JP7088956B2 - A rotary electric machine for an internal combustion engine and a method for manufacturing a rotary electric machine for an internal combustion engine. - Google Patents

Description

Cross-reference of related applications

This application is based on patent application No. 2017-22201 filed in Japan on November 17, 2017, and patent application No. 2018-066967 filed in Japan on March 30, 2018. The contents of the application in the above are incorporated by reference as a whole.

The disclosure in this specification relates to a rotary electric machine for an internal combustion engine, a stator thereof, a method for manufacturing the same, and a method for operating the same.

Patent Document 1 discloses a rotary electric machine for an internal combustion engine and a method for manufacturing the same. The rotary electric machine is connected to the internal combustion engine. The rotating electric machine provides a part of a flywheel that provides an inertial mass in the rotating system of an internal combustion engine. The inertial mass enables continuous operation of the internal combustion engine and affects variable factors caused by the rotation of the internal combustion engine. Fluctuation factors include various factors such as torque fluctuations, vibrations, rotational speed fluctuations, and / or user feelings. Patent Document 2-4 exemplifies a rectifier circuit used in a rotary electric machine for an internal combustion engine. The contents of the prior art documents listed as prior art are incorporated by reference as an explanation of the technical elements in this specification.

Japanese Unexamined Patent Publication No. 10-4650 Japanese Unexamined Patent Publication No. 8-8900 Japanese Unexamined Patent Publication No. 11-8946 Japanese Unexamined Patent Publication No. 2001-93680

The prior art requires machining, for example, cutting a flywheel, in order to adjust the inertial mass. However, the adjustment of the inertial mass only gives a direct current change and / or a dynamic balance change to the variable element. Further improvements are required in the rotary electric machines for internal combustion engines, their stators, their manufacturing methods, and operating methods in the above-mentioned viewpoints or in other viewpoints not mentioned.

The rotary electric machine used for the internal combustion engine uses an external salient pole type stator. The coil winding can be provided by an aluminum-based metal. Aluminum-based metals have advantageous features such as light weight. However, when the coil winding is provided by an aluminum-based metal, it has been difficult to provide an industrially practical rotary electric machine. Further improvements are required in the rotary electric machine for internal combustion engines, its stator, and the method for manufacturing them in the above-mentioned viewpoints or in other viewpoints not mentioned.

One object disclosed is to provide a rotary electric machine for an internal combustion engine, a method of manufacturing the same, and a method of operating the internal combustion engine, in which the internal combustion engine is easy to rotate in a specific rotation angle region of the internal combustion engine.

One object disclosed is to provide a rotary electric machine for an internal combustion engine, a method for manufacturing the same, and a method for operating the rotary electric machine for an internal combustion engine, which suppresses the behavior of electric torque that hinders the rotation of the internal combustion engine in the rotation angle region immediately after the compression top dead center. Is.

The internal combustion engine rotary electric machine disclosed here has a rotor (21) and a stator (31) facing the rotor in the internal combustion engine rotary electric machine connected to the rotary shaft (5) of the internal combustion engine (2). However, when the internal combustion engine rotary electric machine functions as a generator, the electric torque (TQg) consumed to rotate the rotor to generate power by the internal combustion engine rotary electric machine is the compression top dead point (TQg) of the internal combustion engine. In C-TDC), it is adjusted so as to suppress the behavior that hinders the rotation of the internal combustion engine, and the electric torque is from the electric peak point (PKg) which is the maximum value immediately after the compression top dead point of the internal combustion engine. It is adjusted to be low.

According to the disclosed rotary electric machine for internal combustion engine, the electric torque is adjusted. The electric torque is adjusted so as to suppress the behavior that hinders the rotation of the internal combustion engine at the compression top dead center. Therefore, at the compression top dead center where the loss due to the structure of the internal combustion engine is relatively large, the behavior of the electric torque that hinders the rotation of the internal combustion engine is suppressed. As a result, there is provided a rotary electric machine for an internal combustion engine in which the internal combustion engine can easily rotate in a specific rotation angle region of the internal combustion engine.

