JP2006158200A - Ac generator for vehicle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an AC generator for a vehicle with a neodymium magnet arranged between claw magnetic poles of a rotor. <P>SOLUTION: The AC generator for the vehicle includes the rotor having a pair of claw type magnetic pole parts which have a profile of a claw type in a peripheral part arranged and in which a field winding is wound around a core, a neodymium magnet arranged between the pair of the claw-type magnetic pole parts and magnetized in the direction in which the poles face each other, a stator having a stator winding arranged so that the inner peripheral surfaces may counter with the rotor and generating an ac voltage by the magnetization of the field winding, and a rectifying circuit for converting the generated ac voltage into a dc voltage. The inner peripheral surface of the stator core and the front surface of the rotor are arranged, separated by a spacing of 0.4-0.6 mm. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a vehicle alternator.

  A conventional vehicle alternator is described in Japanese Patent Application Laid-Open No. 62-217837.

  In this publication, as a cooling method for the rectifier, it is disclosed that one side of the rectifier is disposed so as to be in contact with the water channel.

  In addition, as a method for cooling the field winding, for a brushless structure in which the field winding does not rotate, the field winding is directly brought into contact with a good heat conductor to release heat to the water channel through the good heat conductor. Is disclosed.

JP 62-217837 A

  Since the prior art is configured to cool the rectifier from one side, it is difficult to cool the heat generated at the terminal for connecting the diode and the stator coil and the lead portion of the diode. Therefore, there is a problem that even if the diode itself can be cooled, the Joule heat generated at the connecting portions (terminal, lead) cannot be cooled.

  In addition, since the cooling cover and the rectifier that constitute the water channel are configured independently in the above-described prior art, there is a problem that heat resistance is large when heat is transmitted from the rectifier through the cooling cover, and cooling efficiency is poor. .

  An object of the present invention is to provide an automotive alternator in which neodymium magnets are arranged between claw magnetic poles.

  According to the vehicle alternator of the present invention, a pair of claw-shaped magnetic pole portions having a claw-shaped shape are disposed on the outer peripheral portion, and a rotor having a field winding wound around the center portion, and the pair of Neodymium magnets arranged between the claw-shaped magnetic poles and magnetized in the direction in which the same poles face each other, and arranged so that the inner peripheral surface faces the rotor, the AC voltage is generated by the magnetization of the field winding. A stator having a stator winding to be generated, and a rectifier circuit for converting the generated AC voltage into a DC voltage, and the inner peripheral surface of the stator core and the surface of the rotor are 0.4. It is characterized by being arranged with an interval of ˜0.6 mm.

  FIG. 1 is a longitudinal sectional view of an automotive alternator that constitutes an embodiment of the present invention.

  The vehicle alternator 1 includes two brackets, and the bracket includes a front bracket 103 and a non-pulley side rear bracket 104 disposed on the pulley 102 side.

  A shaft 101 is supported at the center of both brackets via a pulley-side bearing 100F and an anti-pulley-side bearing 100R, a pulley 102 is attached to one end of the shaft 101, and a slip ring is attached to the other end. 110 is attached.

  As described above, the pulley side bearing 100F is provided with the bearing retainer 120 on the front bracket 103 as a detent for the outer ring of the bearing.

  The pulley 102 is connected to a pulley disposed on the output shaft of the engine via a belt, and rotates in proportion to the rotational speed of the engine.

  A brush 111 is slidably attached to the slip ring 110, and power is supplied from the brush 111 to a field winding 107 described later via a field winding lead wire 107a.

  A rotor (rotor) is attached to the central portion of the shaft 101. A pair of claw-shaped magnetic pole portions 108 having a claw shape are arranged on the outer peripheral portion of the rotor core 300.

  A field winding 107 is wound around the center of the rotor, and the claw-shaped magnetic pole portion 108 is magnetized by passing a direct current from the slip ring 110 through the field winding 107.

