JP2011036092A - Rotary electric machine and vehicle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To wind a stator coil with high-density arrangement using a rectangular wire. <P>SOLUTION: A rotary electric machine has a rotor, and a stator using the rectangular wire at the stator coil (24A1). The stator coil (24A1) is wound around the tooth of a stator core via an insulating bobbin (26A). A groove as wide as the long side of a section in the rectangular wire is formed at the corner of the insulating bobbin (26A) each other stage of the stator coil (24A1) with the rectangular wire wound around, when the long side of the section in the rectangular wire is brought into contact with the corner of the insulating bobbin (26A). Further, the groove as wide as the short side of the section in the rectangular wire is formed at the corner of the insulating bobbin (26A) each other stage of the stator coil (24A1) with the rectangular wire wound around, when the short side of the section in the rectangular wire is brought into contact with the corner of the insulating bobbin (26A). <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a rotating electrical machine that uses a flat wire for a stator coil, and a vehicle equipped with the rotating electrical machine.

Rotating electrical machines for general household appliances, general industrial equipment, vehicle accessory drives, and vehicle drive main machines are desired to have smaller and higher power output. Become. The cause of the temperature rise is heat generation due to the loss of the rotating electrical machine, and it is necessary to reduce the loss. The loss of the rotating electrical machine includes a copper loss caused by energizing the stator coil. To suppress the copper loss, the stator coil of the rotating electrical machine needs to have a high-density winding.
The winding of the stator coil includes a winding made of a so-called round wire having a circular cross section and a winding made of a so-called rectangular wire having a substantially rectangular cross section. In order to realize a high-density winding of the stator coil, it is effective to prevent winding disturbance, arrange the coil in the slot without a gap, and increase the space factor. As a general high-density winding method for increasing the space factor, there is a method in which round wires are aligned in a bowl shape, and as disclosed in Patent Document 1, in order to realize the aligned winding, There is a method in which a groove matching the wire diameter of the coil is provided on the surface where the bobbin and the coil are in contact, and a round wire of the coil is disposed in the groove to prevent winding disturbance. However, the round wire has a low space factor because a gap is generated even when aligned winding is performed on the ridge.
Therefore, in order to realize a high-density winding of the stator coil, the stator coil is changed from a round wire to a flat wire, and the winding is arranged with no gap, thereby increasing the space factor than the round wire, Can be realized.

Japanese Patent No. 4076837 JP 2008-148470 A

However, when the rectangular wires are wound in an aligned manner, since the unevenness between the wires is extremely small like a round wire, the coil is slippery and is likely to be disturbed. Also, when a groove that holds a flat wire is provided on the side surface of the bobbin, the bobbin wall thickness is the thinnest part of the groove that comes to the bottom of the trough, so the top of the mountain becomes higher by the level difference from the bottom of the valley, As a result, the bobbin becomes thick and the proportion of the resin bobbin in the slot increases, and the conductor cannot be made large. Therefore, it is necessary to perform aligned winding using a rectangular wire for the stator coil without causing winding disturbance.
As a method of performing winding while preventing winding disturbance, as disclosed in Patent Document 2, winding is performed while forcing the position of the coil with a jig attached to the winding machine during winding operation for each winding. There is a way to do it. However, this method complicates the winding machine and requires the winding position to be forced every turn, so that the work time becomes long and is not suitable for mass production.

(1) The invention of claim 1 is a rotating electrical machine having a rotor and a stator using a flat wire for the stator coil, and the stator coil is wound around the teeth portion of the stator core via an insulating bobbin. When the long side of the rectangular wire cross section is in contact with the corner of the insulating bobbin, the flat wire is wound around the corner of the insulating bobbin with the width of the long side of the flat wire cross section. When the short side of the flat section of the rectangular wire is in contact with the corner portion of the insulating bobbin, the length of the short side of the flat section of the rectangular wire is defined as the width. The groove to be provided is provided at every other stage of the stator coil wound with a flat wire.
(2) The invention of claim 2 is the rotating electrical machine according to claim 1, wherein the maximum depth of the groove is larger than the radius of the section angle R of the flat wire and the length of the long side of the cross section of the flat wire is long. It is made smaller than the value obtained by subtracting the radius of the cross section angle R portion of the flat wire.
(3) A third aspect of the present invention is the rotating electrical machine according to the first or second aspect, wherein the step in each layer of the stator coil is moved on the side surface of the teeth portion of the stator core.
(4) The invention of claim 4 is a vehicle including the rotating electrical machine according to any one of claims 1 to 3.