The method for manufacturing a rotary electric machine for an internal combustion engine disclosed herein is for an internal combustion engine having a rotor (21) rotated by a rotating shaft (5) of the internal combustion engine (2) and a stator (31) facing the rotor. In order to rotate the rotor to generate power by the internal combustion engine rotary electric machine so as to suppress the behavior that hinders the rotation of the internal combustion engine at the compression top dead point (C-TDC) of the internal combustion engine in the manufacturing method of the internal combustion engine. It has a planning stage for planning the electric torque (TQg) consumed in the internal combustion engine and a forming stage for forming a rotary electric engine so that the electric torque planned in the planning stage is generated. The forming stage forms a magnetic pole in the rotor. In the planning stage, when the rotary electric machine for an internal combustion engine functions as a generator, the electric torque is lower than the maximum electric peak point (PKg) immediately after the compression top dead point of the internal combustion engine. Is adjusted to.

According to the disclosed method for manufacturing a rotary electric machine for an internal combustion engine, the electric torque consumed to rotate the rotor is planned, and the rotary electric machine is formed so as to generate the planned electric torque. The electric torque is designed to suppress the behavior that hinders the rotation of the internal combustion engine at the compression top dead center of the internal combustion engine . As a result, there is provided a method for manufacturing a rotary electric machine for an internal combustion engine in which the internal combustion engine easily rotates in a specific rotation angle region of the internal combustion engine.

The disclosed embodiments herein employ different technical means to achieve their respective objectives. The claims and the reference numerals in parentheses described in this section exemplify the correspondence with the parts of the embodiments described later, and are not intended to limit the technical scope. The objectives, features, and effects disclosed herein will be further clarified by reference to the subsequent detailed description and accompanying drawings.

It is a block diagram of the apparatus which concerns on 1st Embodiment. It is a waveform diagram which shows the crank angle and the engine behavior. It is a top view of a rotary electric machine. It is a waveform diagram which shows the engine behavior and the electric torque. It is a waveform diagram which shows the electric torque at the time of opening. It is a waveform diagram which shows the electric torque at the time of power supply. It is an enlarged waveform diagram which shows the engine behavior and the electric torque. It is a waveform diagram which concerns on 2nd Embodiment. It is an enlarged waveform diagram which shows the engine behavior and the electric torque. It is an enlarged waveform diagram which concerns on 3rd Embodiment. It is a top view of the rotary electric machine which concerns on 4th Embodiment. It is a waveform diagram which shows the engine behavior and the electric torque. It is a waveform diagram which shows the engine behavior and the electric torque. It is sectional drawing of the rotary electric machine which concerns on 5th Embodiment. It is a top view of a rotary electric machine. It is a top view of the stator. It is a perspective view of an insulator. It is a top view which shows one tooth. It is a waveform diagram which shows the performance at the time of a transient by FIG. It is a waveform diagram which enlarged a part of FIG. It is a waveform diagram which enlarged a part of FIG. It is a top view which shows one tooth. It is a waveform diagram which shows the performance at the time of a transient by FIG. 22. FIG. 3 is an enlarged waveform diagram of a part of FIG. 23. FIG. 3 is an enlarged waveform diagram of a part of FIG. 23. It is a top view which shows one tooth. It is a waveform diagram which shows the performance at the time of a transient by FIG. 26. FIG. 6 is an enlarged waveform diagram of a part of FIG. 27. FIG. 6 is an enlarged waveform diagram of a part of FIG. 27. It is a top view which shows one tooth. It is a waveform diagram which shows the performance at the time of a transient by FIG. FIG. 3 is an enlarged waveform diagram of a part of FIG. 31. FIG. 3 is an enlarged waveform diagram of a part of FIG. 31. It is a top view which shows one tooth. It is a waveform diagram which shows the performance at the time of a transient by FIG. 34. FIG. 3 is an enlarged waveform diagram of a part of FIG. 35. FIG. 3 is an enlarged waveform diagram of a part of FIG. 35. It is a top view which shows one tooth. It is a waveform diagram which shows the performance at the time of a transient by FIG. 38. FIG. 3 is an enlarged waveform diagram of a part of FIG. 39. FIG. 3 is an enlarged waveform diagram of a part of FIG. 39. It is a top view which shows one tooth. It is a waveform diagram which shows the performance at the time of a transient by FIG. 42. FIG. 3 is an enlarged waveform diagram of a part of FIG. 43. FIG. 3 is an enlarged waveform diagram of a part of FIG. 43. FIG. 3 is a plan view of a stator core having a round fitting portion (embossed mark) at the base of all teeth. FIG. 3 is a plan view of a stator core having a square fitting portion (embossed mark) at the base of all teeth. FIG. 3 is a plan view of a stator core having a linear trapezoidal connection at the base of all teeth. FIG. 3 is a cross-sectional view of a stator in which an aluminum-based coil winding is wound around the base of the tooth so as to form more layers than the tip of the tooth. FIG. 3 is a plan view of a stator core in which the outer circumferences of a plurality of teeth are continuous and annular. It is sectional drawing of the stator in which a resin spacer is arranged between adjacent teeth. FIG. 3 is a cross-sectional view of a stator in which resin is packed between a plurality of teeth and coils. FIG. 3 is a plan view of a stator core having a slit extending radially outward of the teeth. It is a top view of the stator core of another embodiment.

