JP3760959B2 - Generator - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a rotor coil wound around a rotor core, two current collecting rings for supplying power to the rotor coil, and a generator including two fixed-side brushes that slide on the outer periphery of these current collecting rings. Is.
[0002]
[Prior art]
In general, as shown in FIG. 8, the vehicle alternator 100 includes a three-phase rectifier 101, a voltage regulator 102 that regulates a generated voltage, a shaft 104 that is rotatably supported in a housing 103, A stator 105 fixed to the inner surface of the housing 103, a rotor 106 that rotates relative to the stator 105, a current collector 107 that is fixed to the outer periphery of the end of the shaft 104, and an outer periphery of the current collector 107 slide. A brush device 108.
[0003]
Here, the three-phase rectifier 101 includes a three-phase rectifier circuit that rectifies the generated alternating current with the positive-side diode 111 and the negative-side diode 112 and converts it into direct current. The shaft 104 has a poly V belt pulley 113 assembled to the outer periphery of the tip. The stator 105 includes a stator core 114, a three-phase stator coil 115, and the like. The rotor 106 includes a Landel-type pole core 116, a rotor coil 117, and the like. Cooling fans 118 and 119 for sucking cooling air are attached to both end surfaces of the pole core 116.
[0004]
The current collector 107 includes two metal current collecting rings 121, two connection bars 122, and the like. The metallic current collecting ring 121 is made of a metallic member such as a copper alloy or stainless steel, and is press-fitted or directly formed on the outer periphery of the end of the shaft 104 to rotate integrally with the shaft 104. It has a structure to do.
[0005]
On the other hand, the brush device 108 includes two carbonaceous brushes 123, a brush support 124 that accommodates these carbonaceous brushes 123, and the two carbonaceous brushes 123 on the outer periphery of the two metal current collecting rings 121. The coil spring 125 is configured to be pressed and electrically connected. The two carbonaceous brushes 123 are made of a carbonaceous member. The two carbonaceous brushes 123 are connected by a brush connection terminal (not shown) and a pigtail 126 made of copper wire. Further, the brush support 124 has a structure in which a brush connecting terminal is insert-molded with an electrically insulating resin material member, and a current collecting ring cover 128 that protects the two metallic current collecting rings 121 together with the rubber packing 127 is integrally formed. Have.
[0006]
In recent years, the vehicle AC has been designed to reduce the mounting space for auxiliary equipment due to the downsizing of the engine room of the vehicle, to reduce the size and weight by regulating fuel consumption, and to extend the life of the vehicle by extending the warranty period. A generator is desired. Note that, as a means for reducing the size and weight of a vehicle alternator, it is generally required to reduce the size of the vehicle alternator and reduce the axial dimension of the vehicle alternator.
[0007]
[Problems to be solved by the invention]
However, in the conventional vehicle alternator 100, in order to reduce the voltage drop of the exciting circuit that supplies the exciting current to the rotor coil 117 and prevent the power generation output from being lowered, as shown in FIG. A brush supporter 124 is installed in the vicinity of the voltage adjusting device 102 that controls the excitation current to the coil 117. For this reason, in order to extend the life of the two carbonaceous brushes 123, the radial dimension perpendicular to the axial direction of the brush supporter 124 is large and cannot be set long. Therefore, the axial dimensions of the brush support 124 and the two metal current collecting rings 121 occupy a large proportion of the total axial length of the vehicle alternator 100, and the vehicle alternator 100 is small. The problem is that it has become a major obstacle to the transformation.
[0008]
Further, since the two carbonaceous brushes 123 are made of a carbonaceous member, the electrical resistance of the contact portion of the two carbonaceous brushes 123 that contacts the outer periphery of the two metal current collecting rings 121 is reduced. Therefore, an appropriate area (size) and a pressing force (spring load) of the coil spring 125 are necessary. Therefore, if the surface area of the contact portion of the two carbonaceous brushes 123 is reduced in order to reduce the size of the vehicle alternator 100, the current density increases and the temperature of the two carbonaceous brushes 123 increases. There arises a problem that the durability life is shortened.
[0009]
Here, in small DC rotating electric machines (for example, motors), there is an example in which the stationary brush is made of a metallic member (a thin metal plate or a copper wire) and the rotating side commutator is made of a copper alloy. Abnormal wear occurs due to the step of the rotation side commutator. For this reason, it is used only in the case of low-voltage and constant-speed rotation, and the above-described structure has not been adopted for those used at high-speed rotation such as a vehicle alternator.
[0010]
OBJECT OF THE INVENTION
An object of the invention described in claim 1 is to provide a generator capable of achieving a long life by suppressing the influence of vibration of the fixed side brush by reducing the weight of the fixed side brush and reducing the spring load. Another object of the present invention is to provide a generator that is self-lubricating and can ensure stable wear and power supply even at high speeds. It is another object of the present invention to provide a generator capable of significantly reducing the size and weight of an electrical connection device.
[0013]
  Claim 1An object of the present invention is to provide a generator capable of preventing contact pressure from being applied to the brush fixing portion. It is another object of the present invention to provide a generator that can stably supply power from a stationary brush to a current collecting ring.
  An object of the invention described in claim 2 is to provide a generator capable of significantly reducing the weight of the fixed-side brush.
  Claims 1 and 2It is an object of the present invention to provide a generator that can prevent catching during disassembling work or assembling work and can smoothly perform disassembling work or assembling work.
[0014]
  Claim3An object of the invention described in the above is to provide a generator capable of reducing the product cost by reducing the price of the brush connection terminal.
  Claim4An object of the invention described in the above is to provide a generator that can prevent intrusion of foreign matters such as water and can prevent scattering of wear powder generated by sliding between a stationary brush and a current collecting ring.
[0015]
  Claim5The purpose of the invention described in the above is to improve the conductivity and strength by making the current collecting ring from carbon powder using a copper alloy foam skeleton metal as a metal base, compared with the case where the current collecting ring is made of carbon alone. It is to provide a generator.
  Claim6And claims7An object of the present invention is to provide a generator capable of reducing the size of the electrical connection device by allowing the brush fixing portion and the fixed side brush to be coupled without providing a large mounting space in the radial direction of the shaft. Is to provide.
[0016]
  Claim8An object of the invention described in 1 is to provide a generator capable of reliably connecting a stationary brush and a brush connection terminal..
[0017]
  Claim 9An object of the invention described in the above is to provide a generator that can significantly reduce the size and weight of the stationary brush.
[0018]
  Claim 9An object of the invention described in the above is to provide a generator capable of preventing catching at the time of disassembling work or assembling work and performing the disassembling work or the assembling work smoothly..
[0019]
[Means for Solving the Problems]
  Claim 1And claim 2According to the invention, the stationary brush is slid on the outer periphery of the current collecting ring by the rotation of the shaft, but the stationary brush is made of a metallic member and the current collecting ring is made of a carbonaceous member. This ensures stable wear and power supply even at high speeds. In addition, since the weight of the fixed brush is light, the spring load of the fixed brush is reduced, so that the current collecting ring and the fixed brush are less worn, and the problem of the fixed brush due to vibration is avoided. Is done.
[0020]
In other words, since the current collecting ring is made of a carbonaceous member, the friction coefficient of the current collecting ring can be reduced, and thus self-lubricating properties are provided. Since the current collecting ring is made of a carbonaceous member, even if a stationary brush is made of a metallic member and the stationary brush is slid at high speed on the outer periphery of the current collecting ring, stable wear can be achieved. The power supply to the field coil can be secured. Further, wear is greatly reduced by reducing the weight of the fixed-side brush and reducing the spring load, and the life of the fixed-side brush can be extended by suppressing problems caused by vibration of the fixed-side brush. Accordingly, it is possible to extend the life of the generator.
