JP2005176423A - Alternator for vehicle, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an alternator for a vehicle, where stator winding and a rectifier can be joined surely with each other and the cost can be reduced, and its manufacturing method. <P>SOLUTION: The alternator for a vehicle is equipped with a rotor to be rotated, a stator where stator winding is wound, and the above rectifier to which a lead wire 25 led out of the stator winding is connected via a joint 78 and which converts the AC voltage induced in the stator winding into DC voltage. The rectifier has a joining terminal 76 to which the lead wire 25 is connected. The joint 78 is made by covering the periphery of the joining terminal 76 and the lead wire 25 with a metallic plate-shaped member 77. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a vehicle AC generator mounted on a passenger car, a truck, and the like, and a method for manufacturing the same.

  The electric power generated in the stator winding in the vehicle AC generator is rectified by a rectifier connected to the stator winding. For this reason, it is necessary to join the end part of the lead wire of the stator winding to a connection terminal provided in the rectifier by some method.

For example, a technique is known in which a cross-sectional shape of a connection terminal provided on a terminal block of a rectifier and a cross-sectional shape of a lead wire drawn out from a stator winding are matched to perform bonding between them (for example, (See Patent Document 1). When the cross-sectional shape of the leader line is a rectangle or a circle, a connection terminal having a shape corresponding to the cross-sectional shape is used.
JP 2000-350426 A (page 2-3, FIG. 1-9)

  By the way, in the conventional system disclosed in Patent Document 1, since it is necessary to match the shape of the connection terminal of the rectifier with the cross-sectional shape of the lead wire, it is connected when the cross-sectional shape and wire diameter of the lead wire of the stator winding are different. It is necessary to prepare multiple types of rectifiers with different terminal shapes, or when the cross-sectional shape or wire diameter of the lead wire of the stator winding is changed, the rectifier terminal shape must be changed each time. There was a problem that the number of points increased and the cost increased. Further, if the shape of the conductive wire forming the stator winding or the winding specification is changed for some reason, the sectional shape of the lead wire of the stator winding may not match the shape of the rectifier connection terminal. For example, when producing a small amount of an automotive alternator overseas, the winding specifications of the stator winding and the type of conductor used may be changed due to simplification of the production process or change of production equipment. It is conceivable to combine such a stator winding with an unchanged rectifier. In such a case, there is a problem that the joining state between the lead wire and the connection terminal becomes unstable, which may lead to the occurrence of joint failure.

  The present invention was created in view of the above points, and an object of the present invention is to make it possible to reliably join the stator winding and the rectifier, and to reduce the cost. It is providing the alternating current generator for a motor, and its manufacturing method.

  In order to solve the above-described problems, an automotive alternator according to the present invention includes a rotor that is rotationally driven, a stator around which a stator winding is wound, and a lead wire that is drawn from the stator winding. And a rectifier that converts an AC voltage induced in the stator winding to a DC voltage, and the rectifier has a connection terminal to which a leader line is connected. It is formed by covering the periphery of the terminal and the lead wire with a metal plate member. With the connection terminal of the rectifier and the lead wire of the stator winding connected, the periphery of them is covered and fixed with a metal plate member, so that the connection between the stator winding and the rectifier is ensured. It can be carried out. In addition, even when the shape of the connection terminal and the cross-sectional shape of the leader line do not match, an unstable contact state between them can be prevented, so that the cross-sectional shape of the lead line of the stator winding or Even if the wire diameters are different, there is no need to change the shape of the connection terminal together, and the number of parts can be reduced by sharing the connection terminal used for the rectifier or the entire rectifier, and the associated cost. Reduction is possible.

  Moreover, it is desirable that the connection terminal, the lead wire, and the plate member described above are soldered to each other. Thereby, joining between a stator coil | winding and a rectifier can be performed more reliably.

  Moreover, it is desirable that the plate-like member described above has a through hole. As a result, it becomes possible to pour solder through the through hole, and the gaps between the connection terminal, the lead wire, and the plate-like member can be reliably filled with solder, and the occurrence of poor bonding can be further reduced. .

  Moreover, as for the plate-shaped member mentioned above, it is desirable for the surface facing a leader line to have a shape along the surface shape of a leader line. Thereby, the contact resistance between a leader line and a plate-shaped member can be reduced, and a more favorable joining state can be realized in connection.