A plurality of embodiments will be described with reference to the drawings. In a plurality of embodiments, functionally and / or structurally corresponding parts and / or related parts may be designated with the same reference code or reference numerals having different hundreds or more digits. References can be made to the description of other embodiments for the corresponding and / or associated parts.

1st Embodiment In FIG. 1, an internal combustion engine system 1 includes an internal combustion engine 2 (engine) and a rotary electric machine for an internal combustion engine (hereinafter, simply referred to as a rotary electric machine 10). The engine 2 is a so-called 4-stroke type reciprocating engine. The engine 2 has a cylinder 3 and a piston 4. The engine 2 has a connecting rod 6 that connects the piston 4 and the rotating shaft 5. The engine 2 has a valve operating system 7 including an intake valve, an exhaust valve, and a camshaft. The valve operating system 7 provides 4-stroke operation. The engine 2 has an interlocking system 8 that interlocks the rotary shaft 5 and the valve operating system 7. The engine 2 is a single cylinder. The engine 2 is not limited to a single cylinder.

An example of the use of the rotary electric machine 10 is a generator driven by an engine 2. The rotary electric machine 10 is interlocked with the engine 2 by being mounted on the internal combustion engine. The engine 2 is a vehicle engine mounted on a vehicle or a general-purpose engine. Here, the term vehicle should be construed broadly and includes moving objects such as vehicles, ships and aircraft, and fixed objects such as amusement equipment and simulation equipment. Also, the general-purpose engine can be used as, for example, a generator and a pump. In this embodiment, the engine 2 is mounted on a saddle-riding vehicle.

The rotary electric machine 10 is electrically connected to the electric circuit 11. The electric circuit 11 includes a rectifier circuit (RCF) and an open type regulator circuit that adjusts an output voltage. The electrical circuit 11 includes a battery and / or an electrical load that utilizes single-phase power.

The rotary electric machine 10 is assembled to the engine 2. The engine 2 has a body 9 and a rotation shaft 5 rotatably supported by the body 9. The rotary electric machine 10 is assembled to the body 9 and the rotary shaft 5. The body 9 is a structure such as a crankcase and a mission case of the engine 2. The rotary shaft 5 can be provided by the crankshaft of the engine 2 or a rotary shaft interlocking with the crankshaft.

The rotary electric machine 10 is an outer rotor type rotary electric machine. The rotary electric machine 10 has a rotor 21 and a stator 31. In the following description, the term axial term refers to the direction along the central axis when the rotor 21, stator 31, or stator core 32 is regarded as a cylinder. The radial term refers to the radial direction when the rotor 21, the stator 31, or the stator core 32 is regarded as a cylinder.