[0021]
In addition, since the fixed side brush is made of a metallic member, it is difficult to wear. Therefore, it is not necessary to set the size and length in advance to predict the wear unlike a brush made of a conventional wear member. Thereby, since the stationary brush can be thinned, the electrical connecting device can be significantly reduced in weight and size. Therefore, since the diameter of the generator can be reduced, the generator can be reduced in weight and size.
[0024]
  Claim 1According to the invention described in the above, the stationary brush is held by the brush fixing portion, and the stationary brush is in contact with the current collecting ring on both the front side and the rear side in the rotation direction of the current collecting ring. Excessive vibration is generated in the direction in which the side brush is easy to peel off, and even if one side peels off from the current collector ring, the other will stick to the outer periphery of the current collector ring, so stable from the fixed side brush to the current collector ring Power supply can be performed.In addition, by forming an extension piece having a chamfered shape on the fixed side brush, the fixed side brush can smoothly move to either the front side or the rear side in the axial direction of the current collecting ring. It is possible to prevent catching during assembly work, and to perform disassembly work or assembly work smoothly.
[0025]
  According to the second aspect of the present invention, the fixed side brush is held by the brush fixing portion, and the fixed side brush is in contact with the current collecting ring at least one of the front side and the rear side in the rotation direction of the current collecting ring. Therefore, stable power can be supplied from the stationary brush to the current collecting ring. Also,By forming the chamfered extension piece on the fixed side brush, the fixed side brush can move smoothly to either the front side or the rear side in the axial direction of the current collector ring. It is possible to prevent catching during work, and to perform disassembly work or assembly work smoothly.
[0026]
  Claim3According to the invention, the brush connection terminal mechanically and electrically connects the fixed side brush, so that stable power feeding can be performed between the brush connection terminal and the fixed side brush. Further, since the price of the fixed side brush or the brush connection terminal can be reduced by making the brush connection terminal with a metal member different from the metal member forming the fixed side brush, the product cost of the generator can be reduced.
[0027]
  Claim4According to the invention described in the above, the storage chamber forming member forms a cylindrical storage chamber that stores the current collecting ring and the fixed side brush, so that foreign matter such as water can be collected between the current collecting ring and the fixed side brush. Intrusion into the contact portion can be suppressed, and scattering of wear powder generated by sliding between the stationary brush and the current collecting ring can be suppressed.
[0028]
  Claim5According to the invention described in the above, by making the current collecting ring from carbon powder using a copper alloy foam skeleton metal as a metal base, the conductivity and strength can be improved as compared with the case where the current collecting ring is made of carbon alone. .
  Claim6According to the invention described in the above, by forming the brush fixing portion in such a shape that it is coupled only along the axial direction of the fixed side brush and the shaft, a large mounting space in the radial direction of the shaft is not required, and power generation Since the size of the machine can be reduced, the generator can be reduced in weight and size.
[0029]
  Claim7According to the invention described in the above, the brush fixing portion is provided on the storage chamber forming member that forms the cylindrical storage chamber that stores the current collecting ring and the stationary brush, so that foreign matter such as water is fixed. It is possible to suppress entry into the connecting portion between the side brush and the brush fixing portion.
[0030]
  Claim8According to the invention described in the above, by connecting the brush connection terminal and the fixed side brush mechanically and electrically along the axial direction of the shaft without requiring a large mounting space in the radial direction of the shaft, Stable power feeding can be performed between the brush connection terminal and the stationary brush.
[0034]
  Claim9According to the invention described in (1), since the fixed-side brush can be made thin by making the fixed-side brush from the plate material, the electrical connecting device can be significantly reduced in weight and size. Therefore, since the diameter of the generator can be reduced, the generator can be reduced in weight and size.
  By pressing the contact against the current collecting ring by the spring force of the extension of the fixed side brush, the fixed side brush is urged toward the current collecting ring without a spring. Thereby, since the contact pressure of the stationary brush with respect to the current collection ring can be sufficiently ensured, a stable power supply state can be ensured.
[0037]
  Claim9According to the invention described in the above, by forming the extension piece having a chamfered shape on the opening side of the contact provided at the tip of the extension portion of the fixed side brush, the fixed side brush is moved forward in the axial direction of the current collecting ring. Since it can move smoothly to either the rear side or the rear side, it is possible to prevent catching during the disassembling operation or the assembling operation, and the disassembling operation or the assembling operation can be performed smoothly.
[0039]
DETAILED DESCRIPTION OF THE INVENTION
[Configuration of Example]
FIGS. 1 to 6 show an embodiment in which the generator of the present invention is applied to a vehicle alternator. FIG. 1 is a diagram showing the structure of the main part of the electrical connection device of the vehicle alternator. 2 is a diagram showing the overall structure of the vehicle alternator, FIGS. 3 and 4 are diagrams showing the main structure of the vehicle alternator, and FIG. 5 is a three-phase rectifier in the rear housing. It is the figure which showed the state which assembled | attached the voltage regulator and the brush apparatus.
[0040]
The vehicle alternator 1 is driven by an engine via a poly V belt (not shown), and the generated alternating current is rectified by the three-phase rectifier 9 and converted into direct current, and the battery is mounted on the vehicle. An alternator for charging (not shown) and supplying necessary electric power to an electric load. The vehicle alternator 1 includes a housing 2, a stator 3, a rotor 4, a shaft 5, a current collector 6, a blower 7, a brush device 8, a three-phase rectifier 9, a voltage regulator 10, and the like. .
[0041]
[Description of housing]
Next, the housing 2 will be described with reference to FIGS. The housing 2 includes a front housing (also called a drive frame) 11 and a rear housing (also called a rear frame) 12 made of aluminum die casting, and is fastened by a plurality of stud bolts 13 and nuts 14.
[0042]
A front bearing (bearing) 15 as a bearing that rotatably supports the front side (front end side) of the shaft 5 is fixed to the boss portion (bearing holding portion) 16 by press-fitting and caulking. . A rear bearing 16 as a bearing that rotatably supports the rear side (rear end side) of the shaft 5 is fixed to the boss portion (bearing holding portion) 18 by press-fitting and caulking. In order to suck cooling air into the housing 2, a large number of ventilation openings 19 are provided in the front housing 11, and a large number of ventilation openings 20 and a large number of exhaust openings 21 are provided in a substantially annular shape in the rear housing 12. Yes.
[0043]
Further, a stay portion 22 fastened and fixed to an upper bracket (not shown) of the engine is provided at the upper portion of the front housing 11, and a stay portion 23 fastened and fixed to a lower bracket (not shown) of the engine is provided at the lower portion. It is integrally molded. A stay portion 24 that is fastened and fixed to the lower bracket of the engine is integrally formed at the lower portion of the rear housing 12. Bolt holes 25 to 27 through which the bolts are inserted pass through these stay portions 22 to 24.
[0044]
[Description of stator]
Next, the stator 3 will be described with reference to FIG. The stator 3 is a stator composed of a stator core 31 fixed to the inner surface of the housing 2 and a three-phase stator coil 32 wound around the stator core 31.
[0045]
The stator core 31 constitutes an armature core, and is composed of a laminated core formed by laminating a plurality of thin steel plates made of a magnetic material. The stator core 31 is press-fitted into the inner peripheral surface of the front housing 11 and integrated. A large number of slots (not shown) are formed at equal intervals on the inner peripheral side of the stator core 31.