  Moreover, it is desirable that the connection terminal described above has a flat plate shape or an L-shape. Thereby, it becomes possible to combine with the leader line which has various cross-sectional shapes. In particular, by making the connection terminal L-shaped, the strength against bending and vibration can be increased, so that problems such as disconnection can be prevented.

  In addition, the rectifier described above has a resin terminal block in which a wiring portion connected to the connection terminal is inserted, and the height of the connection terminal protruding from the terminal block and the width of the plate-like member may substantially coincide. desirable. Thereby, when forming a connection part using a plate-shaped member, the position alignment of a plate-shaped member becomes easy, and the simplification of a process and the dispersion | variation reduction of an attachment position are attained.

  Moreover, it is desirable that the above-described lead line is constituted by a plurality of conductors arranged in parallel. When covering the leader line with the plate-like member, it is possible to bundle a plurality of conductors at the same time, and the process can be simplified as compared with the case where they are bundled in the previous process.

  In addition, the method for manufacturing an AC generator for a vehicle according to the present invention includes a first step of matching the position of the lead wire drawn from the stator winding with the position of the connection terminal of the rectifier, and the periphery of the lead wire and the connection terminal. And a third step of deforming the plate member in accordance with the shape of the lead wire and the connection terminal. After aligning the connection terminal of the rectifier and the lead wire of the stator winding, it is possible to reliably perform the joining between the stator winding and the rectifier by simply covering and fixing them with a plate-like member. it can. In addition, even when the shape of the connection terminal and the cross-sectional shape of the leader line do not match, an unstable contact state between them can be prevented, so that the cross-sectional shape of the lead line of the stator winding or Even if the wire diameters are different, there is no need to change the shape of the connection terminal together, and the number of parts can be reduced by sharing the connection terminal used for the rectifier or the entire rectifier, and the associated cost. Reduction is possible.

  Moreover, it is desirable to further include a fourth step of soldering the connection terminal, the lead wire, and the plate-like member after the third step described above. Thereby, joining between a stator coil | winding and a rectifier can be performed more reliably.

  Hereinafter, an AC generator for a vehicle according to an embodiment to which the present invention is applied will be described in detail with reference to the drawings.

  FIG. 1 is a diagram showing an overall configuration of an automotive alternator according to an embodiment. A vehicular AC generator 1 shown in FIG. 1 includes a stator 2, a rotor 3, a front frame 4, a rear frame 5, a brush device 6, a rectifier 7, a rear cover 9, and the like.

  The stator 2 includes a stator core 22, a three-phase stator winding 23 wound around the stator core 22, and an insulator 24 that electrically insulates between the stator core 22 and the stator winding 23. It has. FIG. 2 is a view showing an appearance and a partial cross-sectional structure of the stator 2. As shown in FIG. 2, a lead wire 25 used for connection to the rectifier 7 is drawn from a stator winding 23 wound around the stator core 22. In the present embodiment, the three phase windings constituting the stator winding 23 are formed by winding two conductive wires with an insulating coating having a circular cross section in parallel, and each lead wire 25 is a circular shape in parallel. It is formed by two conductors in cross section. In addition, the stator winding 23 has three phase windings Y-connected. In addition to the three lead wires 25 being drawn from the end portions of the respective phase windings, the lead wires 25 are also drawn from the neutral point. Has been pulled out.

  The rotor 3 has a structure in which a field winding 31 in which an insulated copper wire is wound in a cylindrical and concentric manner is sandwiched from both sides through a rotating shaft 33 by a pole core 32 having six claws. have. A cooling fan 35 for discharging the cooling air sucked from the front side in the axial direction and the radial direction is attached to the end face of the pole core 32 on the front side by welding or the like. Similarly, a cooling fan 36 for discharging the cooling air sucked from the rear side in the radial direction is attached to the end surface of the pole core 32 on the rear side by welding or the like. In addition, two slip rings 37 and 38 that are electrically connected to both ends of the field winding 31 are formed in the vicinity of the rear side end portion of the rotating shaft 33, and the slip rings 37 and 38 are interposed through these slip rings 37 and 38. Then, power is supplied from the brush device 6 to the field winding 31.

