JP3656279B2 - Vehicular coil device and vehicular AC generator - Google Patents

Description

[0001]
[Industrial application fields]
The present invention relates to a vehicular coil device including a coil bobbin that winds a coil such as a rotating electrical machine, an ignition coil, and an electromagnetic actuator mounted on a vehicle, and in particular, winds a rotor coil such as a vehicular alternator. The present invention relates to a vehicle alternator equipped with a coil bobbin.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, in a two-wheeled vehicle AC generator, for example, a rotor is composed of a pole core that constitutes an excitation pole and a rotor coil that is wound around the outer periphery of the pole core via a coil bobbin and through which an excitation current flows. The coil bobbin has a cylindrical portion around which the rotor coil is wound, and two hook-shaped portions provided at both ends of the cylindrical portion.
[0003]
In addition, at least one of the two hook-shaped portions (the hook-shaped portion close to the slip ring) has a T-shaped holding portion shape that holds the drawn-out portion of the rotor coil. And the drawer part of the rotor coil was wound around the T-shaped holding part 1-2 times and fixed.
[0004]
[Problems to be solved by the invention]
However, in the two-wheeled vehicle AC generator, there is a problem in that the drawing portion of the rotor coil is disconnected due to the large vibration and rotational fluctuation of the two-wheeled vehicle and the resonance of the holding portion. To prevent this, do not wrap the rotor coil lead-out part around the holding part, insert the rotor coil lead-out part into the tube, and hold the lead-out part by winding a tape-like object around the rotor coil lead-out part. There is also a method of fixing to the part. However, since it is difficult to wind a tape-like object around the outer circumference of the rotor coil lead-out portion, the product cost of the AC generator for motorcycles is significantly increased due to the increase in the number of work steps and the lengthening of the work time. The problem has arisen.
[0005]
The object of the invention described in claims 1 to 4 is for a vehicle capable of preventing the disconnection of the coil lead-out portion and reducing the product cost by simplifying the fixing method of the coil lead-out portion. To provide a coil device. Another object of the invention described in claim 2, can be easily manufactured notches is to provide a vehicular coil device capable of and alleviate vibrations.
[0006]
An object of the invention described in claim 3 is to provide a vehicular coil device capable of easily fixing a coil lead-out portion to a cut-out portion even if the coil has various wire diameters. is there. Another object of the invention described in claim 4 is to provide a vehicular coil apparatus which can prevent the lead-out portion of the coil comes out from the notch.
Furthermore, the object of the invention described in claim 5 is to prevent disconnection of the drawn-out portion of the rotor coil and to simplify the fixing method of the drawn-out portion of the rotor coil, thereby reducing the work cost. The object is to provide a vehicle alternator.
[0007]
[Means for Solving the Problems]
According to the first aspect of the present invention, there is provided a coil bobbin having a cylindrical part extended in the cylindrical direction, and a flanged part formed at one end of the cylindrical part in the cylindrical direction, and an outer periphery of the cylindrical part of the coil bobbin. A coil device for a vehicle comprising a wound coil part, and a coil having a lead part drawn out from one end of the coil part,
The drawn-out portion of the coil is covered with a tubular covering material,
Wherein the outer periphery of the flange portion of the coil bobbin, the cutout portion is formed in the write Mutame insert the covering material covering the lead-out portion of the coil,
The opening size of the notch portion is smaller than the wire diameter of the lead portion of the coil .
[0008]
The invention according to claim 2, in addition to the vehicle coil device of claim 1, the pre-Symbol bobbin with integrally molded by a resin, the cut-out portion in the portion which protrudes from the radially said collar portion It is formed.
[0009]
According to a third aspect of the present invention, in addition to the vehicular coil device according to the first or second aspect , the cutout portion has an opening size on the outer peripheral side larger than an opening size on the inner peripheral side. It is characterized by having formed in the taper shape by this .
The invention described in 請 Motomeko 4, in addition to the vehicle coil device according to any one of claims 1 to 3, the cutout portion, the locking portion for locking the drawer portion of the coil Is provided.
[0010]
According to a fifth aspect of the present invention, there is provided a rotating shaft that is rotationally driven by a drive source mounted on a vehicle, a rotor core that rotates integrally with the rotating shaft, and the rotor core that is held by the rotor core in a cylindrical direction. A coil bobbin having an extended cylindrical part and a flanged part formed at one end of the cylindrical part in the cylindrical direction, a coil part wound around the outer periphery of the cylindrical part of the coil bobbin, and the coil part An AC generator for a vehicle comprising a rotor coil having a lead-out portion drawn out from one end;
The drawn out portion of the rotor coil is covered with a tubular covering material,
The outer periphery of the flange portion of said coil bobbin, characterized in that the notch for inserting the covering material to cover the lead portions of the rotor coils are formed.