[0046]
The three-phase stator coil 32 is a three-phase armature winding that is connected by Y-connection or Δ-connection and induces a three-phase AC output as the rotor 4 rotates. The winding ends of the stator coils 32 are electrically connected to the three-phase rectifier circuit of the three-phase rectifier 9 using soldering or the like.
[0047]
[Description of rotor]
Next, the rotor 4 will be described with reference to FIG. The rotor 4 is a portion that functions as a field device and is a rotor that rotates integrally with the shaft 5. The rotor 4 includes a shaft 5, a Landel-type pole core 33 fixed to the shaft 5, a field coil 34 wound around the pole core 33, and a current collector 6 for supplying an excitation current to the field coil 34. , And a blower 7 that generates cooling air.
[0048]
The pole core 33 is a rotor core (also referred to as a field magnetic pole, a field iron core, or a rotor iron core) according to the present invention, and a field coil 34 is wound around the center and is made of a ferromagnetic material. In the pole core 33, when an exciting current flows through the field coil 34, one claw-shaped magnetic pole portion 35 becomes all N poles, and the other claw-shaped magnetic pole portion 36 becomes all S poles. A blower 7 for sucking cooling air into the housing 2 is attached to the rear side wall surface of the other claw-shaped magnetic pole portion 36 by means such as welding.
[0049]
The field coil 34 is a rotor coil according to the present invention. The field coil 34 is wound around the central portion of the pole core 33 via a coil bobbin 37, and magnetizes the pole core 33 when an excitation current flows (also referred to as a rotor winding). ). The coil bobbin 37 is made of an electrically insulating resinous material that electrically insulates the field coil 34 and the pole core 33.
[0050]
[Description of shaft]
Next, the shaft 5 will be described with reference to FIG. The shaft 5 is rotatably supported by boss portions 16 and 18 of the housing 2 via front and rear bearings 15 and 17. A V-ribbed pulley (poly V-belt pulley) 38 for transmitting the rotational power of the engine to the shaft 5 is provided between one end portion (front end portion and front side end portion) of the shaft 5 between the seated nut 39 and the front bearing 15. Fastened and fixed between.
[0051]
The V-ribbed pulley 38 is drivingly connected to a poly V-belt pulley (not shown) mounted on an engine output shaft (crankshaft) via a transmission means (not shown) such as a poly V belt. Note that clutch means such as an electromagnetic clutch may be disposed between the shaft 5 and the V-ribbed pulley 38.
[0052]
[Description of current collector]
Next, the current collector 6 will be described with reference to FIGS. The current collector 6 includes two carbonaceous current collecting rings 41 used for connecting the battery and voltage adjusting device 10 and the field coil 34 through the brush device 8, and the carbonaceous current collecting rings 41. It consists of two connection bars (also referred to as slip ring terminals) 42 (see FIG. 3) connected to each.
[0053]
The two carbonaceous current collecting rings 41 are so-called slip rings, which are provided on the outer periphery of the other end portion (rear end portion, rear end portion) of the shaft 5 and are two circles that are electrically independent from each other. An annular current collector ring body. These carbonaceous current collecting rings 41 are held side by side with a predetermined gap in the axial direction of the shaft 5 on the outer periphery of the other end portion of the shaft 5 by an electrically insulating resinous member to be described later. Insulated. One end of the connection bar 42 is insert-molded to the two carbonaceous current collecting rings 41 so that both are mechanically and electrically connected. As the material of the carbonaceous current collecting ring 41, a carbonaceous member (for example, carbon powder, natural graphite, electrographite, metal graphite or the like using a copper alloy foam skeleton metal as a metal base) is used. . In the connection bar 42, the terminal wire of the field coil 34 is electrically joined by means such as soldering.
[0054]
  [Explanation of blower]
  Next, the blower 7 will be described with reference to FIGS. This blower7Is formed with an electrically insulating resinous member, and two carbonaceous current collecting rings 41 and two connection bars 42 are insert-molded with a resinous member. The blower 7 is also a terminal protection member that protects a connection portion between the two carbonaceous current collecting rings 41 and the two connection bars 42. Examples of the resinous member include, for example, polyphenylene, which has excellent electrical insulation and heat resistance, high strength and excellent dimensional stability.SulphiIt is desirable to use a resin (PPS resin).
[0055]
The blower 7 includes a plurality of blades 43 constituting cooling blades of a centrifugal fan, an annular support plate portion (base plate) 44 that supports these blades 43, and two carbonaceous current collecting rings 41 and 2. Each of the connection bars 42 includes a cylindrical current collecting ring fixing portion 45 formed by insert molding of an axial portion. As shown in FIGS. 3 and 4, a plurality of blades 43 are arranged in an annular shape on the end surface of the outer peripheral portion of the support plate portion 44. The support plate portion 44 is fixed to the current collector ring side end surface (side surface on the rear end side) of the pole core 33 and insert-molded in the radial direction of the two connection bars 42. The current collecting ring fixing portion 45 is integrated with the axial portions of the two carbonaceous current collecting rings 41 and the two connection bars 42 and is press-fitted and fixed to the outer periphery of the other end portion of the shaft 5.
[0056]
[Description of brush device]
Next, the brush device 8 will be described with reference to FIGS. The brush device 8 includes two metallic brushes 51 that are in contact with the outer circumferences of the two carbonaceous current collecting rings 41 and are electrically independent from each other, and a housing chamber forming member that supports and fixes these metallic brushes 51. 52, and connection terminals 53, 54, etc., which are insert-molded in the storage chamber forming member 52.
[0057]
Each metallic brush 51 is a fixed-side brush of the present invention, and is a brush that is integrally formed only by pressing and supplies an exciting current to the field coil 34 via the two carbonaceous current collecting rings 41. . As the material of the metallic brush 51, a metallic member (for example, a conductive thin elastic plate material such as phosphor bronze or beryllium copper which is a spring material of a copper alloy) is used.
[0058]
The metallic brush 51 includes a semi-arc shaped brush main body 55 formed so as to surround the carbonaceous current collecting ring 41, and a brush fixing portion 56 protruding from the brush main body 55 toward the storage chamber forming member 52. Are formed respectively. The brush main body 55 is provided with plate-like extensions (arm portions) 551 and 552 extending in an arc shape along the outer periphery of the carbonaceous current collecting ring 41 from the brush fixing portion 56, and at the tips thereof. Two contactors 57 and 58 that are in sliding contact with the outer peripheral surface of the current collecting ring 41 are provided.
[0059]
The brush body 55 extends from the base end (top end) 55a to both the front side (leading side) and the rear side (trailing side) in the rotational direction of the carbonaceous current collecting ring 41. The carbonaceous current collecting ring 41 is in contact with the contacts 57 and 58 on both the rear side and the rear side. That is, as shown in FIG. 1, the brush body 55 has a dimension difference between the tip A of both the extensions 551 and 552 (between both contacts 57 and 58) and the carbonaceous current collector ring diameter B ( It is formed in a semicircular arc shape (horse-shoe shape) so as to come into contact with the outer peripheral surface of the carbonaceous current collector ring 41 by both contactors 57 and 58 by being pressed against the carbonaceous current collector ring 41 by the tightening margin of B-A). Yes. Note that the brush body 55 may extend from the base end portion 55 a to only one of the front side and the rear side in the rotation direction of the carbonaceous current collecting ring 41 and may be in contact with the carbonaceous current collecting ring 41.
