JP5242897B2 - Rotating electric machine for vehicles - Google Patents

Description

  The present invention relates to a vehicular rotating electrical machine mounted on a passenger car, a truck, or the like.

In recent years, engine rooms have become narrower due to the need for a slant nose to reduce vehicle running resistance and the need to secure a living space in the vehicle interior, and there is room for mounting auxiliary equipment such as AC generators for vehicles. As it disappears, the temperature around the AC generator for vehicles is also increasing. In addition, the engine speed during idling has been lowered to improve fuel economy, and the rotational speed of the vehicle alternator has also decreased. On the other hand, the electrical load of safety control equipment has increased. Yes. Accordingly, there is a need for a small-sized, high-output vehicle alternator with excellent output characteristics, particularly in the low-rotation region. In order to achieve high output and high efficiency, it is conceivable to reduce the heat loss by reducing the winding resistance value in the stator that is the largest heat source. For this purpose, a winding conductor having a large cross-sectional area is used, and the area occupied by the conductor (stator winding) in the slots of the stator core (hereinafter referred to as “space factor”) is improved. It is necessary. In order to improve the space factor, a rectangular conductor having a substantially rectangular cross section is used, the R dimension of the corner of the rectangular conductor corresponding to the four corners of the slot is increased, and the R dimension of the four corners of the slot are increased. There is known a vehicular rotating electrical machine in which the R dimension of a corner portion of a flat rectangular conductor corresponding to the four corner portions is substantially matched and the R dimension of other corner portions is reduced (see, for example, Patent Document 1). As a result, the gap generated around the rectangular conductor in the slot is reduced, thereby realizing higher output, higher efficiency, and improved durability (temperature reduction) by improving the space factor.
Japanese Patent Laying-Open No. 2003-18779 (page 4-6, FIG. 1-9)

  By the way, even in the flat conductor used for the stator of the rotating electrical machine for a vehicle of Patent Document 1, each conductor needs an insulating film having a predetermined film thickness, and has a uniform film thickness so as to surround one conductor. Since the insulating film was formed, two layers of insulating films existed between the conductors. For this reason, in particular, when a large number of conductors are accommodated in the slot, the ratio occupied by the insulating film increases, and there is a problem that the space factor in the slot decreases accordingly.

  Conventionally, when an insulating film is formed on a conductor having a rectangular cross section, when the R dimension of the corner portion is reduced, a flat portion and an insulating film having a uniform thickness can be formed at the corner portion. It is very difficult and usually the thickness of the insulating film is thinner than other parts. Even if a thick insulating film can be formed, it is difficult to maintain good insulation because the insulating film is easily scratched when the corners of adjacent conductors interfere with each other in the subsequent process. Eventually, the R dimension of the corner portion could not be made very small (for example, R = 0.4 mm was the limit), which was an obstacle to improving the space factor.

  The present invention has been created in view of the above points, and its purpose is to improve the space factor of the stator winding, and accordingly, increase in output, efficiency, and durability. An object of the present invention is to provide a vehicular rotating electrical machine capable of improving the performance.

In order to solve the above-described problems, a rotating electrical machine for a vehicle according to the present invention includes a rotor that is rotationally driven, a stator core that is disposed to face the rotor, and a stator winding that is installed in a slot of the stator core. A stator having a wire, and a rotor and a frame that supports the stator. The stator winding is composed of a plurality of electric conductors having a substantially rectangular cross-sectional shape. A plurality of the above-mentioned plural pieces are formed as one set, and one insulating film is formed around the electric conductors and between the electric conductors. As a result, the two-layer insulation film between two adjacent electrical conductors can be reduced to a thickness of approximately one layer, so that the space factor in the slot can be increased accordingly. Accordingly, higher output, higher efficiency, and improved durability can be realized.
Furthermore, it is desirable that a plurality of electric conductors in one set have a radius r of a corner where no adjacent electric conductor exists to be larger than a radius R of the corner where an adjacent electric conductor exists. As a result, it is possible to prevent the insulating film from being partially thinned at the corner portion having the large radius r, and the insulating film is partially formed at the corner portion having the small radius R where the electric conductor is adjacent. Since it is not necessary to consider the reduction in thickness, the radius R can be reduced accordingly, and the space factor can be improved.