  The front frame 4 and the rear frame 5 accommodate the stator 2 and the rotor 3. The rotor 3 is supported so as to be rotatable about a rotation shaft 33, and the stator 2 disposed via a predetermined gap is fixed to the outer peripheral side of the pole core 32 of the rotor 3. The front frame 4 is formed with a housing portion 44 for housing the bearing 43. Similarly, the rear frame 5 is formed with an accommodating portion 54 for accommodating the bearing 53.

  Further, the front frame 4 has a cooling air exhaust window 41 at a portion facing the stator winding 23 protruding from the axial end surface of the stator core 22 to the front side, and an intake window 42 at the axial end surface. doing. Similarly, the rear frame 5 has an exhaust window 51 for cooling air at a portion facing the stator winding 23 protruding from the axial end surface of the stator core 22 to the rear side, and an intake window 52 at the axial end surface. Have.

  The brush device 6 is for flowing an exciting current from the rectifier 7 to the field winding 31 of the rotor 3, and is a brush that presses each of the slip rings 37 and 38 formed on the rotating shaft 33 of the rotor 3. 61, 62. The rectifier 7 is for rectifying a three-phase AC voltage that is an output voltage of the three-phase stator winding 23 to obtain a DC output voltage. The rear cover 9 covers and protects electrical components such as the brush device 6, the rectifier 7, and the IC regulator 8 that are attached to the outside of the rear frame 5.

  Next, details of the rectifier 7 will be described. FIG. 3 is a bottom view of the rectifier 7. As shown in FIGS. 1 and 3, the rectifier 7 includes a negative-side radiating fin 72 in which a negative-side rectifying element 71 is joined by soldering or press-fitting, and a positive-side rectifying element 73 by soldering or press-fitting. The positive-side radiating fins 74 are joined, and the negative-side radiating fins 72 and the positive-side radiating fins 74 are fixed and resin-made terminal blocks 75 that perform internal wiring are configured. The terminal block 75 has a connection terminal 76 formed by insert molding. The rectifying element 71 joined to the negative-side radiating fin 72 and the rectifying element 73 joined to the positive-side radiating fin 74 are inserted into the terminal block 75 by the connection terminal 76 and passed through a wiring portion (not shown). A three-phase full-wave rectifier circuit is configured by connecting them to each other.

  FIG. 4 is a partial side view of the rectifier 7 and shows the peripheral structure of the connection terminal 76 exposed from the terminal block 75. FIG. 5 is a plan view of the connection terminal 76 shown in FIG. These drawings show a partial structure of the rectifier 7 alone, and the state in which the lead wire 25 drawn from the stator winding 23 is connected to the rectifier 7 is shown in FIGS. 6 and 7, respectively. It is shown.

  As shown in these drawings, the connection terminal 76 has an L-shaped cross section at a portion protruding from the terminal block 75. The lead wire 25 drawn from the stator winding 23 is arranged so that the two conductors 25A and 25B are in contact with one surface of the L-shape. In the present embodiment, the connection portion 76 is covered with a plate member 77 made of metal (for example, a bell-plated steel plate suitable for soldering) in a state where the lead wire 25 is in contact with the connection terminal 76. 78 is formed. Further, as shown in FIG. 6, the width of the plate-like member 77 (length in the vertical direction in FIG. 6) is set so as to substantially coincide with the height of the connection terminal 76 protruding from the terminal block 75. When the connection portion 78 is formed using the member 77, the end position of the plate member 77 and the end position of the connection terminal 76 are substantially matched.

  FIG. 8 is a perspective view showing a state before the plate-like member 77 is assembled. As shown in FIG. 8, the plate-like member 77 has a U-shaped cross section before assembly. The plate-like member 77 has one surface 77A out of the two opposing surfaces 77A and 77B, and one surface of the L-shaped connecting terminal 76 is a surface 77C other than the two opposing surfaces 77A and 77B. Are assembled so that the other surfaces of the connection terminals 76 are almost in contact with each other. Thereafter, the other surface 77B of the two opposing surfaces 77A and 77B of the plate-like member 77 (the surface on the side where the connection terminal 76 is not in contact) is pressurized from the outside, and the two wires constituting the lead wire 25 are formed. A connecting portion 78 is formed by deforming the conductors 25A and 25B so as to cover them according to the shape of the conductors 25A and 25B.