[0060]
The two contacts 57 and 58 are sliding portions that slide on the outer peripheral surface of each carbonaceous current collecting ring 41. And these contactors 57 and 58 ensure the contact pressure with each carbonaceous current collection ring 41 by the spring characteristic of the brush main body 55. Four extension pieces 57a, 57b, 58a, and 58b protrude from both opening sides of the two contactors 57 and 58 in the axial direction. The four extension pieces 57a, 57b, 58a, and 58b are extended from both ends in the axial direction of the current collecting ring 41 toward both sides in the axial direction, and are extended outwardly with respect to the axial direction of the respective contacts 57 and 58. It is formed in a round shape (chamfered shape).
[0061]
Since the brush fixed portion 56 uses a copper alloy spring material as the material of the metallic brush 51, that is, the connection terminals 53, 54 and the connection terminals 53, 54 are electrically and electrically connected by a method using the spring characteristics that are characteristic of the spring material. It is fixed mechanically. For this reason, the brush fixing portion 56 of this embodiment is formed in a faston shape that is the minimum space in terms of performance and manufacturing.
[0062]
That is, as shown in FIG. 1, the brush fixed portion 56 has a protruding piece 56a protruding in the axial direction from the base end portion 55a of the brush body 55, and both sides of the protruding piece 56a are substantially oval in cross section. It has elastically deformable locking pieces 56b, 56c bent so as to draw the circumference of the. And the brush fixed part 56 is inserted between the protruding piece 56a and the locking pieces 56b, 56c by inserting the tip ends of the connection terminals 53, 54 into the protruding piece 56a and the locking pieces 56b, 56c. The front ends of the connection terminals 53 and 54 are sandwiched between them.
[0063]
As described above, one carbonaceous current collecting ring 41 and one metallic brush 51 are electrically connected. Similarly, the other carbonaceous current collecting ring 41 and the other metallic brush 51 are electrically connected. As described above, the two pairs of carbonaceous current collecting rings 41 and the metallic brush 51 constitute an electrical connection device. Thereby, the connection terminal 53, one metallic brush 51, one carbonaceous current collecting ring 41, one connection bar 42, one field coil 34, the other connection bar 42, the other carbonaceous current collecting ring 41, the other An energization path is formed by the path of the metallic brush 51 and the connection terminal 54.
[0064]
FIG. 2 shows a connection state between the carbonaceous current collecting ring 41 and the metallic brush 51 on the pole core 33 side of the shaft 5. However, in order to facilitate understanding, the positional relationship in the circumferential direction between the contactor 57 and the brush fixing portion 56 is schematically illustrated. The arrangement of these portions in the circumferential direction is as shown in FIG. That is, the two metallic brushes 51 are fixed at a predetermined distance apart in the circumferential direction of the shaft 5. As shown in FIG. 3, the two metallic brushes 51 are fixed at a predetermined distance apart in the axial direction of the shaft 5.
[0065]
The storage chamber forming member 52 is made of an electrically insulating resinous member (for example, PPS resin). The housing chamber forming member 52 includes a brush holding portion (also referred to as a brush holder) 59 for holding and fixing the two metallic brushes 51, and a collection extending from the front end side of the brush holding portion 59 to the front side in the axial direction. The electrocyclic cover 61 is integrally formed. The brush holding part 59 insert-molds the connection terminals 53 and 54, and holds the connection terminals 53 and 54 in a state where both end parts of the connection terminals 53 and 54 protrude.
[0066]
The current collecting ring cover 61 is formed in a cylindrical shape having an opening on the pole core 33 side, and houses the two carbonaceous current collecting rings 41 and the two metallic brushes 51 together with the current collecting ring fixing portion 45, and This is a so-called slip ring cover in which a cylindrical storage chamber 48 surrounding the outer periphery of two carbonaceous current collecting rings 41 is formed. In addition, an annular space 49 is defined between the outer periphery of the current collecting ring cover 61 and the inner periphery of the annular blade row of the blower 7 as shown in FIG. The annular space 49 forms a suction side space evenly toward the entire circumference of the annular blade row of the blower 7.
[0067]
The connection terminal 53 is a brush fixing portion and a brush connection terminal according to the present invention, and has a substantially L-shaped cross section. The connection terminal 53 is fastened and fixed to the excitation current output terminal 69 of the voltage regulator 10 by a fixing screw 70. Connected to each other. The connection terminal 54 is a brush fixing portion and a brush connection terminal according to the present invention, and is formed in a substantially inverted L shape so as to extend on the opposite side with respect to the connection terminal 53. The power supply terminal is fastened and fixed electrically to the output terminal 71 by a fixing screw 72.
[0068]
The connection terminals 53 and 54 are formed in a shape that is coupled to the brush fixed portion 56 of the metallic brush 51 only along the axial direction of the shaft 5. That is, as shown in FIG. 1, the tip ends of the connection terminals 53 and 54 are formed in a tapered shape so that they can be easily inserted between the protruding pieces 56a and the locking pieces 56b and 56c of the brush fixed portion 56. ing.
[0069]
Further, FIG. 5 shows connection terminals 53 and 54 exposed side by side in the circumferential direction. These connection terminals 53 and 54 are arranged in the axial direction so as to correspond to the two carbonaceous current collecting rings 41. Then, a brush fixing portion 56 of one metallic brush 51 is fixed to one connection terminal 53, and a brush fixing portion 56 of another metallic brush 51 is fixed to the other connection terminal 53. Therefore, the two metallic brushes 51 are held away from each other in the axial direction corresponding to the axial positions of the two carbonaceous current collecting rings 41 and also correspond to the positions of the connection terminals 53 and 54. In the circumferential direction. With this configuration, two metallic brushes 51 having a semicircular arc shape can be arranged in a cylindrical space.
[0070]
[Description of three-phase rectifier]
Next, the three-phase rectifier 9 will be described with reference to FIGS. 2, 3, 5, and 6. The three-phase rectifier 9 is a so-called rectifier, and includes a DC output terminal 71, a positive-side cooling fin 73, a negative-side cooling fin 74, three positive-side diodes 75, three negative-side diodes 76, and a terminal block. 77 or the like.
[0071]
The DC output terminal 71 is an external connection terminal of the three-phase rectifier 9, and is electrically connected to one end of the battery via a conductive wire (not shown) and the other end is a connection terminal 54 of the brush device 8. The positive-side cooling fin 73 is electrically connected by fastening a fixing screw (not shown). The DC output terminal 71 is a terminal that supplies a charging current to the battery (also referred to as a DC output positive terminal) and constitutes the B terminal of the vehicle alternator 1.
[0072]
The positive-side cooling fins 73 are integrally formed in a predetermined shape so as to surround the accommodation chamber forming member 52 together with the negative-side cooling fins 74, and are arranged along the side surface of the rear housing 12. The positive-side cooling fin 73 is fixed to the inner surface of the rear frame 12 via an insulating member (not shown). The negative-side cooling fin 74 is body-grounded (grounded) via the rear frame 12. That is, the positive side cooling fin 73 is electrically connected to the positive (+) side of the battery, and the negative side cooling fin 74 is electrically connected to the negative (−) side of the battery.
[0073]
The positive-side and negative-side cooling fins 73 and 74 are each made of a conductive metal plate (for example, an aluminum plate) having excellent thermal conductivity, and the heat generation of each of the three positive-side and negative-side diodes 75 and 76. And a rectifying element holding means for holding and fixing three positive electrode and negative electrode diodes 75 and 76 each.