  A permanent magnet 118 is disposed between the pair of claw-shaped magnetic pole portions 108, a good heat conductor 116 is disposed from the remaining space portion to the space portion of the field winding 107, and the claw-shaped magnetic pole portion 108 of the rotor. An anti-scattering cover 117 for preventing the good heat conductor 116 from jumping out is disposed on the outermost peripheral portion of the.

  A housing 115 containing a stator core 105 is disposed between the pulley-side front bracket 103 and the non-pulley-side rear bracket 104, and the inner peripheral surface of the stator core 105 is on the surface of the claw-shaped magnetic pole portion 108 of the rotor. The anti-scattering cover 117 is arranged at a slight distance (mechanical gap).

  This mechanical gap length is 0.4 to 0.6 mm. Teeth and slots are arranged in the stator core 105, and stator windings 106 are wound in three phases in slots corresponding to the recesses of the stator core 105, and claw-shaped magnetic pole portions 108 are driven by the engine. When rotated and magnetized, a three-phase induced voltage is generated in the stator winding 106.

The stator core 105 is fixed to the inside of the housing 115 by a flare, but the gap and the coil end of the stator winding 106 in the slot of the stator core 105 are filled with a good heat conductor 116, and as a result. The stator core 105, the stator winding 106, and the housing 115 are integrally molded with a good heat conductor 116 and are thermally connected. The good thermal conductor described here is, for example, a silicon rubber-based material having a thermal conductivity higher than 1.0 (W / mK), an epoxy resin having a high thermal conductivity, or the like.

  The housing 115 is formed with a water channel 114 through which cooling water flows. Further, a water channel 114 for cooling the diode is also formed on the side opposite to the pulley of the housing 115. A rear plate 112 is disposed to block the cooling water channel 114 of the diode, and a diode module is disposed on the rear plate 112.

  A sealing material (not shown) for preventing water leakage is arranged between the housing 115 and the rear plate 112. The rear plate 112 is fixed to the housing 115 with screws by a rear bracket 104 disposed on the outside thereof.

  Inside the non-pulley side rear bracket 104, a diode plus fin 109a is formed on a diode minus fin 109b which is a diode module constituting a rectifier circuit via an insulating material, and the diode minus fin 109b is directly connected to the diode minus fin 109b. It is fixed to a rear plate 112 for sealing the cooling water channel 114.

  Further, the IC regulator 113 for adjusting the generated voltage is arranged so that the cooling surface is in contact with the rear bracket 104.

  The positive fin 109a of the diode is connected to the positive electrode of the battery (not shown), and the negative fin 109b of the diode is at the same potential as the main body of the vehicle alternator 1, and is electrically connected to the negative terminal side of the battery (not shown). Connected.

  These diodes convert the three-phase AC voltage generated in the stator winding 106 into a DC voltage by full-wave rectification.

  The IC regulator 113 controls the field winding current so that the DC voltage rectified by the diode for charging the battery is maintained at a constant voltage of about 14.3V.

  In addition, the negative fin 109b of the diode, the positive fin 109a of the diode, and the terminal 121 for connecting the diode and the lead wire of the stator winding 106 are sealed by the good heat conductor 116, and the rear bracket 104 and the rear plate 112 are heated. Are connected to each other for good heat dissipation and have a waterproof effect.

  Of the casing members facing the surface 200 forming the axial end of the rotor core 300, the cooling promotion part 119F is disposed on the front bracket 103 and the cooling promotion part 119R is disposed on the opposite side of the housing 115 from the pulley. . The gap lengths g1 and g2 of the surface 200 that forms the axial end of the casing member and the rotor core 300 are about 0.3 mm to 1.0 mm.

In the vehicular AC generator 1 configured as described above, when the pulley 102 is rotated by driving the engine, the shaft 101 rotates together with the slip ring 110 and the rotor, and the DC current from the brush 111 is generated inside the rotor. The field winding 107 is energized, and the field winding 107 operates to form an N pole and an S pole on each magnetic pole of the claw-shaped magnetic pole portion 108.