The process of joining the lead wire 25 and the connection terminal 76 in the connection part 78 is as follows.
(1) The position of the lead wire 25 drawn from the stator winding 23 and the position of the connection terminal 76 of the rectifier 7 are matched (first step).
(2) The entire leader line 25 and connection terminal 76 arranged at the same position are surrounded by a plate-shaped member 77 having a U-shaped cross section (second step).
(3) The plate-like member 77 is deformed in accordance with the shapes of the lead wire 25 and the connection terminal 76 (third step).
(4) The connection terminal 76, the lead wire 25, and the plate-like member 77 are soldered (fourth step).

  As described above, in the vehicle alternator 1 according to the present embodiment, the connection terminal 76 of the rectifier 7 and the lead wire 25 of the stator winding 23 are connected to each other with the metal plate member 77. By covering and fixing, the joint between the stator winding 23 and the rectifier 7 can be reliably performed. Even if the shape of the connection terminal 76 does not match the cross-sectional shape of the lead wire 25 (in this embodiment, the lead wire 25 has a circular cross section and the connection terminal 76 is L-shaped) Since the unstable contact state between the lead wires 25 can be prevented, the shape of the connection terminal 76 must be changed in accordance with the cross-sectional shape and wire diameter of the lead wire 25 of the stator winding 23. Therefore, the number of parts can be reduced by sharing the connection terminal 76 used in the rectifier 7 or the entire rectifier 7, and the cost can be reduced accordingly. In particular, since the connection terminal 76, the lead wire 25, and the plate-like member 77 are soldered to each other, the joining between the stator winding 23 and the rectifier 7 can be performed more reliably.

  Further, since the shaped plate-like member 77 has a surface that faces the leader line 25 along the surface shape of the leader line 25, the contact between the leader line 25 and the plate-like member 77. The resistance can be reduced, and an even better bonding state can be realized in connection.

  Further, the connection terminal 76 has an L-shape and can be combined with the leader line 25 having a circular cross section and other leader lines having various cross-sectional shapes. In particular, by making the connection terminal 76 L-shaped, the strength against bending and vibration can be increased, so that problems such as disconnection can be prevented.

  The rectifier 7 includes a resin terminal block 75 in which a wiring portion connected to the connection terminal is inserted, and the height of the connection terminal 76 protruding from the terminal block 75 and the width of the plate-like member 77 are substantially equal. I'm doing it. Thereby, when forming the connection part 78 using the plate-shaped member 77, the position alignment of the plate-shaped member 77 becomes easy, and it becomes possible to simplify a process and reduce the dispersion | variation in an attachment position.

  The lead wire 25 is composed of a plurality of (in the embodiment, two) conductors 25A and 25B arranged in parallel. When the lead wire 25 is covered with the plate member 77, the two conductors 25A are formed. , 25B can be bound at the same time, so that the process can be simplified as compared with the case of binding in the previous process.

  In addition, this invention is not limited to the said embodiment, A various deformation | transformation implementation is possible within the range of the summary of this invention. In the above-described embodiment, the case where the lead wire 25 including the two conductors 25A and 25B having a circular cross-sectional shape and the connection terminal 76 are connected at the connection portion 78 has been described. However, the cross-sectional shape of the lead wire 25 is rectangular or other. Even if it is the shape of this invention, this invention is applicable. For example, as shown in FIG. 9, even when the lead wire 124 having a rectangular cross-sectional shape is joined to the connection terminal 76, a reliable joining state can be realized by covering the periphery with a plate-like member 77. . In the example shown in FIG. 9, the lead line 124 made of one conductor is used. However, a lead line made of two (or more) conductors having a rectangular cross section may be used. Or even if it is a case where the leader line which consists of a conductor of a circular section is used like this embodiment, you may make it comprise a leader line with one conductor.