[0074]
The three positive and negative diodes 75 and 76 are positive and negative rectifiers that rectify and convert (rectify) the AC output of the three-phase stator coil 32 to DC output. Each of the three positive electrode side and negative electrode side diodes 75 and 76 has one end side (lead wire) electrically connected to three AC input terminals 78 by soldering, and the other end side is positive side and negative side cooling respectively. The fins 73 and 74 are electrically connected by soldering. The three-phase rectifier circuit is composed of the DC output terminal 71, positive and negative cooling fins 73 and 74, three positive electrodes, three negative diodes 75 and 76, and three AC input terminals 78. Is done.
[0075]
The terminal block 77 is made of an electrically insulating resinous material (for example, PPS resin) into a predetermined shape, inserts and holds the three AC input terminals 78, and the positive side cooling fin 73 and the negative side. The cooling fins 74 are electrically insulated. The terminal block 77 has positive and negative cooling fins 73 and 74 fixed by fixing screws 79.
[0076]
[Description of voltage regulator]
Next, the voltage regulator 10 will be described with reference to FIGS. 2, 3, 5, and 6. The voltage adjusting device 10 is a so-called IC regulator, and includes an exciting current output terminal 69, an integrated circuit (not shown), a casing 62, and the like.
[0077]
The exciting current output terminal 69 is an external connection terminal of the voltage regulator 10, is held by a casing 62 fixed to the rear housing 12, and is fixed to two metal brushes 51 via the connection terminal 53. Are connected mechanically. Thereby, the exciting current output terminal 69 functions as a brush fixing means for fixing the accommodation chamber forming member 52 and the two metallic brushes 51 to the rear housing 12.
[0078]
The integrated circuit is voltage adjusting means for adjusting the generated voltage of the three-phase stator coil 32 by controlling the excitation current supplied to the field coil 34. This integrated circuit incorporates a power transistor as a switching element that controls energization and de-energization of the field coil 34, a back electromotive force absorption diode that attenuates the excitation current flowing in the field coil 34, and the like.
[0079]
The casing 62 is made of an electrically insulating resin material (for example, PPS resin) and has a bracket 66 that is fastened and fixed to the rear housing 12 by a fixing screw 65. In the casing 62, electronic components such as an integrated circuit are molded with an epoxy resin-based resin material.
[0080]
(Effects of Example)
Next, the operation of the vehicle alternator 1 of this embodiment will be briefly described with reference to FIGS.
[0081]
When the engine mounted on the vehicle is started, the rotational power of the engine is transmitted to the V-ribbed pulley 38 via a transmission means such as a poly V belt and is rotatably supported by the housing 2 via the front and rear bearings 15 and 17. The rotor 4 is rotated by rotating the shaft 5 being rotated. At this time, the pole core 33, the field coil 34, and the two carbonaceous current collecting rings 41 rotate integrally with the shaft 5.
[0082]
When the voltage regulator 10 starts to feed the field coil 34, the battery → DC output terminal 71 → connection terminal 54 → one metallic brush 51 → one carbonaceous current collecting ring 41 → one connection bar 42 → Field coil 34 → the other connection bar 42 → the other carbonaceous current collecting ring 41 → the other metallic brush 51 → the connection terminal 53 → the exciting current output terminal 69 → the voltage regulator 10 → the rear frame 12 → the body Excitation current flows. Therefore, when a voltage is applied to the field coil 34 from the battery and an exciting current flows through the field coil 34, the two claw-shaped magnetic pole portions 35 and 36 of the pole core 33 are magnetized. As a result, all of the one claw-shaped magnetic pole portion 35 becomes an N pole, and the other claw-shaped magnetic pole portion 36 becomes an S pole.
[0083]
Then, an alternating current is sequentially induced in the three-phase stator coil 32 wound around the stator core 31 of the stator 3 that rotates relative to the rotor 4, and the generated voltage rises rapidly. This three-phase alternating current is input to the three-phase rectifier circuit via three alternating input terminals 78. That is, the three-phase AC current is rectified and converted into a DC current by being input to the three positive-side diodes 75 and the three negative-side diodes 76.
[0084]
When the generated voltage of the three-phase stator coil 32 (the voltage of the DC output terminal 71, the B terminal voltage) exceeds the battery voltage, the rectified DC current, that is, the charging current is converted into three positive diodes 75 → The battery is supplied to the battery via the positive-side cooling fin 73 → the DC output terminal 71 → the conductive wire. Thereby, the battery is charged by the charging current flowing through the battery, and power is supplied to the electric load mounted on the vehicle.
[0085]
Then, by operating the vehicle alternator 1 for a long period of time, two carbonaceous current collecting rings 41 integrally provided on the outer periphery of the shaft 5 and a connection terminal 53 held by the storage chamber forming member 52, The two metallic brushes 51 mechanically fixed to 54 slide and wear at a high speed.
[0086]
However, since the two carbonaceous current collecting rings 41 are made of carbonaceous members, they have self-lubricating properties. That is, by reducing the friction coefficient of the carbonaceous current collector ring 41 itself, the amount of wear of the carbonaceous current collector ring 41 is greatly reduced as compared with a conventional metal current collector ring made of copper alloy. Further, since the two metallic brushes 51 are made of a metallic member, the amount of wear of the two metallic brushes 51 is greatly reduced by reducing the weight and reducing the spring load. Therefore, the durable life of the two carbonaceous current collecting rings 41 and the two metallic brushes 51 can be extended.
[0087]
Here, the three-phase stator coil 32, the field coil 34, the three-phase rectifier 9 and the voltage regulator 10 of the vehicle alternator 1 generate heat when energized. This heat is cooled by the cooling air being sucked into the housing 2 by the rotation of the rotor 4 and the rotation of the plurality of blades 43 of the blower 7 fixed to the side surface of the pole core 33.
[0088]
Specifically, the three-phase stator coil 32 of the stator 3 and the field coil 34 of the rotor 4 are made up of a number of ventilation openings formed in the front housing 11 and the rear housing 12 as shown in FIGS. It is cooled directly by the cooling air sent through 19 and a large number of ventilation openings 20. Further, the heat generated by the three positive and negative diodes 75 and 76 is applied to the positive and negative cooling fins 73 and 74 by the cooling air sent through the vent hole 20 of the rear housing 12. By cooling the positive electrode side and negative electrode side cooling fins 73 and 74, heat is radiated through the positive electrode side and negative electrode side cooling fins 73 and 74.
[0089]
In this embodiment, two carbonaceous current collecting rings 41 and two metallic brushes 51 are arranged on the inner side in the radial direction of the annular blade row of the blower 7, and the accommodation chamber forming member 52 is arranged. An annular space 49 is formed between the outer periphery of the current collector ring cover 61 and the annular blade row of the blower 7. Thereby, since there is no member that prevents the passage of the cooling air in the annular space 49 on the inner peripheral side of the plurality of blades 43 of the blower device 7, the cooling air sucked from the ventilation port 20 is collected by the current collecting ring cover. Since the cooling air is smoothly sucked into the inner peripheral portions of the plurality of blades 43 through the outer peripheral side of 61, the noise of the blower 7 can be suppressed. Furthermore, since a sufficient amount of cooling air can be obtained, the cooling efficiency of each electrical component can be improved and the power generation efficiency can be improved.
[0090]
When the cooling air is sucked into the housing 2, foreign matters such as water and dust also enter the housing 2. In particular, if foreign matter enters the housing 2 through the ventilation opening 20 of the rear housing 12, there is a possibility that the sliding portion between the carbonaceous current collecting ring 41 and the metallic brush 51 may enter. However, in this embodiment, the cylindrical storage chamber 48 is defined by the current collection ring cover 61 of the storage chamber forming member 52 so as to surround the two carbonaceous current collection rings 41, and the Since the opening side of the electric ring cover 61 is located on the inner side in the radial direction of the plurality of blades 43 of the blower 7, foreign matters such as water and dust on the sliding portion between the carbonaceous current collecting ring 41 and the metallic brush 51 are present. Hard to invade.