[0011]
Operation and effect of the invention
According to the first aspect of the present invention, the coil covering portion is sandwiched between the notch portions by inserting the tubular covering material covering the coil drawing portion into the notches formed on the outer periphery of the flange portion of the coil bobbin. Fixed in a fixed state. As described above, since the fixing of the coil drawing portion is simplified, the tape-like object wound around the coil drawing portion can be eliminated. For this reason, since the work man-hour of the work which fixes the drawer part of a coil can be reduced and the work time can be shortened, the work cost of the coil apparatus for vehicles can be reduced significantly. Further, since the coil drawing portion is not wound around the flange portion of the coil bobbin, damage and disconnection of the coil drawing portion can be suppressed even when the vibration of the vehicle is large.
Moreover, damage and disconnection of the drawer part can be prevented by covering the drawer part inserted into the notch with a tubular covering material.
[0012]
Further , by making the opening size of the notch portion smaller than the wire diameter of the coil, the coil lead-out portion can be firmly fixed to the notch portion.
According to the second aspect of the present invention, the notch can be easily formed on the outer periphery of the bowl-shaped portion of the coil bobbin, and the vibration of the vehicle transmitted to the coil bobbin can be reduced.
According to the third aspect of the invention, the opening size on the outer periphery side of the notch portion is made larger than the opening size on the inner periphery side so that the shape of the notch portion is a tapered shape. Even if the coil bobbin is changed, the coil can be inserted into the cutout portion of the coil bobbin having the same shape, so that it is not necessary to prepare many types of coil bobbin shapes.
[0013]
According to the invention described in 請 Motomeko 4, by providing the locking portion for locking the drawer portion of the coil in the notch, thereby preventing once the Merged drawer unit comes out to the notch.
[0014]
According to the fifth aspect of the present invention, by inserting the tubular covering material covering the drawn-out portion of the rotor coil into the notch formed on the outer periphery of the bowl-shaped portion of the coil bobbin, the drawn-out portion of the rotor coil is It is fixed in a state of being sandwiched between the notches. As described above, since the fixing of the drawn-out portion of the rotor coil is simplified, the tape-like object wound around the drawn-out portion of the rotor coil can be eliminated. For this reason, since the work man-hour of the work which fixes the drawer | drawing-out part of a rotor coil can be reduced, and the work time can be shortened, the work cost of the alternating current generator for vehicles can be reduced significantly. In addition, since the rotor coil lead-out portion is not wound around the coil-shaped portion of the coil bobbin, damage or disconnection of the rotor coil lead-out portion can be suppressed even if the vehicle vibration or rotation fluctuation is large. Moreover, damage and disconnection of the drawer part can be prevented by covering the drawer part inserted into the notch with a tubular covering material.
[0015]
【Example】
[Configuration of Example]
Next, the vehicular coil device and vehicular AC generator according to the present invention will be described based on an embodiment applied to a two-wheeler alternator. 1 and 2 are views showing a coil bobbin and a coil, FIG. 3 is a view showing a main part of the coil bobbin, and FIG. 4 is a view showing an entire structure of the alternator for a motorcycle.
[0016]
The alternator 1 for a motorcycle is a rotating field type AC generator. The alternator 1 for a motorcycle includes a housing 2, a stator (stator) 3 fixed to the inner peripheral surface of the housing 2, and a rotor (rotor) 5 that rotates integrally with a shaft (rotary shaft) 4. Has been.
[0017]
Next, the housing 2 will be described with reference to FIG. The housing 2 includes a drive frame 11, a rear frame 12, and a rear cover 13. The drive frame 11 and the rear frame 12 hold and fix the stator 3 and the rotor 5 and at the same time attach to the engine.
[0018]
The drive frame 11 and the rear frame 12 are directly joined by a plurality of fastening tools such as stud bolts 14 and nuts 15. The drive frame 11 and the rear frame 12 have a large number of holes 16 and 17 for ventilating cooling air. Further, the shaft 4 is rotatably supported on the inner peripheral sides of the drive frame 11 and the rear frame 12 via ball bearings 18 and 19. An oil seal 20 is attached to the tip side of the shaft 4 relative to the ball bearing 18 on the front side.
[0019]
Between the rear frame 12 and the rear cover 13, two brushes 21, a rectifying device 22, an output terminal (not shown), and the like are attached. Between the rear frame 12 and the rear cover 13, a rectifier (rectifier) 22, an IC regulator (output voltage regulator) 23, and the like are assembled by means such as screws. The two brushes 21 are housed and held in a brush holder 24 fixed in the rear cover 13.