  According to the present invention, the space factor of the stator coil can be improved without impairing workability, and a high-density aligned winding of a stator coil using a rectangular wire can be achieved by simply adding a simple shape to an insulating bobbin. can do.

Sectional drawing which shows the whole structure of the rotary electric machine of one Embodiment The perspective view which shows the structure of the rotary electric machine of one embodiment The front view which shows the stator structure of the rotary electric machine of one embodiment The perspective view which shows the structure of the stator tea score and resin bobbin used for the rotary electric machine of one Embodiment Sectional drawing which shows the corner | angular R part of the stator tee score and resin bobbin used for the rotary electric machine of one embodiment Enlarged view of stator tea score and resin bobbin used in the rotating electrical machine of one embodiment In the stator of the rotating electrical machine according to the embodiment, an enlarged view of a state in which a stator coil made of a flat wire is wound around a resin bobbin for one turn. The enlarged view of the stator of the rotary electric machine of one Embodiment in the state where the stator coil which consists of a rectangular wire was wound by 2 turns on the resin bobbin In the stator of the rotating electrical machine according to one embodiment, an enlarged view of a state in which one layer of a stator coil made of a flat wire is wound around a resin bobbin. In the stator of the rotating electrical machine of one embodiment, when the first layer step movement (a) and the second layer step movement (b) of the stator coil made of a rectangular wire wound around a resin bobbin are performed at the coil end Front view of In the stator of the rotating electrical machine of one embodiment, the first layer step movement (a) and the second layer step movement (b) of the stator coil made of a rectangular wire wound around a resin bobbin are performed on the side surface of the stator tea score. Front view when The perspective view of the state which wound the stator coil which consists of a flat wire to the stator tee score of the rotating electrical machine of one embodiment Front view (a) and sectional view (b) of a coil end in a state where a stator coil made of a rectangular wire is wound around a stator tee score of a rotating electrical machine of an embodiment Front view (a) and sectional view (b) of side surface of stator tee score in a state in which stator coil made of rectangular wire is wound around stator tee score of rotating electric machine of one embodiment Sectional drawing of the corner | angular R part of the stator tea score of the rotary electric machine of one Embodiment The block diagram which shows the 1st structure of the vehicle carrying the rotary electric machine of one embodiment. The block diagram which shows the 2nd structure of the vehicle carrying the rotary electric machine of one embodiment. 1 is a block diagram showing a first arrangement example of an engine ENG, a rotating electrical machine RM, and a transmission TM in a hybrid vehicle equipped with the rotating electrical machine of an embodiment. The block diagram which shows the 2nd example of arrangement | positioning of the engine ENG, the rotary electric machine RM, and the transmission TM in the hybrid vehicle carrying the rotary electric machine of one embodiment.

  Hereinafter, the configuration of a rotating electrical machine according to an embodiment will be described with reference to FIGS. FIG. 1 is a cross-sectional view illustrating an overall configuration of a rotating electrical machine RM according to an embodiment. In this embodiment, a rotating electric machine RM for driving a hybrid vehicle will be described as an example, but the rotating electric machine of the present invention is not limited to driving a hybrid vehicle. The rotating electrical machine RM is mounted between the engine and the transmission or in the transmission, and requires a small high output. For this reason, the temperature rise becomes a problem, and it is necessary to reduce the loss of the rotating electrical machine that is the cause of heat generation.

  The rotating electrical machine RM is a three-phase synchronous motor with a built-in permanent magnet. When a three-phase alternating current with a large current is supplied to the stator coil, the stator coil operates. Further, when the rotating electrical machine RM is driven by the engine, it operates as a generator and outputs three-phase AC generated power. The rotating electrical machine RM according to the embodiment is a flat rotating electrical machine having a thickness in the rotation axis direction smaller than the outer diameter.