[0091]
[Effects of Examples]
First, the effect in the case of using two metallic brushes 51 made of metallic members as the stationary brushes of the vehicle alternator 1 will be described.
[0092]
When a carbonaceous brush 123 made of a carbonaceous member is used as a fixed side brush as in the prior art, in order to reduce the contact electrical resistance, copper powder is mixed into the carbon and the contact electrical resistance and carbon are mixed. The blending ratio was determined by the wear life of the quality brush 123. In addition, when a metallic member such as copper powder is blended with carbon, the weight of the carbonaceous brush 123 becomes heavy, and a problem due to vibration has to be taken into consideration. The vibration resistance of the fixed-side brush is generally expressed by the following formula 1 according to the literature of the machine design document.
[0093]
[Expression 1]
Vibration resistance {(k x spring load) / (fixed side brush weight)} + {spring weight}
Here, it can be seen that if the weight of the fixed side brush (brush main body) is reduced, the spring load of the fixed side brush can be reduced.
[0094]
In the present invention, a metallic brush 51 serving both as a spring and a pigtail is used as the stationary brush, and a copper alloy spring material (in the embodiment, phosphor bronze or beryllium copper) is used as the material of the metallic brush 51. The weight of the metallic brush 51, particularly the weight of the brush body 55, is greatly reduced.
[0095]
As a result, the spring load of the metallic brush 51 can be greatly reduced as compared with the conventional carbonaceous brush 123, so that the amount of wear of the metallic brush 51 can be greatly reduced, and problems due to vibration of the metallic brush 51 can be avoided. By being able to suppress, the lifetime of the metallic brush 51 can be prolonged. Therefore, the life extension of the vehicle alternator 1 can be achieved.
[0096]
Further, as shown in FIG. 1, the shape of the brush body 55 of the metallic brush 51 is formed in a substantially semicircular arc shape, and the carbonaceous current collecting ring 41 is sandwiched between the two contacts 57 and 58. As a result, the combined vector of the contact pressure when the metallic brush 51 comes into contact with the outer circumference of the carbonaceous current collecting ring 41 becomes 0, so that the brush fixed portion 56 that is mechanically fixed to the connection terminals 53 and 54 The contact pressure force is not applied.
[0097]
Then, even if excessive vibration occurs in the direction in which the brush body 55 of the metallic brush 51 is easily peeled off from the carbonaceous current collector ring 41, that is, in the radial direction of the carbonaceous current collector ring 41, the contactor 57 (58 ) And the contactor 58 (57) that does not peel off, the electrical connection between the metallic brush 51 and the carbonaceous current collector ring 41 is maintained, and a stable excitation current flows through the field coil 34. Can do.
[0098]
Further, as shown in FIG. 1, by providing chamfered extension pieces 57a, 57b, 58a, 58b on both axial sides of the contacts 57, 58 of the metallic brush 51, the contacts 57, 58 are pivoted. Since the metal brush 51 can be assembled to the outer periphery of the carbonaceous current collector ring 41, or the metal brush 51 can be detached from the outer periphery of the carbonaceous current collector ring 41 and disassembled. It will be very easy. Thereby, since the productivity of the alternator 1 for vehicles improves, the product cost of the alternator 1 for vehicles can be reduced.
[0099]
In the case of the metal current collector ring 121 made of a metal member as in the prior art, the metal current collector ring 121 and the connection bar 122 are welded and the metal current collector ring 121 is formed into a precise circular shape. Considering the machinability for finishing, a problem has arisen that the hardness of the metallic member, which is the material of the metallic current collecting ring 121, cannot be improved in order to extend the life. However, since the metallic brush 51 of the present invention is a conductive thin plate elastic material (sheet metal) and can be formed into the shape shown in FIG. 1 only by pressing, the wear life of the metallic member that is the material of the metallic brush 51 is increased. The hardness of the affected material can be increased sufficiently. Thereby, the lifetime improvement of the metallic brush 51 can be achieved.
[0100]
Next, the effect of the fixing method (support structure) of the metallic brush 51 will be described. The manufacturing cost of the alternator 1 for a vehicle can be reduced by setting the metal to be fixed 56 and the connection terminals 53 and 54 of the metallic brush 51 by setting different metals in terms of cost. In addition, when the housing chamber forming member 52 is integrally formed of an electrically insulating resinous material that is integral with the connection terminals 53 and 54, the metal characteristics change depending on the resin temperature at the time of insert molding of the connection terminals 53 and 54. Since the wear resistance of the metallic brush 51 may be lowered, it is necessary to mechanically fix the connection terminals 53 and 54 and the brush fixing portion 56 after the insert molding to make electrical connection therebetween. is there.
[0101]
A fixing method such as welding or caulking can be used as a fixing method for the connection terminals 53 and 54 and the brush fixing portion 56. However, the performance of the metallic brush 51 is a copper alloy spring material. The fixing method by the faston shape (see FIG. 1) which is the minimum space in the upper and manufacturing is optimal.
[0102]
Next, the effect when the carbonaceous current collecting ring 41 is made of a carbonaceous member (for example, formed from carbon powder using a copper alloy foam skeleton metal as a metal base) will be described.
In the case of the conventional structure, since the carbonaceous brush 123 is a wear member, it is necessary to set the size and length in which wear has been predicted in advance, and the voltage regulator is further used to reduce the drop voltage of the excitation circuit. It is arranged near the main body. For this reason, the physique of the vehicle alternator 1 cannot be reduced, which hinders the compactness of the vehicle alternator 1.
[0103]
However, since the metallic brush 51 is made of a metallic member, the metallic brush 51 is less likely to be worn. Thus, the size and length of wear predicted in advance like the carbonaceous brush 123 made of a conventional wearing member. There is no need to set to. Thereby, the metallic brush 51 can be made very thin. That is, since the metallic brush 51 can be manufactured from a thin plate elastic material, the brush device 8 including the metallic brush 51 and the storage chamber forming member 52 can be significantly reduced in weight and size. Therefore, even when the voltage adjusting device 10 is installed in the vicinity of the metallic brush 51, the size of the vehicle alternator 1 can be reduced and the axial dimension can be reduced, so that the vehicle alternator 1 can be reduced in weight. Can be downsized.
[0104]
Further, as in the present invention, the carbonaceous current collecting ring 41 is made of a carbonaceous member, and the self-lubricating property (reduction of friction coefficient) of the carbonaceous current collecting ring 41 and the contact with the metallic brush 51 are obtained. By significantly reducing the probability, the amount of wear can be greatly reduced as compared with the conventional metallic current collecting ring 121. Further, as shown in the above equation 1, the amount of wear of the carbonaceous current collecting ring 41 can be further reduced by reducing the spring load of the metallic brush 51 in order to reduce the weight of the metallic brush 51. Therefore, the lifetime of the carbonaceous current collecting ring 41 can be increased. Therefore, the life extension of the vehicle alternator 1 can be achieved.
[0105]
Further, since the metallic brush 51 is made of a metallic member, the contact portion of the metallic brush 51 is reduced in order to reduce the electrical resistance of the contact portion that contacts the outer periphery of the carbonaceous brush 41 in the metallic brush 51. Since the current density does not change even if the surface area of the metallic brush 51 is reduced, the temperature rise of the metallic brush 51 is suppressed and the durable life of the metallic brush 51 is extended. On the other hand, the carbonaceous current collector ring 41 is made of a carbonaceous member, but the portion of the annular carbonaceous current collector ring 41 that contacts the metallic brush 51 is a part of the circumferential dimension. The temperature rise of the carbonaceous current collecting ring 41 is also suppressed, and the durable life of the carbonaceous current collecting ring 41 is extended. Therefore, the life extension of the vehicle alternator 1 can be achieved.