[0020]
Next, the rectifier 22 will be described with reference to FIG. This rectifier 22 is a collection of a plurality of rectifier elements (not shown) such as diodes, and converts (rectifies) an alternating current output from a three-phase stator coil 26 described later into a direct current. is there. This rectifier 22 is electrically connected to an electric load and a battery (none of them are shown) mounted on the motorcycle.
[0021]
Next, the IC regulator 23 will be described with reference to FIG. The IC regulator 23 controls the excitation current flowing through the rotor coil 7 by turning on and off a switching element (not shown) such as a transistor placed between the rotor coil 7 and ground (not shown) described later. Thus, the output voltage of the alternator 1 for a motorcycle is made constant.
[0022]
Next, the stator 3 will be described with reference to FIG. The stator 3 includes a stator core (armature core) 25 disposed opposite to the outer periphery of the rotor 5, a three-phase stator coil (armature winding) 26 wound around the stator core 25, and the like. . The stator core 25 is formed by stacking a plurality of thin plates made of a magnetic material, and is press-fitted into the inner periphery of the housing 2 to be integrated.
[0023]
Further, the stator core 25 forms a magnetic flux path that is formed so that the magnetic flux emitted from the claw-shaped magnetic pole portions 31 and 32 of the pole core 6 effectively intersects with the three-phase stator coil 26. A large number of slots (not shown) are formed at equal intervals on the inner peripheral side of the stator core 25. The three-phase stator coil 26 is connected by Y connection or Δ connection, and a three-phase AC output is induced as the rotor 5 rotates.
[0024]
The tip of the shaft 4 is directly connected to a rotating shaft (not shown) such as a crankshaft of the engine. Two slip rings 27 are attached to the outer periphery of the other end (rear end) of the shaft 4. These slip rings 27 are electrically connected by their respective outer circumferences being in sliding contact with the two brushes 21.
[0025]
Next, the rotor 5 will be described with reference to FIG. The rotor 5 is a part that functions as a field, and is composed of a Landel-type pole core (field core) 6, a rotor coil (field winding) 7, the above-described two slip rings 27, and the like.
The pole core 6 is press-fitted and fixed to the outer periphery of the central portion of the shaft 4 by spline fitting or the like. A plurality of claw-shaped magnetic pole portions 31 and 32 are provided on both sides of the pole core 6 so as to mesh with each other. Two cooling fans 33 and 34 for sucking cooling air into the housing 2 are integrally attached to both end surfaces of the pole core 6.
[0026]
The rotor coil 7 is a rotor coil according to the present invention, in which a copper wire having a wire diameter of, for example, 0.5 mm to 2.0 mm is used and accommodated in a coil bobbin 9 disposed in the center of the pole core 6. The coil portion 35 is wound and the two lead portions 36 are drawn to the rear end side (slip ring 27 side) of the coil portion 35. Most of these lead-out portions 36 are covered with a circular tube-shaped silicon tube (covering material) 37, and the terminal is respectively connected to two shaft connection bars (slip ring terminals) 38 by means of welding or the like. It is connected. Note that the ends of the two drawer portions 36 and the two shaft connection bars 38 are covered and fixed by an impregnating agent (epoxy resin or the like) 39 as shown by oblique lines in FIG. .
[0027]
The coil bobbin 9 includes a wound portion 41 around which the coil portion 35 of the rotor coil 7 is wound, a flange-like flange portion 42 provided on the distal end side of the wound portion 41 in the cylinder direction, and the wound portion. 41 includes a flange-like flange portion 43 provided on the rear end side in the cylinder direction, and is integrally formed of nylon resin or the like. The wound portion 41 is a cylindrical portion of the present invention, and is attached to the outer periphery of the central portion of the pole core 6 and has a cylindrical cross section extending in a direction parallel to the axial direction of the shaft 4.
[0028]
The flange portion 42 has a plurality of projecting portions 44 projecting radially on the outer periphery, provided between two adjacent projecting portions 44, and an impregnating agent made of an epoxy resin (not shown) for fixing the coil portion 35. Is inserted into the coil bobbin 9.
[0029]
The flange portion 43 is a bowl-shaped portion according to the present invention. Like the flange portion 42, the flange portion 43 has a plurality of overhang portions 46 on the outer periphery, and an impregnating agent is placed in the coil bobbin 9 between two adjacent overhang portions 44. It has a plurality of insertion holes 47 for insertion. In addition, thick portions 48 having a larger thickness than the other portions are formed at two locations on the outer periphery of the flange portion 43. The thick portion 48 is formed with a U-shaped groove 49 into which the silicon tube 37 covering the lead-out portion 36 of the rotor coil 7 is inserted.