  The magnetic flux generated by the field winding 107 forms a magnetic circuit in which the magnetic flux output from the claw portion of the N-pole claw-shaped magnetic pole portion passes through the stator core 105 and returns to the claw portion of the S-pole claw-shaped magnetic pole portion. When magnetic flux of this magnetic circuit crosses the stator winding 106, a three-phase induced voltage is generated in the stator winding 106.

  This three-phase induced voltage is full-wave rectified and converted into a DC voltage by the diode group arranged on the previous diode plus fin 109a and minus fin 109b. This is achieved by controlling the field winding current with the IC regulator 113 so that the rectified DC voltage becomes a constant voltage of about 14.3V.

  The permanent magnets arranged between the claw magnetic poles described above are magnetized in the direction in which the same poles face each other between the claw magnetic poles, and are for increasing the effective magnetic flux passing through the stator winding.

  In this embodiment, since water cooling is adopted as a cooling method, a cooling effect can be expected even when power is generated at a low speed. Therefore, a highly heat-resistant neodymium magnet is adopted between the claw magnetic poles.

  Next, cooling of heat generation due to copper loss generated in the stator winding 106 will be described.

As described above, the stator core 105 in which the stator winding 106 is disposed is fixed to the housing 115 by a flare so that heat can be easily transferred to the housing 115. Further, as described above, in order to improve heat dissipation of the stator winding 106, a heat dissipation path is formed with a resin having high thermal conductivity so that the stator winding 106 and the inner surface of the housing 115 are in thermal contact with each other. Provided.

A plurality of holes pass through the outer periphery of the housing 115 in the axial direction, and the water channel is sealed by the front bracket 103 and the rear plate 112 to form a water channel in a zigzag shape. The cooling water is configured to flow in a zigzag channel on the outer peripheral surface of the housing 115, and can be cooled from the outer peripheral surface of the stator core 105. Further, the heat generated by the copper loss of the field winding 107 generated inside the rotor is a cooling promotion portion that is in contact with the axial surface 200 of the rotor with a slight gap inside the front bracket 103 and the housing 115 on the side opposite to the pulley. 119 is a structure that can dissipate heat.

  In this way, by arranging the axial surface and the outer peripheral surface so as to be indirectly in contact with the water channel 114 through which the cooling water passes, the cooling of the entire rotor can be promoted.

  Although not shown, in the present invention, the even number of water channels arranged in the housing 115 is eight, and the water flow enters from the anti-pulley side and turns back at the front bracket 103, and flows to the anti-pulley side to the pulley side. It was made to come out from the non-pulley side after four reciprocations like folding.

  Thus, by setting the water channel to an even number, it is possible to provide water supply / drainage piping in the same direction, and the radiator hose 4 can be easily routed.

  In addition, the possibility of entanglement with the belt can be greatly reduced by arranging the hose joint for water supply / drainage on the side opposite to the pulley.

  In the above description, the IC regulator 113 is disposed on the rear bracket 104. However, the IC regulator 113 may be disposed so as to be in contact with the rear plate 112 that is in direct contact with the water channel 114, so that the water temperature detection accuracy can be improved.

  Next, cooling of the diode as a rectifier will be described in detail with reference to FIG.

  As shown in FIG. 1, the diode of the full-wave rectifier circuit is composed of 6 diodes when the stator winding is △ -connected and 8 neutral diodes when Y-connected. The In the present embodiment, the Y connection will be described as an example.

Four diodes U ⁻ , V ⁻ , N ⁻ and W ⁻ are press-fitted into the diode minus fin 109b in the diode minus fin 109b. Similarly, four diodes U ⁺ , V ⁺ , N ⁺ , and W ⁺ are press-fitted in the diode plus fin 109a. The diode plus fin 109a overlaps the diode minus fin 109b via the insulating material 109ab.