[0106]
Since the carbonaceous current collecting ring 41 is made of a carbonaceous member, the metallic brush 51 is made of a metallic member, and the metallic brush 51 is operated on the outer circumference of the carbonaceous current collecting ring 41 at high speed. Stable wear and energization of the field coil 34 can be ensured even when sliding at (for example, 10,000 rpm or more).
[0107]
Next, the effect when the two metallic brushes 51 and the two connection terminals 53 and 54 are held in the storage chamber forming member 52 will be described.
In the cylindrical brush holder 59 included in the storage chamber forming member 52, as shown in FIGS. 3, 5, and 6, the two connection terminals 53 and 54 have a predetermined distance in the axial direction of the shaft 5. The shaft 5 is held and fixed at a distance, and is also held and fixed at a predetermined distance in the circumferential direction of the shaft 5. Accordingly, the two connection terminals 53 and 54 can be accommodated in a compact manner while maintaining a predetermined insulation distance in the narrow brush holding portion 59.
[0108]
In the brush holder 59, as shown in FIG. 4, the two metallic brushes 51 are held and fixed at a predetermined distance in the axial direction of the shaft 5, and are also specified in the circumferential direction of the shaft 5. It is held fixed by a distance. Thus, a predetermined insulation distance is maintained in the cylindrical storage chamber 48 surrounded by the outer peripheral surfaces of the two current collecting rings 41, the front end surface of the brush holding portion 59, and the inner peripheral surface of the current collecting ring cover 61. However, the two metallic brushes 51 can be accommodated in a compact manner.
Accordingly, the brush device 8 including the metallic brush 51 and the storage chamber forming member 52 can be significantly reduced in weight and size. Therefore, since the radial dimension and the axial dimension of the vehicle alternator 1 can be reduced, the vehicle alternator 1 can be reduced in weight and size.
[0109]
Next, an effect when two carbonaceous current collecting rings 41 and two metallic brushes 51 are arranged inside the radial blade row of the blower 7 will be described.
In this embodiment, a current collecting ring cover 61 that forms an accommodation chamber 48 for accommodating two carbonaceous current collecting rings 41 and two metallic brushes 51 inside the radial blade array of the blower 7. The opening end of is arranged. Thereby, size reduction of the axial physique of the vehicle alternator 1, that is, shortening of the axial length of the vehicle alternator 1 can be realized.
[0110]
Moreover, the accommodating chamber 48 that accommodates the two metallic brushes 51 is surrounded by a very simple cylindrical current collecting ring cover 61, and the suction side space (annular space 49) of the blower device 7 is entirely disposed. It is secured evenly over the circumference. According to such a configuration, the axial length of the vehicle alternator 1 can be shortened, and the blowing performance of the blower 7 is not deteriorated. In particular, such a configuration cannot be realized by using the vehicular AC generator 100 having the conventional rod-like carbonaceous brush 123.
[0111]
Further, in this embodiment, the cylindrical current collecting ring fixing portion 45 extends rearward from the end face of the pole core 33 along the axial direction of the shaft 5, and the end face of the pole core 33 and the shaft 5 extending from the end face Since the accommodation chamber 48 for accommodating the two metallic brushes 51 is formed without wasting the corner space, the axial length of the vehicle alternator 1 can be shortened. As described above, the vehicle alternator 1 can be reduced in size and weight.
[0112]
In this embodiment, since the casing 62 of the voltage adjusting device 10 is arranged on the outer side in the axial direction with respect to the annular blade row of the blower 7, the plurality of blades 43 are rotated when the plurality of blades 43 of the blower 7 are rotated. 43 and the casing 62 can be prevented from interfering with each other.
[0113]
In the conventional vehicle alternator 100, the brush support 124 (brush holder) 124 that is enlarged from the shaft 104 toward the outside in the radial direction is provided, so that the cooling fan 119 and a predetermined axial dimension are provided. Since the brush supporter 124 is arranged with a gap therebetween, the ventilation efficiency (cooling efficiency) of the cooling fan 119 is reduced by blocking the ventilation path of the cooling fan 119. However, in this embodiment, the suction side space of the air blower 7 is entirely reduced by a very simple cylindrical current collecting ring cover 61 that extends forward in the axial direction from the front end surface of the brush holder 59. Since it is ensured uniformly over the circumference, the blowing efficiency (cooling efficiency) of the blowing device 7 can be improved, and the air sucked into the annular blade row is not disturbed, so that the generation of noise can be suppressed.
[0114]
[Comparison between Example and Conventional Example]
Next, an experiment in which the embodiment including the carbonaceous current collecting ring 41 and the metallic brush 51 is compared with the conventional example including the metallic current collecting ring 121 and the carbonaceous brush 123 will be described. In this experiment, the spring load P of the metallic brush 51 of the example and the carbonaceous brush 123 of the conventional example was variously changed to investigate how the wear amount Q of both the brushes changed. The results are shown in the graph of FIG.
[0115]
As can be confirmed from the graph of FIG. 7, when the spring load P of the carbonaceous brush 123 of the conventional example is less than 80 gf, the wear amount Q (mm) of the carbonaceous brush 123 is abruptly increased.^Three/ 1000h) tends to increase. Further, when the spring load P of the carbonaceous brush 123 of the conventional example is gradually increased from 170 gf, the wear amount Q (mm) of the carbonaceous brush 123 is gradually increased.^Three/ 1000h) tends to increase.
[0116]
On the other hand, when the spring load P of the metallic brush 51 of the embodiment is smaller than 30 gf, the wear amount Q (mm) of the metallic brush 51 is suddenly reduced.^Three/ 1000h) tends to increase, but it can be seen that the wear amount is 1/3 of the wear amount Q of the conventional carbonaceous brush 123. Further, when the spring load P of the metallic brush 51 of the embodiment gradually becomes larger than 50 gf, the wear amount Q (mm) of the metallic brush 51 gradually.^Three/ 1000h) tends to increase, but is slightly smaller than the increasing tendency of the wear amount Q of the conventional carbonaceous brush 123.
[0117]
Accordingly, the metallic brush 51 of the embodiment can achieve a reduction in the spring load of the metallic brush 51, and therefore the amount of wear is significantly reduced compared with the carbonaceous brush 123 of the conventional example. Longer life can be achieved. Further, compared to the conventional carbonaceous brush 123 in which the pigtail 126 is integrally formed with the carbonaceous brush 123 and the coil spring 125 is required to ensure the contact pressure, the metallic brush 51 of the embodiment includes the spring and Since it is made of a metallic member that is a copper alloy spring material that also serves as a pigtail, the number of parts can be reduced. For this reason, the assembling work for assembling the brush device 8 around the carbonaceous current collecting ring 41 can be simplified, whereby the manufacturing cost of the automotive alternator 1 can be reduced.
[0118]
[Modification]
In this embodiment, the present invention is applied to a vehicular AC generator (so-called alternator) 1, but the present invention may be applied to a stationary AC generator that supplies power in a building. Further, the present invention may be applied to a generator motor. The shaft 5 may be directly connected to the output shaft of a drive source such as an engine. In this case, a pulley is not necessary. Further, power transmission means such as one or more gear transmissions or V-belt type continuously variable transmissions may be connected between the shaft 5 and the output shaft of the engine. Further, the shaft 5 may be rotationally driven by an electric motor.