[0030]
The U-shaped groove 49 is a cutout portion of the present invention, and as shown in FIG. 2, the U-shaped groove 49 is formed in a portion protruding in the radial direction (vertical direction) substantially perpendicular to the axial direction of the shaft 4 of the flange portion 43. Is formed. As shown in FIG. 3, the U-shaped groove 49 is provided on the outer peripheral side groove portion 50 having parallel wall surfaces, and on the inner peripheral side with respect to the outer peripheral side groove portion 50, and the inner peripheral surface having a substantially circular wall surface. A side groove portion (locking portion) 51 is provided. The opening size of the outer circumferential groove portion 50 is smaller than the wire diameter of the drawing portion 36 of the rotor coil 7, and the opening size of the inner circumferential groove portion 51 is larger than the wire diameter of the drawing portion 36 of the rotor coil 7. This is approximately the same size as the outer diameter. The wall surface of the U-shaped groove 49 may be formed in a taper shape in which the opening size on the outer peripheral side is larger than the opening size on the inner peripheral side.
[0031]
The flange portion 43 is formed with a positioning groove 52 that is inclined by a predetermined inclination angle from the one thick portion 48 toward the wound portion 41 and has a substantially semicircular arc cross section. The positioning groove 52 is positioned by fitting a winding start portion of the coil portion 35 of the rotor coil 7.
[0032]
[Fixing method of Example]
Next, a method for fixing the drawing portion 36 of the rotor coil 7 will be briefly described with reference to FIGS.
[0033]
When the rotor coil 7 is wound around the coil bobbin 9, the drawing portion 36 on the winding start side is first inserted into the silicon tube 37 and then inserted into the U-shaped groove 49 of the flange portion 43 of each silicon tube 37. Then, the drawer | drawing-out part 36 is inserted in the inner peripheral side groove part 51 wider than an own wire diameter through the outer peripheral side groove part 50 narrower than an own wire diameter. Thereby, the drawer | drawing-out part 36 is firmly fixed in the inner peripheral side groove part 51, and does not slip out to the outer peripheral side groove part 50 side.
[0034]
Next, after the winding start portion of the coil portion 35 is fitted into the positioning groove 52 and the winding start portion is positioned, the rotor coil 7 is wound around the outer periphery of the wound portion 41 with a predetermined number of turns and a predetermined winding layer. The coil part 35 is formed by winding a certain number. Next, after the drawing end portion 36 on the winding end side is inserted into the silicon tube 37, the silicon tube 37 is inserted into the U-shaped groove 49 of each flange portion 43. Then, like the drawing portion 36 on the winding start side, the inner circumferential side groove portion 51 is firmly fixed. As a result, the fixing of the drawing portion 36 of the rotor coil 7 and the winding of the rotor coil 7 around the coil bobbin 9 are completed.
[0035]
(Effects of Example)
Next, the operation of the alternator 1 for a motorcycle according to this embodiment will be briefly described with reference to FIGS. When the engine mounted on the two-wheeled vehicle is operated, the rotor 5 is rotated by the rotation of the shaft 4. That is, the pole core 6, the rotor coil 7, and the two slip rings 27 rotate.
[0036]
Then, when a voltage is applied to the rotor coil 7 from the battery and an exciting current flows through the rotor coil 7, the claw-shaped magnetic pole portions 31 and 32 on both sides of the pole core 6 are excited. That is, for example, the claw-shaped magnetic pole portions 31 on one side are all N poles, and for example, the claw-shaped magnetic pole portions 32 on the other side are S poles. A rotating magnetic field is generated in the stator core 25 of the stator 3 that rotates relative to the rotor 5, and an alternating current is induced in the three-phase stator coil 26. This three-phase alternating current is converted into a direct current by the rectifier 22 to charge the battery and supply power to the electric load of the motorcycle.
[0037]
[Effects of Examples]
As described above, in the alternator 1 for a motorcycle, the lead-out portion 36 of the rotor coil 7 is inserted into the U-shaped groove 49 of the coil bobbin 9, so that the lead-out portion 36 of the rotor coil 7 is the inner circumferential groove 51 of the U-shaped groove 49. It is firmly fixed on the surrounding wall. Thus, the tape-shaped thing wound around the drawer | drawing-out part 36 of the rotor coil 7 can be abolished by fixing the drawer | drawing-out part 36 of the rotor coil 7 by a simple operation | work. As a result, it is possible to reduce the work man-hour for the work of fixing the drawing portion 36 of the rotor coil 7 and to shorten the work time thereof, so that the work cost of the fixing work of the drawing portion 36 of the rotor coil 7 can be reduced. 7 and the price of the rotor 5 including the coil bobbin 9 can be reduced.