  Further, in the above-described embodiment, soldering is performed after the plate-shaped member 77 is deformed. However, when the contact resistance between the plate-shaped member 77 and the connection terminal 76 and the lead wire 25 is small or the connection portion 78 is The soldering may be omitted when the current flowing through the connector is small. Alternatively, as shown in FIG. 10, a plate-like member 177 having through holes 178 formed at one side or a plurality of points (two in the example of FIG. 10) on the side is used, and solder is passed through the through holes 178 in the soldering process. May be poured. As a result, it becomes possible to make it easy for solder to flow into the entire inner region covered with the plate-like member 177, and the gaps among the connection terminals 76, the lead wires 25, and the plate-like member 177 are reliably filled with solder. It is possible to further reduce the occurrence of defective bonding.

  In the above-described embodiment, the connection terminal 76 having an L-shaped cross-section and the plate-shaped member 77 having a U-shaped cross-section before assembly are combined. These connection terminals may be used. Moreover, you may make it deform | transform so that the cross section before an assembly | attachment may cover the whole of the connection terminal 76 and the leader line 25 at the time of an assembly | attachment using a plate-shaped or L-shaped plate-shaped member. Or you may make it the edge parts of the plate-shaped member 77 mutually overlap after a deformation | transformation.

  In the above-described embodiment, the height of the portion where the connection terminal 76 protrudes from the terminal block 75 and the length of the plate-like member 77 are matched, but the plate-like member 77 is longer or shorter. It may be. In addition, the connecting member 78 is formed by assembling the plate member 77 so that the end of the plate member 77 on the terminal block 75 side contacts the terminal block 75, but the plate member 77 is separated from the end surface of the terminal block 75. May be assembled.

  In the embodiment described above, soldering is performed after the plate-like member 77 is deformed, but welding may be performed instead of soldering.

It is a figure showing the whole composition of the alternator for vehicles of one embodiment. It is a figure which shows the external appearance and partial cross-section of a stator. It is a bottom view of a rectifier. It is a partial side view of a rectifier. FIG. 5 is a plan view of the connection terminal shown in FIG. 4. It is a figure which shows the state by which the leader line and the rectifier were connected. It is a figure which shows the state by which the leader line and the rectifier were connected. It is a perspective view which shows the state before the assembly | attachment of a plate-shaped member. It is a figure which shows the modification using the leader line which has a rectangular cross-sectional shape. It is a perspective view which shows the plate-shaped member which has a through-hole.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Vehicle alternator 2 Stator 3 Rotor 4 Front frame 5 Rear frame 6 Brush device 7 Rectifier 9 Rear cover 22 Stator iron core 23 Stator winding 25 Leader wires 71 and 73 Rectifier element 72 Negative electrode side radiation fin 74 Positive electrode side Radiation fin 75 Terminal block 76 Connection terminal 77 Plate member 78 Connection part

Claims (9)

A rotor that is driven to rotate, a stator on which a stator winding is wound, and a lead wire drawn out from the stator winding are connected to each other through a connecting portion and are induced in the stator winding. A rectifier that converts AC voltage to DC voltage,
The rectifier has a connection terminal to which the lead wire is connected,
The connection portion is formed by covering the periphery of the connection terminal and the lead wire with a metal plate member. In claim 1,
The vehicular AC generator, wherein the connection terminal, the lead wire, and the plate member are soldered to each other. In claim 2,
A vehicular AC generator, wherein the plate-like member is formed with a through hole. In any one of Claims 1-3,
The plate-like member has a shape in which a surface facing the leader line has a shape along a surface shape of the leader line. In any one of Claims 1-4,
The AC generator for vehicles, wherein the connection terminal has a flat plate shape or an L-shape. In any one of Claims 1-5,
The rectifier has a resin terminal block in which a wiring portion connected to the connection terminal is inserted,
The vehicle alternator according to claim 1, wherein a height of the connection terminal projecting from the terminal block and a width of the plate-like member substantially coincide with each other. In any one of Claims 1-6,
The lead wire is constituted by a plurality of conductors arranged in parallel, and the AC generator for vehicles. A first step of matching the position of the lead wire drawn from the stator winding with the position of the connection terminal of the rectifier;
A second step of surrounding the lead wire and the connection terminal with a metal plate member;
A third step of deforming the plate-like member according to the shape of the lead wire and the connection terminal;
The manufacturing method of the alternating current generator for vehicles characterized by having. In claim 8,
The method for manufacturing an AC generator for vehicles, further comprising a fourth step of soldering the connection terminal, the lead wire, and the plate-like member after the third step.

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