  In addition, it is desirable that the above-described electrical conductors have an insulating film formed of two wires as one set. Thereby, it becomes possible to make compatible the reduction | decrease of the film thickness of an insulating film, and the workability | operativity at the time of shape | molding an electrical conductor in a predetermined shape.

  Moreover, as for the insulating film mentioned above, it is desirable for the film thickness T between two electric conductors to be set thinner than twice the film thickness t around the other electric conductors. Thereby, compared with the case where an insulating film is individually formed on each electric conductor, the film thickness can be reliably reduced and the space factor can be improved.

  Moreover, as for the insulating film mentioned above, it is desirable for the film thickness T between two electric conductors to be set to be substantially the same as the film thickness t around the other electric conductors. Thereby, the maximum space factor can be realized while ensuring the minimum necessary film thickness t for the entire insulating film.

  The radius r described above is preferably set in accordance with the R shape of the four corners of the slot. By setting the shape of the corner of the electric conductor in accordance with the slot shape, the gap generated around the electric conductor in the slot can be reduced, and the space factor can be improved.

  Hereinafter, an automotive alternator according to an embodiment to which a rotating electrical machine for a vehicle of the present invention is applied will be described in detail with reference to the drawings. FIG. 1 is a diagram showing an overall configuration of an automotive alternator according to an embodiment. The vehicle alternator 1 shown in FIG. 1 includes a stator 2, a rotor 3, a frame 4, a brush device 5, a rectifying device 6, a rear cover 7, and the like.

  The stator 2 includes a stator core 22 and a stator winding 23 formed by joining together a plurality of segment conductors as electric conductors provided in a plurality of slots formed in the stator core 22. It has. Details of the stator 2 will be described later.

  The rotor 3 has a structure in which a field winding 31 in which an insulated copper wire is wound in a cylindrical and concentric manner is sandwiched from both sides through a rotating shaft 33 by a pole core 32 having a plurality of claws. have. A cooling fan 35 is attached to the end face of the pole core 32 on the front side by welding or the like as a blowing means for discharging the cooling air sucked from the front side in the axial direction and the radial direction. Similarly, a cooling fan 36 is attached to the end face of the pole core 32 on the rear side by welding or the like as a blowing means for discharging the cooling air sucked from the rear side in the radial direction. In addition, two slip rings 37 and 38 that are electrically connected to both ends of the field winding 31 are formed in the vicinity of the rear side end portion of the rotating shaft 33, and the slip rings 37 and 38 are interposed through these slip rings 37 and 38. Then, power is supplied from the brush device 5 to the field winding 31.

  The frame 4 accommodates the stator 2 and the rotor 3, and is supported in a state where the rotor 3 can rotate around the rotation shaft 33, and a predetermined value is provided on the outer peripheral side of the pole core 32 of the rotor 3. A stator 2 arranged via a gap is fixed. The frame 4 has a cooling air discharge window 41 at a portion facing the stator winding 23 protruding from the axial end face of the stator core 22 and a suction window 42 at the axial end face.

  The brush device 5 is for passing an exciting current from the rectifying device 6 to the field winding 31 of the rotor 3, and presses each of the slip rings 37 and 38 formed on the rotating shaft 33 of the rotor 3. Brushes 51 and 52 are provided. The rectifier 6 is for rectifying the three-phase alternating current output from the three-phase stator winding 23 to obtain direct-current output power. The rear cover 7 covers and protects electrical components such as the brush device 5, the rectifying device 6, and the IC regulator 9 that are attached to the outside of the frame 4 on the rear side.

  Next, details of the stator 2 will be described. FIG. 2 is a partial cross-sectional view of the stator 2. The stator core 22 of this embodiment is formed by laminating thin steel plates. Slots 25 are formed in advance in each steel plate to be laminated by press working, and magnetic flux collecting projections 27 are formed in the tooth tip portions 26 between the slots 25 in the circumferential direction. As described above, when the slots 25 are formed by press working, the four corner portions 28 of each slot 25 have a predetermined arc shape (r shape), thereby ensuring the life of the press die and securing the magnetic path area. Considering this, the radius (r dimension) of this arc cannot be made extremely small.