  The rotating electrical machine RM includes a rotor 10, a stator 20, and a housing 50, and the rotor 10 is disposed on the inner peripheral side of the stator 20 via a gap. The rotor 10 is fixed to a shaft 12, and both ends of the shaft 12 are rotatably supported by bearings 14A and 14B. The outer periphery of the stator 20 is fixed to the inner periphery of the housing 50, and the outer periphery of the housing 50 is fixed to the inner periphery side of the case 130.

  FIG. 2 is a perspective view showing the configuration of the rotating electrical machine of the embodiment, and FIG. 3 is a front view showing the configuration of the rotating electrical machine of the embodiment. In FIG. 2 and FIG. 3, the same components as those in FIG. As shown in FIG. 2, the rotating electrical machine RM includes a rotor 10, a stator 20, and a housing 50. The rotor 10 has a multipolar structure in which a permanent magnet is inserted into a rotor core. A U-phase stator coil, a V-phase stator coil, and a W-phase stator coil are wound around the stator tee score of the stator 20 by concentrated winding. There are a plurality of stator coils. In this embodiment, there are eight stator coils for each phase.

  The power connection terminals 29U, 29V, and 29W are terminals for supplying power to each phase stator coil, and are connected to the power converter. The three-phase alternating current converted by the power converter is supplied to the power connection terminals 29U, 29V, and 29W. Moreover, the three-phase alternating current output from the power connection terminals 29U, 29V, and 29W is supplied to the power converter and converted into direct current. Between the power connection terminals 29U, 29V, 29W and the respective stator coils, a power distribution unit 27 is provided for supplying electric power from the power connection terminals 29U, 29V, 29W to the respective stator coils.

  The power distribution unit 27 includes a U-phase connection ring 27U, a V-phase connection ring 27V, a W-phase connection ring 27W, a neutral point connection ring 27N, and a holder 27H. Each of these connection rings 27U, 27V, 27W, and 27N is obtained by bending a copper wire into an arc shape. The holder 27H has a ring shape and is made of resin. In the holder 27H, grooves into which the U-phase connection ring 27U, the V-phase connection ring 27V, the W-phase connection ring 27W and the neutral point connection ring 27N can be inserted are formed in advance. The connection rings 27U, 27V, 27W, 27N are inserted and held in the grooves of the holder 27H.

  One end of eight U-phase stator coils is connected to the U-phase connection ring 27U, one end of eight V-phase stator coils is connected to the V-phase connection ring 27V, and a W-phase connection ring One end of eight W-phase stator coils is connected to 27W. Further, the neutral point connection ring 27N includes the other end portions of the eight U-phase stator coils, the other end portion of the eight V-phase stator coils, and the other end portion of the eight W-phase stator coils. And are connected.

  The power connection terminal 29U is connected to the U-phase connection ring 27U. Similarly, the power connection terminal 29V is connected to the V-phase connection ring 27V, and the power connection terminal 29W is connected to the W-phase connection ring 27W. The electric power input to the power connection terminals 29U, 29V, 29W is supplied to the stator coil by the power distribution unit 27. As described above, since the rotating electrical machine RM is mounted between the engine and the transmission or in the transmission, a small high output is required. For this reason, temperature rise becomes a problem, and it is necessary to minimize heat generation in the stator coil of the rotating electrical machine RM used as the main power of the vehicle.

  In general, the stator core includes an annular ring portion and a teeth portion protruding from the ring portion in the inner diameter direction. As shown in FIG. 3, the stator core of one embodiment is formed of a plurality of stator tea scores in which a ring portion and a tooth portion are integrally formed and divided in the circumferential direction by a number equal to the number of the tooth portions. Yes. That is, the stator core of one embodiment is composed of 24 stator tea scores 22A, 22B, 22C, ..., 22V, 22W, 22X. Each stator tea score is formed by laminating electromagnetic steel plates in the axial direction of the rotating electrical machine.

  For example, when one stator tee score 22A is viewed, it is composed of an arc portion and a teeth portion protruding from the center of the arc portion, and has a T shape when viewed from the side. A ring is formed by connecting 24 arc portions adjacent to each other. Stator coils 24A, 24B, 24C,..., 24V, 24W, 24X are wound around the stator tea scores 22A, 22B, 22C,.