[0119]
In this embodiment, the centrifugal fan is constituted by the annular blade row and the support plate portion 44 of the blower 7, but the axial fan may be constituted by the annular blade row and the support plate portion 44 of the blower device 7. In addition, the current collector 6, the blower 7, and the brush device 8 may be provided in the front housing 11, that is, on the front side in the axial direction from the pole core 33 in the housing 2.
[0120]
In this embodiment, the carbonaceous current collecting ring 41 is used as the current collecting ring (slip ring), but a metal current collecting ring such as a copper alloy or stainless steel may be used as the current collecting ring. Further, in this embodiment, the plate-like metallic brush 51 is used as the fixed-side brush (brush), but a plate-like carbonaceous brush made of carbon powder, natural graphite, metallic graphite or the like is used as the stationary-side brush. May be. Further, the pigtail may be integrally formed with the fixed-side brush, and the contact pressure of the fixed-side brush may be secured by a separate spring.
[0121]
In this embodiment, a plurality of blades 43, a support plate portion 44 that supports them, and a current collector ring fixing portion 45 in which a carbonaceous current collector ring 41 is insert-molded are integrally formed of a resinous member. You may make it with. Moreover, you may manufacture the some braid | blade 43 or the support plate part 44 with a metallic material. Further, the blade and the support plate portion made of a metal member may be insert-molded with a resin member together with a current collecting ring.
[Brief description of the drawings]
FIG. 1 is a perspective view showing the structure of a main part of an electrical connection device for an AC generator for a vehicle according to the present invention (Example).
FIG. 2 is a cross-sectional view showing an overall structure of an automotive alternator according to the present invention (Example).
FIG. 3 is a cross-sectional view taken along line AA of FIG. 2 (Example).
FIG. 4 is a cross-sectional view showing the structure of the main part of an automotive alternator according to the present invention (Example).
FIG. 5 is a plan view showing a main part structure of an automotive alternator according to the present invention (Example).
FIG. 6 is an enlarged view of FIG. 5 (Example).
FIG. 7 is a graph showing wear characteristics of a metallic brush of an example and a carbonaceous brush of a conventional example.
FIG. 8 is a cross-sectional view showing a conventional vehicular AC generator (conventional example).
[Explanation of symbols]
1 AC generator for vehicles
2 Housing
3 Stator
4 Rotor
5 Shaft
6 Current collector
7 Blower
8 Brush device
9 Three-phase rectifier
10 Voltage regulator
17 Rear bearing
18 Boss part (bearing holding part)
19 Ventilation openings
20 Ventilation opening
21 Exhaust port
31 Stator core
32 Stator coil
33 Pole core (rotor core)
34 Field coil (rotor coil)
41 Carbonaceous current collector ring
43 blades
44 Support plate
45 Current collector ring fixing part
48 containment room
49 Annular space
51 Metallic brush (fixed side brush)
52 Chamber forming member
53 Connection terminal (Brush fixing part, Brush connection terminal)
54 Connection terminal (Brush fixing part, Brush connection terminal)
55 Brush body
56 Brush fixed part
57 Contact
58 Contact
59 Brush holder
61 Current collector ring cover
57a Extension piece
57b Extension piece
58a extension piece
58b extension piece
551 Extension
552 extension

Claims (9)

A housing;
A stator having a stator coil and a stator core, fixed to the housing;
A rotor coil, a rotor core, and a rotor having a shaft extending from the rotor core and rotating relative to the stator;
A generator provided between the housing and the rotor, and comprising an electrical connection device for forming a current path through the rotor coil;
The electrical connection device is provided on the shaft, connected to the rotor coil, and a current collecting ring made of a carbonaceous member;
In contact with the current collector ring, a stationary brush made of a metallic member ,
A brush fixing portion for holding the fixed side brush ,
The fixed side brush extends from the brush fixing portion to both the front side and the rear side in the rotation direction of the current collecting ring, and is in contact with the current collecting ring on both the front side and the rear side. ,
An extension piece having a chamfered shape is formed on the side portion in the axial direction of the contact portion with the current collecting ring provided on the fixed side brush,
The generator is characterized in that the extension piece is extended to either the front side or the rear side in the axial direction of the current collecting ring . A housing;
A stator having a stator coil and a stator core, fixed to the housing;
A rotor coil, a rotor core, and a rotor having a shaft extending from the rotor core and rotating relative to the stator;
An electrical connection device provided between the housing and the rotor for forming a current path through the rotor coil;
A generator with
The electrical connection device is provided on the shaft, connected to the rotor coil, and a current collecting ring made of a carbonaceous member;
In contact with the current collector ring, a stationary brush made of a metallic member,
A brush fixing portion for holding the fixed side brush;
With
The fixed side brush extends from the brush fixing portion to at least one of a front side and a rear side in a rotation direction of the current collecting ring, and at least one of the front side and the rear side includes the current collecting ring. In contact,
An extension piece having a chamfered shape is formed on the side portion in the axial direction of the contact portion with the current collecting ring provided on the fixed side brush,
The generator is characterized in that the extension piece is extended to either the front side or the rear side in the axial direction of the current collecting ring . The generator according to claim 1 or claim 2 ,
The brush fixing portion is a brush connection terminal electrically connected to the fixed side brush,
The brush connection terminal mechanically fixes the fixed-side brush and is made of a metallic member different from a metallic member forming the stationary-side brush. The generator according to claim 1 or claim 2 ,
The electrical connection device includes a housing chamber forming member that houses the stationary brush and the current collecting ring and forms a cylindrical housing chamber that surrounds the outer periphery of the current collecting ring. Machine. The generator according to claim 1 or claim 2 ,
The generator is characterized in that the carbonaceous member is formed from carbon powder using a foam skeleton metal having excellent conductivity as a metal matrix. The generator according to claim 1 or claim 2 ,
The generator is characterized in that the brush fixing portion is formed in a shape that is coupled to the stationary brush only along the axial direction of the shaft. The generator according to claim 6 ,
The electrical connection device includes a storage chamber forming member that stores the stationary brush and the current collector ring and forms a cylindrical storage chamber that surrounds the outer periphery of the current collector ring,
The generator is characterized in that the brush fixing portion is provided on the storage chamber forming member located at the axial end of the storage chamber. The generator according to claim 7 ,
The brush fixing portion is a brush connection terminal extending along the axial direction of the shaft,
The generator is characterized in that the fixed-side brush has a brush-fixed portion that is electrically and mechanically connected to the brush connection terminal. A housing;
A stator having a stator coil and a stator core, fixed to the housing;
A rotor coil, a rotor core, and a rotor having a shaft extending from the rotor core and rotating relative to the stator;
Two current collecting rings provided on the shaft and connected to the rotor coil;
Two fixed-side brushes each contacting these current collector rings,
A generator comprising a storage chamber forming member for forming a storage chamber for storing the two current collecting rings and the two stationary brushes;
The stationary brush is made of a plate material,
A fixed part fixed to a brush holding part included in the storage chamber forming member;
An extension extending in an arc shape along the outer periphery of the current collecting ring from the fixed portion;
Provided at the tip of this extension, comprising a contactor that contacts the current collector ring,
The contactor is pressed against the current collecting ring by the spring force of the extension ,
An extension piece having a chamfered shape is formed on the opening side of the contact provided at the tip of the extension of the stationary brush,
The generator is characterized in that the extension piece is extended to either the front side or the rear side in the axial direction of the current collecting ring .

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