  Further, the stator winding 23 provided in the slot 25 of the stator core 22 is constituted by a plurality of segment conductors, and each slot 25 accommodates a plurality (four in this embodiment) of electrical conductors. Yes. The four electrical conductors in one slot 25 are arranged in a row from the first layer to the fourth layer from the inside in the radial direction of the stator core 22. The electric conductors of these layers correspond to the two straight portions of the substantially U-shaped segment conductor. The first layer corresponds to the inner end layer, the second layer corresponds to the inner middle layer, the third layer corresponds to the outer middle layer, and the fourth layer corresponds to the outer end layer.

  FIG. 3 is a perspective view of segment conductors constituting the stator winding 23. As shown in FIG. 3, in this embodiment, two types of large and small segment conductors 231 and 232 are used in a superimposed state. One segment conductor 231 disposed on the outside when superimposed is formed by bending one linear electric conductor having a rectangular cross section into a substantially U shape, and two linear portions 231a and 231b; It has a turn part 231c that is a U-shaped folded part and a skew part 231f that connects these parts. In addition, the other segment conductor 232 that is disposed on the inner side when it is overlaid is formed by bending one linear electric conductor having a rectangular cross section into a substantially U shape, and two linear portions 232a and 232b. And a turn portion 232c that is a U-shaped folded portion, and a skew portion 232f that connects the turn portion 232c. The straight portions 231a and 232a and the straight portions 231b and 232b are accommodated in two slots 25 that are separated from each other by one magnetic pole pitch.

  As shown in FIG. 2, two linear conductors 231 a and 232 a of two segment conductors 231 and 232 are formed as a set, and an insulating film 24 is formed. Similarly, the other linear portions 231b and 232b of the two segment conductors 231 and 232 are formed as a set, and the insulating film 24 is formed. In FIG. 2, “′” added to the straight portions 231 b and 232 b is included in the other segment conductors 231 and 232 different from the segment conductors 231 and 232 including the one straight portions 231 a and 232 a. It is shown that.

  FIG. 4 is a diagram showing details of the insulating coating formed on the two adjacent linear portions 231a and 232a. The same applies to the other two straight portions 231b and 232b. Hereinafter, the two straight portions 231a and 232a will be described. As shown in FIG. 4, the insulating film 24 formed around the straight portions 231a and 232a has a film thickness in the region sandwiched between these two straight portions 231a and 232a and a film in the other region. The thickness is set to t. The film thickness T is smaller than twice the film thickness t, and is preferably set to be the same as the film thickness t.

  In the present embodiment, the radius R of the corners adjacent to each other in each of the two straight portions 231a and 232a is set smaller than the radius r of the other corners. The radius r of the other corners is set in accordance with the r dimension of the four corners 28 of the slot 25, so that no gap is generated between the four corners 28 and the corners of the straight line 231a. It has become.

  By the way, when the insulating film 24 is formed around the electric conductor, if there is an acute convex portion on the surface of the electric conductor, the film thickness of the insulating film 24 is reduced at that portion. Therefore, as shown in FIG. 5, when it is considered that the insulating film 24 is formed around one electric conductor, there is a case where a corner portion having a radius R and a corner portion having a radius r exist in the electric conductor. Thus, if the value of the radius R is made too small in order to increase the space factor, the film thickness of the insulating film 24 at the corners of the radius R becomes thinner than the other parts, and the insulating properties deteriorate. In contrast, in the present embodiment, as shown in FIGS. 2 and 4, the corners of the radius R are arranged so that the linear portions 231a and 232a that are two electric conductors are adjacent to each other. The film thickness of the insulating film 24 around the corner is not reduced.

  Thus, in this embodiment, since the two-layer insulating film 24 between two adjacent electrical conductors can be reduced to one layer, the space factor in the slot 25 can be increased accordingly. Accordingly, it is possible to achieve higher output, higher efficiency, and improved durability of the vehicle alternator 1. In particular, by forming the insulating film 24 as a set of two, it is possible to achieve both reduction in the film thickness of the insulating film 24 and workability when forming the electric conductor into a predetermined shape.