  FIG. 4 shows an enlarged view of the stator tea score 22A divided. Here, the stator tea score 22A will be described, but the same applies to the other stator tea scores 22B to 22X. A stator bobbin 26A divided in two in the axial direction is attached to the stator tea score 22A. At the corners of the four corners of the resin bobbin 26A, there are provided grooves 26Z that prevent the winding of the stator coil, which is a rectangular wire as shown in the sectional view of FIG. 5 and the enlarged view of FIG. Here, the maximum depth of the groove 26 </ b> Z that prevents winding disturbance is hb. How much the maximum depth hb is set will be described later.

  FIG. 7 shows a state in which the first turn 24A1 of the stator coil 24A made of a rectangular wire is wound around the stator tee score 22A to which the resin bobbin 26A is attached. As is apparent from the drawing, the stator coil 24A made of a rectangular wire is fitted and fixed in a groove 26Z that prevents winding disturbance at the corner R portion of the resin bobbin 26A. In FIG. 7, when the long side of the rectangular wire cross section is in contact with the corner of the insulating bobbin, the groove having the width of the long side of the flat wire cross section as the width is connected to the corner of the insulating bobbin. An example is shown in which a stator coil wound with a wire is provided in every other stage. However, when the short side of the flat section of the flat wire is in contact with the corner of the insulating bobbin, the cross section of the flat wire is in contact with the corner of the insulating bobbin. A groove having a short side length as a width is provided in every other stage of the stator coil wound with a flat wire.

  Further, FIG. 8 shows a state where the second turn 24A2 of the stator coil 24A made of a rectangular wire is wound. The riding position of the second turn 24A2 of the stator coil 24A made of a flat wire is determined on the first turn 24A1 of the stator coil 24A made of a flat wire. When the winding is further advanced and the winding for one layer is performed, a coil as shown in FIG. 9 is obtained, and the coil that fits in the groove and the coil that is sandwiched between the coils are alternately arranged to prevent winding disturbance of the stator coil 24A that is a flat wire. And a groove is formed at the corner of the winding. This groove has an effect similar to that of the groove 26Z provided at the corner R portion of the resin bobbin 26A to prevent winding disturbance.

  In order to move the stage within one layer of the stator coil 24A made of a rectangular wire, a method of moving at the coil end as in the case of a normal round wire as shown in FIG. Even in the second and subsequent layers, it can be moved on one side or both sides as shown in FIG. Further, when the width of the stator tea score is not sufficiently wide, it can be moved on the side surface of the stator tea score as shown in FIGS. 11 (a) and 11 (b). That is, the movement of the step within one layer of the stator coil 24A made of a rectangular wire is moved on the side surface of the stator tea score as shown in FIG. 11A, and the second and subsequent layers are also shown in FIG. 11B. Move on the side of the stator tea score.

  FIG. 12 is a perspective view of a state in which a stator coil made of a rectangular wire is wound around the stator tee score of the rotating electrical machine according to the embodiment. FIG. 13 is a front view (a) and a cross-sectional view (b) of the coil end in a state where a stator coil made of a rectangular wire is wound around the stator tee score of the rotating electrical machine according to the embodiment. Furthermore, FIG. 14 is a front view (a) and a sectional view (b) of the side surface of the stator tee score in a state in which a stator coil made of a rectangular wire is wound around the stator tee score of the rotating electrical machine of the embodiment.

FIG. 15 is a cross-sectional view of a corner R portion of the stator tea score of the rotating electrical machine according to the embodiment. Here, the stator tea score 22A will be described, but the same applies to the other stator tea scores 22B to 22X. As described above with reference to FIG. 5, the corners at the four corners of the resin bobbin 26A are provided with grooves 26Z for preventing the winding of the stator coil 24A made of a rectangular wire, and the maximum depth thereof is hb. . This maximum depth hb is larger than the radius Rc of the corner R section of the flat section of the rectangular wire, and is a value obtained by subtracting the radius Rc of the corner R section of the flat section from the width Wc of the short side of the section of the flat section (Wc− It is desirable to make it smaller than Rc).
Rc <hb <(Wc−Rc) (1)
Thereby, no matter how the size of the rectangular shape of the cross section of the flat wire changes, the short side of the cross section of the flat wire comes into contact with the side surface of the groove 26Z in the first layer, and the cross section of the flat wire in the second and subsequent layers. The short sides of each other come into contact with each other, and the winding disturbance can be reliably prevented.