[0038]
Thereby, the product cost of the alternator 1 for a motorcycle including the inexpensive rotor 5 can be significantly reduced. Further, since the drawn portion 36 of the rotor coil 7 is not wound around the flange portion 43 of the coil bobbin 9, the drawn portion 36 of the rotor coil 7 is damaged even if the vibration of the two-wheeled vehicle or the rotational fluctuation of the shaft 4 and the rotor 5 is very large. And disconnection can be suppressed.
[0039]
[Modification]
In this embodiment, the present invention is applied to the alternator 1 for a two-wheeled vehicle. However, the present invention is applied to a coil bobbin for winding coils such as other AC generators for vehicles, magnet switches for vehicle starters, ignition coils, and electromagnetic actuators. You may apply to the coil apparatus for vehicles provided.
[0040]
In this embodiment, the shaft 4 is directly connected to the output shaft of the engine. However, a pulley may be provided on the shaft 4 so that the power of the drive source such as the engine is transmitted to the shaft 4 via transmission means such as a belt. good. Further, as the drive source, power other than the engine such as an electric motor or a hydraulic motor may be used.
[0041]
In this embodiment, the U-shaped groove 49 notched in the radial direction (vertical direction) substantially orthogonal to the axial direction of the shaft 4 is used as the notched portion. A V-shaped groove, a U-shaped groove or a polygonal groove cut out in a substantially orthogonal radial direction (vertical direction) may be used. Further, a U-shaped groove, a V-shaped groove, a U-shaped groove, a polygonal groove, or the like that is cut in a lateral direction substantially orthogonal to the radial direction of the shaft 4 may be used as the notched portion.
[Brief description of the drawings]
FIG. 1 is a front view showing a coil bobbin and a coil (Example).
FIG. 2 is a cross-sectional view taken along the line AA of FIG. 1 (Example).
FIG. 3 is a front view showing a main part of the coil bobbin of FIG. 1 (Example).
FIG. 4 is a cross-sectional view showing the overall structure of a two-wheeler alternator (Example).
[Explanation of symbols]
1 Two-wheeler alternator (coil device for vehicle)
4 Shaft (Rotating shaft)
5 Rotor (rotor)
6 Pole core (rotor core)
7 Rotor coil (rotor coil, rotor winding)
9 Coil bobbin 35 Coil part 36 Drawer part 37 Silicon tube (covering material)
41 Wound Part 43 Flange (Ring)
49 U-shaped groove (notch)
51 Inner peripheral side groove (locking part)

Claims (5)

A coil bobbin having a tubular part extended in the tubular direction, and a flanged part formed at one end of the tubular part in the tubular direction, a coil part wound around the outer periphery of the tubular part of the coil bobbin, and this A coil device for a vehicle including a coil having a lead-out portion drawn out from one end of the coil portion;
The drawn-out portion of the coil is covered with a tubular covering material,
Wherein the outer periphery of the flange portion of the coil bobbin, the cutout portion is formed in the write Mutame insert the covering material covering the lead-out portion of the coil,
The vehicular coil device characterized in that the opening size of the notch portion is made smaller than the wire diameter of the lead portion of the coil. In the coil device for vehicles according to claim 1,
The coil bobbin is integrally formed of resin,
The vehicular coil device , wherein the cutout portion is formed in a portion protruding in a radial direction from the hook-shaped portion . The vehicle coil device according to claim 1 or 2,
The vehicular coil device is characterized in that the notch is formed in a tapered shape having an opening size on the outer peripheral side larger than an opening size on the inner peripheral side . The coil device for a vehicle according to any one of claims 1 to 3,
The vehicular coil device according to claim 1, wherein the cutout portion includes a locking portion that locks a drawing portion of the coil. A rotating shaft that is rotationally driven by a drive source mounted on the vehicle, a rotor core that rotates integrally with the rotating shaft, a cylindrical portion that is held by the rotor core and extends in the cylindrical direction, and A coil bobbin having a hook-shaped part formed at one end of the cylindrical part in the cylindrical direction, a coil part wound around the outer periphery of the cylindrical part of the coil bobbin, and a lead-out part drawn out from one end of the coil part An AC generator for a vehicle comprising a rotor coil having
The drawn out portion of the rotor coil is covered with a tubular covering material,
Wherein the outer periphery of the flange portion of the coil bobbin, the automotive alternator wherein the notch is formed for inserting the covering material to cover the lead portions of the rotor coils.

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