  Further, by setting the film thickness T of the insulating film 24 between the two electric conductors to be thinner than twice the film thickness t around the other electric conductors, the insulating film 24 is individually applied to each electric conductor. Compared with the case of forming the film, the film thickness can be reliably reduced and the space factor can be improved. In particular, by setting the film thickness T of the insulating film 24 between two electric conductors to be substantially the same as the film thickness t around the other electric conductors, the minimum necessary film thickness of the insulating film 24 as a whole. The maximum space factor can be realized while securing t.

  Further, in the plurality of electric conductors in one set, the radius r of the corner where the adjacent electric conductor does not exist is set larger than the radius R of the corner where the adjacent electric conductor exists. Thereby, it is possible to prevent the insulating film 24 from being partially thinned at the corner portion of the large radius r, and the insulating film 24 is a portion where the electric conductor is adjacent to the corner portion of the small radius R. Therefore, it is not necessary to consider the reduction in thickness, and the radius R can be reduced by that amount to improve the space factor.

  Further, by setting the radius r in accordance with the shape of the four corner portions 28 of the slot 25, the gap generated around the electric conductor in the slot 25 can be reduced, and the space factor can be improved.

  In addition, this invention is not limited to the said embodiment, A various deformation | transformation implementation is possible within the range of the summary of this invention. For example, in the above-described embodiment, the insulating film 24 is formed by setting two electric conductors (straight line portions) as one set, but the insulating film 24 is formed around and between three or more electric conductors as one set. 24 may be formed.

  In the above-described embodiment, the case where two straight portions (electrical conductors) of the U-shaped segment conductor are adjacent to each other has been described. However, when two or more linear segment conductors are adjacent to each other. The present invention can also be applied to. In the above-described embodiment, the case where four electrical conductors are stored in each slot 25 has been described. However, the present invention is also applied to a case where a larger number of electrical conductors are stored in each slot 25. be able to.

It is a figure showing the whole composition of the alternator for vehicles of one embodiment. It is a fragmentary sectional view of a stator. It is a perspective view of the segment conductor which comprises a stator winding | coil. It is a figure which shows the detail of the insulating film formed in two adjacent linear parts. It is explanatory drawing in the case of forming an insulating film around one electric conductor.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Vehicle alternator 2 Stator 3 Rotor 4 Frame 5 Brush device 6 Rectifier 7 Rear cover 22 Stator iron core 23 Stator winding 24 Insulation film 25 Slot 26 Tooth tip 27 Magnetic flux collecting projection 28 Four corners 31 Field winding 32 Pole core 33 Rotating shaft 231, 232 Segment conductor 231a, 231b, 232a, 232b Straight line part 231c, 232c Turn part

Claims (5)

A stator having a rotor to be driven to rotate, a stator core disposed opposite to the rotor, and a stator winding installed in a slot of the stator core, and supporting the rotor and the stator A rotating electrical machine for a vehicle comprising a frame that
The stator winding is composed of a plurality of electric conductors having a substantially rectangular cross-sectional shape,
The electrical conductor is a set of two or more wires, and one insulating film is formed around each of the electrical conductors and between the electrical conductors ,
The plurality of electric conductors in one set is characterized in that a radius r of a corner where the adjacent electric conductor does not exist is set larger than a radius R of the corner where the adjacent electric conductor exists. Rotating electric machine for vehicles. In claim 1,
The electric rotating machine for vehicles, wherein the electric conductor is formed with the insulating film as a set of two conductors. In claim 1 or 2,
In the rotating electrical machine for a vehicle, the film thickness T between the two electric conductors is set to be thinner than twice the film thickness t around the other electric conductors. In claim 3,
The rotating electrical machine for a vehicle according to claim 1, wherein the insulating film has a film thickness T between the two electric conductors set to be substantially the same as a film thickness t around the other electric conductors. In claim 1 ,
The vehicular rotating electrical machine according to claim 1, wherein the radius r is set in accordance with an R shape of the four corners of the slot.

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