  Next, the configuration of the vehicle on which the rotating electrical machine RM according to the embodiment is mounted will be described with reference to FIGS. 16 and 17. 16 and 17 show a power train on the premise of a hybrid vehicle. FIG. 16 is a block diagram illustrating a first configuration of a vehicle on which the rotating electrical machine RM according to the embodiment is mounted. FIG. 17 is a block diagram illustrating a second configuration of the vehicle on which the rotating electrical machine RM according to the embodiment is mounted. is there.

  The first configuration shown in FIG. 16 is a power train of a four-wheel drive hybrid vehicle. An engine ENG and a rotating electrical machine RM are provided as main power on the front wheel side. The power generated by the engine ENG and the rotating electrical machine RM is shifted by the transmission TM and transmitted to the front wheel drive wheels FW. On the other hand, in driving the rear wheel, the rotating electric machine RM ′ and the rear wheel side driving wheel RW arranged on the rear wheel side are mechanically connected, and the power generated by the rotating electric machine RM ′ is transmitted to the rear wheel side driving wheel RW. Directly transmitted.

  The rotating electrical machine RM starts the engine ENG and switches between generation of driving force for driving and generation of electric power for recovering energy at the time of vehicle deceleration as electric energy according to the traveling state of the vehicle. The operation of the rotating electrical machine RM and the operation of power generation are controlled by the power converter PC so that the torque and the rotational speed are optimized in accordance with the driving situation of the vehicle. Electric power necessary for driving the rotating electrical machine RM is supplied from the battery BA via the power converter PC. Further, when the rotating electrical machine RM is in the power generation operation, the battery BA is charged with electric energy via the power converter PC.

  Here, the rotating electrical machine RM serving as a driving source for the front wheels together with the engine ENG is disposed between the engine ENG and the transmission TM and has the configuration described with reference to FIGS. As the rotating electrical machine RM 'that is the power source on the rear wheel side, the same rotating electrical machine RM as the front wheel side can be used, or a rotating electrical machine having another general configuration can be used. In the first configuration shown in FIG. 16, if the rear wheels are not used as drive wheels without attaching the rear wheel drive side rotating electrical machine RM ', the configuration is a front wheel drive hybrid vehicle.

  FIG. 17 shows the powertrain of a rear-wheel drive hybrid vehicle. The engine ENG and the rotating electrical machine RM are provided as main powers on the front wheel FW side, and the power generated by the engine ENG and the rotating electrical machine RM is shifted using the transmission TM, and the power is transmitted to the rear wheel drive wheels RW.

  The rotating electrical machine RM starts the engine ENG and switches between generation of driving force and generation of electric power for recovering energy at the time of vehicle deceleration as electric energy according to the traveling state of the vehicle. The driving of the rotating electrical machine RM and the operation of power generation are controlled by the power converter PC so that the torque and the rotational speed are optimized in accordance with the driving situation of the vehicle. Electric power necessary for driving the rotating electrical machine RM is supplied from the battery BA via the power converter PC. Further, when the rotating electrical machine RM is in the power generation operation, the battery BA is charged with electric energy via the power converter PC.

  Here, the rotating electrical machine RM that serves as a drive source for the rear wheels together with the engine ENG is disposed between the engine ENG and the transmission TM, and has the configuration described with reference to FIGS. In addition, it becomes a structure of a four-wheel drive vehicle by adding the mechanism which transmits motive power to the front wheel from the output part of a transmission like a normal motor vehicle.

  Next, with reference to FIGS. 18 and 19, the arrangement of the engine ENG, the rotating electrical machine RM, and the transmission TM in a hybrid vehicle equipped with the rotating electrical machine of the embodiment will be described.

  FIG. 18 is a block diagram illustrating a first arrangement example of the engine ENG, the rotating electrical machine RM, and the transmission TM in a hybrid vehicle equipped with the rotating electrical machine of one embodiment. FIG. 19 is a block diagram illustrating a second arrangement example of the engine ENG, the rotating electrical machine RM, and the transmission TM in a hybrid vehicle equipped with the rotating electrical machine of one embodiment. The arrangement of the engine ENG, the rotating electrical machine RM, and the transmission TM in the hybrid vehicle is roughly divided into two types.

