a substantially U-shaped conductor for one phase of the stator winding according to the first embodiment of the present invention.
FIG. 5 is a plan view of the stator according to the first embodiment of the present invention as viewed in the axial direction.
FIG. 6 is a wiring diagram illustrating an arrangement of stator windings for one phase according to the first embodiment of the present invention.
FIG. 7 is a plan view of the stator according to the first embodiment of the present invention as viewed from the opposite side of FIG. 5 in the axial direction.
FIG. 8 is a circuit diagram showing two windings of the stator according to the first embodiment of the present invention.
FIG. 9 is a partial sectional view showing an arrangement of a stator winding according to the first embodiment of the present invention.
FIG. 10 is a perspective view showing a crossover portion between the same layers according to the first embodiment of the present invention.
FIG. 11 is a plan view showing an arrangement of output lines of a stator winding according to the first embodiment of the present invention.
FIG. 12 is a perspective view showing a winding jig for a stator winding according to the first embodiment of the present invention.
FIG. 13 is a partial perspective view showing a stator winding according to the first embodiment of the present invention.
FIG. 14 is a partial wiring diagram showing a stator winding according to the first embodiment of the present invention, showing one phase of the winding shown in FIG. 13;
FIG. 15 is a partial cross-sectional view showing an arrangement of a stator winding according to a second embodiment of the present invention.
FIG. 16 is a wiring diagram showing a conventional arrangement of stator windings for one phase.
[Explanation of symbols]
1 AC generator for vehicles
2 rotor
3 Stator
31 Stator winding
31a First coil end
31b Second coil end
33a Turn part of transition
33b Turn part of transition part
33c Turn part of transition
33d Crossover turn
311 Stator winding output line
32 Stator core

Claims (17)

A field rotor having a plurality of claw-shaped magnetic poles alternately forming NS poles along a rotational circumferential direction, a stator core arranged opposite to the rotor, and a plurality of slots formed in the stator core A stator having a multi-phase stator winding equipped with a plurality of layers at a radial depth of the vehicle AC generator,
Each phase winding of the multi-phase stator winding is formed of a continuous line, and each phase winding connects the same layer in a slot spaced apart corresponding to the magnetic pole pitch of the NS pole of the rotor in series. One of the layers has a crossover portion, and the other has a crossover portion for connecting different layers in series in slots spaced apart in correspondence with the magnetic pole pitch of the NS pole of the rotor, and has both ends in the axial direction of the stator core. An alternator for a vehicle, wherein a coil end is formed in the alternator. The vehicle alternator according to claim 1,
The crossover portion is composed of a skew portion and a turn portion. Except for the crossover portion of the same layer, the skew portions of the adjacent layers are opposite in the skew direction to each other, and the crossover portions of the same layer are radially opposite to each other. The vehicle according to claim 1, wherein a turn portion of an adjacent crossing portion connects the inclined portions in series at a position where a radial depth of the slot differs by one layer from a turn portion of another crossing portion. For alternator. The vehicle alternator according to claim 1,
An AC generator for vehicles, wherein a transition portion radially adjacent to a transition portion between the same layers serves as an output line. The vehicle alternator according to any one of claims 1 to 3,
An alternator for a vehicle, wherein a turn portion of the crossover portion has a substantially annular shape in a radial direction. The alternator for a vehicle according to any one of claims 1 to 4,
An AC generator for a vehicle, wherein output lines of each phase of the stator winding are drawn from the same layer of an adjacent slot. The vehicle alternator according to any one of claims 1 to 5,
An alternator for a vehicle, wherein a substantially U-shaped conductor has a turn over at a transition portion between the same layers, is twisted like a coil spring, and is arranged in a slot separated by a predetermined magnetic pole pitch. The vehicle alternator according to any one of claims 1 to 6,
The slot has a first slot group separated according to the magnetic pole pitch of the NS pole and a second slot group adjacent to the first slot group and shifted by an electrical angle of 30 degrees. The first polyphase winding is disposed, the second polyphase winding is disposed in the second slot group, and the output is taken out from the first polyphase winding and the second polyphase winding respectively. Characteristic alternator for vehicles. A rotor having a plurality of claw-shaped magnetic poles,
A stator core having a plurality of slots and a stator winding forming a multi-phase winding including a plurality of phase windings supported in a plurality of layers in the slots,
Each of the phase windings is constituted by a continuous wire,
A coil end is formed at both ends of the stator core, and a crossover portion that connects layers accommodated in different slots separated by a magnetic pole pitch is provided.
The vehicle according to claim 1, wherein the transition portion includes a single-layer connection transition portion that connects the same layer accommodated in the different slots, and another transition portion that connects different layers accommodated in the different slots. Alternator. The vehicle alternator according to claim 8,
Each of the transition portions has a pair of skewing portions extending inclining in opposite directions to each other, and a turn portion connecting the skewing portions,
The intermediate connection bridging part radially adjacent to the same-layer connection bridging part connects a pair of layers different by one layer from a pair of layers connected by the bridging part other than the same-layer connection bridging part. Vehicle alternator. The vehicle alternator according to claim 9,
The same-layer connection transition portion connects between first layers located at one radial end of the slot,
The intermediate connection bridging part radially adjacent to the same-layer connection bridging part connects between a second layer and a third layer,
The other crossing portion has a first group of crossing portions connecting a first layer and a second layer, and a second group of crossing portions connecting a third layer and a fourth layer. For alternator. The vehicle alternator according to claim 9 or 10,
The alternating current for vehicles, wherein the skewed portion of the same-layer connection transition portion and the skewed portion of the intermediate connection transition portion radially adjacent to the same-layer connection transition portion are arranged in parallel. Generator. The vehicular alternator according to any one of claims 9 to 11,
An alternator for a vehicle, wherein the same-layer connection crossover portion and the other crossover portion form a gap between them extending toward an axial end. The vehicle alternator according to any one of claims 8 to 12,
An alternator for a vehicle, wherein each of the phase windings has an output line arranged radially inside or outside the same-layer connection transition portion. The alternator for a vehicle according to any one of claims 8 to 13,
The alternator for a vehicle, wherein the crossover portion is formed in a substantially circular shape. The vehicle alternator according to any one of claims 8 to 14,
An alternator for a vehicle, wherein each of the phase windings has an output line drawn from the same layer of slots adjacent to each other. The alternator for a vehicle according to any one of claims 8 to 15,
The vehicle wherein the continuous line has a substantially U-shaped line having a turn portion for the same-layer connection transition portion, and the continuous line is formed as a laminated wave winding. For alternator. The alternator for a vehicle according to any one of claims 8 to 16,
The slot is
A plurality of slots forming a first group;
A plurality of slots forming a second group that is shifted by 30 degrees in electrical angle from the first group;
The stator winding,
A first polyphase winding housed in said first group of slots;
A second polyphase winding housed in the second group of slots.

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