Then, U of those diodes as is illustrated by dotted lines diode ^- diode lead 122 and the diode U ⁺ leads are connected by the terminal 121.

The portion of the terminal that protrudes from the terminal fixing member is connected to the output line of the stator winding. Accordingly, the lead portion of U ⁻ of the diode corresponds to the cathode, and the side press-fitted into the fin serves as the anode. In the U ⁺ diode, the lead side corresponds to the anode, and the plus fin side corresponds to the cathode.

  The diode minus fin 109b, the insulating material 109ab, the plus fin 109a, the terminal 121, and the terminal fixing member 109t are integrally molded by a good heat conductor 116 that is an insulating material and has high thermal conductivity. Therefore, since it is excellent in waterproof properties and the internal voltage is insulated, it can be arranged in direct contact with the rear bracket as shown in FIG.

  The portions with the largest heat generation are the lead 122 portion and the terminal 121 portion of the diode having a high current density. In particular, since the terminal 121 is fixed by the terminal fixing member 109t and the heat dissipation is hindered, the temperature rise is greatest.

  In the measurement by experiment, the temperature of the terminal 121 was about 35 ° C. higher than the temperature of the diode. The temperature of the terminal could be lowered by about 60 ° C. by contacting the rear bracket with the good thermal conductor 116 as in this embodiment.

  In the present invention, the terminal 121 described above uses copper having a small specific resistance value. However, the same effect can be obtained by using a copper alloy obtained by mixing copper with another metal.

  Moreover, in order to raise cooling efficiency, it can achieve by using the same copper or copper alloy for the material of the plus fin and the minus fin which press-fit the diode.

  In the present invention, the terminal fixing member 109t is used to hold the terminal, but it may not be used.

  Next, a case where a negative element of a diode is arranged on the rear plate 112 will be described with reference to FIG.

  The difference from FIG. 2 is that the minus fin 109b of the diode is omitted and the minus element of the diode is directly press-fitted into the rear plate 112.

  A dotted line indicates a water channel blocked by the rear plate 112 and can cool the diode well.

  Thus, by directly attaching the negative element of the diode to the rear plate 112, the thermal resistance can be reduced, and the temperature rise of the diode can be lowered. In other words, the minus fin 109b of the diode is used as a member for closing the water channel.

  FIG. 4 shows a cross-sectional view of the embedded negative diode. As shown in FIG. 1, the structure is a member for sealing the water channel 114 in the cooling promotion portion 119 </ b> R disposed on the side opposite to the pulley of the housing 115.

  The rear plate 112 is omitted, and the negative side of the diode is disposed on the negative fin 109b of the diode. A plus fin 109a of a diode is disposed on the minus side fin 109b via an insulating material 109ab.

  The positive side of the diode is arranged on the positive fin 109 a of the diode, and the lead 122 of each diode is connected by a terminal 121.

  Thus, by omitting the rear plate 112, there is an effect that the thermal resistance from the diode to the water channel 114 and the contact thermal resistance between the rear plate 112, the rear plate 112, and the minus fin 109b can be reduced.

  FIG. 5 shows a case where not only the minus side diode but also the plus side diode are mixed in the rear plate 112.

  In this case, since it is necessary to electrically insulate the disk 109d of the plus-side diode, an insulating material 109ab is disposed on the outer periphery of the disk 109d. Needless to say, the insulating material 109ab has a good thermal conductivity. In FIG. 2, the diode plus fin is placed on the rear plate 112 over the diode minus fin 109b using the insulating material 109ab. However, as another method, the minus diode is directly attached to the rear plate 112. The plus fins can be directly fixed to the rear plate 112 via the insulating material 109ab.

  By doing so, the positive fin 109a of the diode can be in contact with the rear plate 112 close to the water channel only with an insulator, and good cooling can be achieved.