  First, in the first arrangement example shown in FIG. 18, the engine ENG, the rotating electrical machine RM, and the transmission TM are each configured independently, and the rotating electrical machine RM is mechanically connected between the engine ENG and the transmission TM. The output of the transmission TM is transmitted to the drive wheels WH. On the other hand, in the second arrangement example shown in FIG. 19, the engine ENG and the transmission TM are independently configured and mechanically connected, and the rotating electrical machine RM is mounted inside the transmission TM, and the transmission TM And the rotating electrical machine RM are mechanically connected. Then, the output of the transmission TM is transmitted to the drive wheels WH. In the above configuration, the rotating electrical machine RM that is the power source of the drive wheels WH has the configuration described with reference to FIGS.

  According to embodiment mentioned above, there can exist the following effects. First, in a rotating electrical machine having a rotor and a stator using a flat wire as a stator coil, the stator coil is wound around the teeth portion of the stator core via an insulating bobbin, and the rectangular wire is formed at the corner portion of the insulating bobbin. When the long side of the cross section of the flat wire is in contact with each other, a groove having a width of the long side of the cross section of the flat wire is provided at every corner of the insulating bobbin at every other stage of the stator coil wound with the flat wire. When the short side of the flat section of the rectangular wire is in contact with the corner of the insulating bobbin, a groove having a width that is the length of the short side of the flat section of the rectangular wire is wound around the corner of the insulating bobbin. Since the stator coil is installed in every other stage, it is possible to prevent the winding of the stator coil using a flat wire that is slippery and prone to winding disturbance, improving the space factor of the stator coil without impairing workability, and insulating. Add a simple shape to the bobbin It may enable high-density alignment winding of the stator coil using a rectangular wire only.

  Further, according to one embodiment, the maximum depth of the groove is larger than the radius of the rectangular wire section angle R portion, and from the length of the long side of the rectangular wire cross section, the rectangular wire section angle R portion Since the radius is smaller than the value obtained by subtracting the radius, the short side of the flat section of the rectangular wire is in contact with the side surface of the groove in the first layer, no matter how the rectangular shape of the flat section changes. After the eyes, the short sides of the cross section of the flat wire come into contact with each other, and winding disturbance can be reliably prevented.

  Furthermore, according to one embodiment, since the stage movement in each layer of the stator coil is performed on the side surface of the teeth portion of the stator core, the width of the teeth portion of the stator core is narrow and the stator coil in each layer of the stator coil in the coil end portion. Even when it is difficult to move the stage, a rectangular wire can be used to enable high-density aligned winding of the stator coil.

  The rotating electrical machine according to the embodiment can be used not only for the hybrid vehicle described above but also for driving an auxiliary machine for a general electric vehicle or a vehicle, and is highly reliable in a harsh driving environment of the vehicle. A source can be provided.

  In the above-described embodiments and their modifications, all combinations of the embodiments and the modifications are possible.

DESCRIPTION OF SYMBOLS 10; Rotor, 20; Stator, 22A-22X; Stator tee score, 24A-24X; Stator coil, 26A; Bobbin, 26Z; Groove, RM;

Claims (4)

In a rotating electrical machine having a rotor and a stator using a rectangular wire as a stator coil,
The stator coil is wound around the teeth portion of the stator core via an insulating bobbin,
When the long side of the cross section of the rectangular wire is in contact with the corner of the insulating bobbin, a groove whose width is the length of the long side of the cross section of the flat wire is connected to the corner of the insulating bobbin. When the short side of the section of the rectangular wire is in contact with the corner of the insulating bobbin, the stator coil is wound around the corner of the rectangular bobbin. A rotating electrical machine, wherein a groove having a width of a short side of a cross section is provided in every other stage of the stator coil around which the rectangular wire is wound. In the rotating electrical machine according to claim 1,
The maximum depth of the groove is larger than the radius of the cross section angle R of the flat wire, and the value obtained by subtracting the radius of the cross section angle R of the flat wire from the length of the long side of the cross section of the flat wire. A rotating electrical machine characterized by a smaller size. In the rotating electrical machine according to claim 1 or 2,
A rotating electric machine characterized in that a step in each layer of the stator coil is moved on a side surface of a teeth portion of the stator core.   A vehicle comprising the rotating electrical machine according to any one of claims 1 to 3.

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