  FIG. 6 is a longitudinal sectional view of the vehicle alternator 1 shown in FIG. Since the same reference numerals as those in FIG. 1 denote the same components, detailed description thereof is omitted.

  The difference from FIG. 1 is that the bearing retainer 120 provided in the rotation stop of the outer ring of the bearing 100F disposed on the pulley side is omitted, and the cooling promoting portion 119F is enlarged to be shared with the bearing retainer. This cooling promotion part 119F is comprised with the aluminum member, and is fixed to the front bracket 103 with a screw | thread.

As described above, the cooling promotion part 119F can be arranged up to the inner peripheral side of the rotor, so that the cooling of the field winding 107 of the rotor can be promoted. When the height of the cooling promotion part 119F provided on the front bracket 103 is H1, the winding height H2 of the field winding, and the height of the cooling promotion part 119R arranged on the opposite pulley side is H3, each cooling promotion part Is assumed to satisfy the following formula.

H1 ≧ H2, H3 ≧ H2
Moreover, the gap lengths g1 and g2 of the butted surfaces are about 0.3 mm to 1.0 mm. This is because the heat dissipation effect of the field winding 107 is sufficiently secured.

  FIG. 7 shows a longitudinal sectional view of the vehicle alternator 1 shown in FIG. Since the same reference numerals as those in FIG. 6 denote the same components, detailed description thereof is omitted.

  The difference from FIG. 6 is that the lead wire 107a of the field winding 107 is provided with a groove on the side surface of the claw magnetic pole and the wiring is embedded in the recess. The lead wire 107a and the concave portion of the claw-shaped magnetic pole portion are fixed by varnish. Therefore, since the surface on the side opposite to the pulley of the rotor can be a flat surface, the effect of the cooling promoting portion 119R can be sufficiently exerted.

  In the case of FIG. 6, even if the gap length between the outside of the field winding lead wire 107a and the cooling promoting portion 119R is set to 0.3 mm, the wire length of the lead wire is increased because the gap length is increased. The gap length was about 2 mm. Therefore, the cooling effect of the cooling promoting portion 110R on the side opposite to the pulley is small.

  In addition, the number of claw magnetic poles when the claw magnetic poles are formed on the side surfaces of the claw magnetic poles of the rotor is set as many as the number of claw magnetic poles. This has the effect of improving mass productivity.

  In addition, since the concave portions that are not used are arranged radially toward the outer periphery of the rotor, the function of the internal fan can be provided, so that the air in the apparatus can be agitated and the cooling can be promoted.

  FIG. 8 shows a longitudinal sectional view of the vehicle alternator 1 shown in FIG. Since the same reference numerals as those in FIG. 7 denote the same components, detailed description thereof is omitted.

  The difference from FIG. 7 is that a heat radiating opening 122 is provided in the outer diameter portion substantially the same as the stator winding 106 of the front bracket 103. Since the opening 122 is not in direct contact with the rotating portion, there is an advantage that the rotor is not easily fixed even if foreign matter is mixed in. In addition, because it is effective for cooling in the machine by the stirring action by the claw-shaped magnetic pole part, the field winding temperature can be lowered, so the effect of improving the reliability of the field winding and the permanent magnet disposed between the claw magnetic poles High temperature demagnetization suppression effect.

  In addition, the scope of claims which form the basis of the present invention is shown below.

  A rotor having a plurality of magnetic poles; a stator that generates an alternating voltage by magnetizing the plurality of magnetic poles; and a rectifier that outputs the alternating voltage, and a plurality of positive-side rectifying elements and A rectifier circuit constituted by a plurality of negative-side rectifier elements, a housing for fixing the stator, provided with a first cooling water channel for cooling the stator, and an axial direction of the rotor A first member constituting a second cooling water channel for cooling the rectifying circuit, and a second member constituting the second cooling water channel, the second member constituting the second cooling water channel, and disposed at a portion facing the end portion; An AC generator for a vehicle, wherein the negative rectifier element is provided on the second member to be cooled.

  2. The vehicle alternator according to claim 1, further comprising: a cooling fin provided with the plurality of positive-side rectifying elements; and an insulating member for insulating the cooling fin, wherein the cooling fin is the insulating member. An AC generator for a vehicle, which is provided on the second member via

  2. The vehicular AC generator according to claim 1, further comprising an insulating member for insulating the plurality of positive-side rectifying elements, wherein the plurality of positive-side rectifying elements are interposed between the second member and the insulating member. An AC generator for a vehicle that is provided and cooled.

  2. The vehicular AC generator according to claim 1, further comprising: a bracket disposed outside the second member and in contact with the second cooling water channel; and a good heat conductor covering the rectifier circuit, An AC generator for a vehicle, wherein the circuit is in contact with the bracket via the good heat conductor.

  2. The vehicle AC generator according to claim 1, wherein the first member is provided with a cooling promotion portion having a thickness equal to or larger than a winding thickness of the field winding. Generator.

  6. The vehicle alternator according to claim 5, further comprising a bearing that supports the shaft of the rotor, wherein the cooling promoting portion also serves as a retainer of the bearing. .

  6. The vehicular AC generator according to claim 5, wherein the field winding includes a lead wire, and the lead wire is embedded in a core side surface of the rotor. Machine.

  The alternating current generator for vehicles of Claim 1 WHEREIN: The said rectifier is equipped with the terminal for electrically connecting the said rectifier circuit and the coil | winding of the said stator, and the said terminal is copper or a copper alloy. An AC generator for a vehicle characterized by being a thing.

  2. The vehicle alternator according to claim 1, further comprising: two brackets covering axially opposite sides of the stator and the rotor, wherein at least one of the two brackets includes the stator. An AC generator for a vehicle, characterized in that an opening having an outer diameter substantially the same as that of the winding is provided.

The longitudinal cross-sectional view of the alternating current generator for vehicles is shown. The top view of the whole structure of a rectifier circuit is shown. The top view of the whole structure of a rectifier circuit is shown. The longitudinal cross-sectional view of a diode part is shown. The longitudinal cross-sectional view of a diode part is shown. The longitudinal cross-sectional view of the alternating current generator for vehicles is shown. The longitudinal cross-sectional view of the alternating current generator for vehicles is shown. The longitudinal cross-sectional view of the alternating current generator for vehicles is shown.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Vehicle alternator, 104 ... Bracket, 107 ... Field winding, 109 ... Diode, 114 ... Cooling water channel, 116 ... Good heat conductor, 119 ... Cooling promotion part, 121 ... Terminal, 122 ... Opening part, 200... Surface constituting the axial end portion, 300... Rotor core.

Claims (4)

A pair of claw-shaped magnetic pole portions having a claw-shaped shape are arranged on the outer periphery, and a rotor around which a field winding is wound at the center,
A neodymium magnet disposed between the pair of claw-shaped magnetic pole portions and magnetized in a direction in which the same poles face each other;
A stator having a stator winding that is arranged so that an inner peripheral surface faces the rotor and generates an AC voltage by magnetization of the field winding;
A rectifier circuit for converting the generated AC voltage into a DC voltage;
Have
An AC generator for a vehicle, wherein an inner peripheral surface of the stator core and a surface of the rotor are arranged with an interval of 0.4 to 0.6 mm. In the vehicle alternator according to claim 1,
A vehicular AC generator comprising a cooling water passage for cooling the rectifier circuit and the stator. The vehicle alternator according to claim 1 or 2,
An AC generator for vehicles, wherein a good heat conductor is disposed from the remaining space portion of the claw-shaped magnetic pole portion to the space portion of the field winding. In the vehicle alternator according to any one of claims 1 to 3,
An AC generator for vehicles, wherein a scattering prevention cover is disposed on an outermost peripheral portion of the claw-shaped magnetic pole portion of the rotor.

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