The rotor 21 is a field magnet. The stator 31 is an armature. The rotor 21 has a cup shape as a whole. The rotor 21 is connected to the end of the rotating shaft 5. The rotor 21 rotates together with the rotation shaft 5. The rotor 21 is rotated by the engine 2. A gap is formed between the rotor 21 and the stator 31 in the radial and axial directions. In order to make the rotary electric machine 10 compact, it is desirable that the gap related to the stator 31 is small. The rotor 21 has a cup-shaped rotor core 22. The rotor core 22 provides a yoke for a permanent magnet, which will be described later. The rotor core 22 is made of magnetic metal. The rotor 21 has a permanent magnet 23 arranged on the inner surface of the rotor core 22. The rotor 21 provides a field magnet by means of a permanent magnet 23.

The stator 31 is an annular member. The stator 31 is arranged so as to face the rotor 21. The stator 31 has a stator core 32. The stator core 32 is provided by a laminated body of magnetic metal such as an electromagnetic steel plate. The stator core 32 is fixed to the body 9. The stator 31 has a stator coil 33 mounted on the stator core 32. The stator coil 33 provides an armature winding. The stator coil 33 is a single-phase winding or a multi-phase winding. The stator coil 33 causes the rotor 21 and the stator 31 to function as a generator. The coil wire forming the stator coil 33 is a single wire conductor coated with an insulating coating. The coil wire is made of an aluminum-based metal such as aluminum or an aluminum alloy.

The rotary electric machine 10 has a wire harness 15 that provides an electrical connection between the rotary electric machine 10 and the electric circuit 11. The wire harness 15 is an electric wire having better flexibility than a coil wire. The wire harness 15 includes a plurality of electric wires. Each electric wire is a coated conductor wire in which a bundle of a plurality of thin wires is covered with a resin coating. Each thin wire is made of copper-based metal or aluminum-based metal.

The wire harness 15 includes a plurality of power lines connecting the stator coil 33 and the electric circuit 11. The electric circuit 11 is an external circuit to which a power line is connected. The power line supplies the electric power induced in the stator coil 33 to the electric circuit 11 when the rotary electric machine 10 functions as a generator.

The electric circuit 11 includes a rectifier circuit 11a (RCF), a battery 11b (BT), and a load 11c (LT). The battery 11b is a secondary battery charged by the rotary electric machine 10. The battery 11b supplies the starting power of the engine 2 and / or the power of the load 11c. The load 11c is a headlight, a light such as a turn signal, and / or an ignition device of the engine 2. The rectifier circuit 11a includes switching elements 11d and 11e (SW) as rectifier elements for rectifying half-wave components, and a control device 11f (CNT). The switching elements 11d and 11e are provided by, for example, a thyristor element and a transistor element. For example, the switching element 11d provides a half-wave rectifier circuit that supplies a positive half-wave component to the battery 11b. For example, the switching element 11e provides a half-wave rectifier circuit that supplies a negative half-wave component to the load 11c.

The control device 11f is provided by an analog circuit or a digital circuit. The control device 11f controls the on / off of the switching elements 11d and 11e to control the period for supplying power from the rotary electric machine 10 to the battery 11b or the load 11c. Therefore, the rectifier circuit 11a is also a regulator circuit that controls the power supplied from the rotary electric machine 10. The description of Patent Document 2-4 is incorporated by reference as part of the description of this specification.

The control device 11f has at least one arithmetic processing unit (CPU) and at least one memory device (MMR) as a storage medium for storing programs and data. The control device 11f is provided by a microcomputer provided with a storage medium readable by a computer. The storage medium is a non-transitional substantive storage medium that stores a computer-readable program non-temporarily. The storage medium may be provided by a semiconductor memory, a magnetic disk, or the like. The control device 11f may be provided by a single computer or a set of computer resources linked by a data communication device. By being executed by the controller 11f, the program causes the controller 11f to function as the apparatus described herein and to perform the methods described herein.

The control device 11f, the signal source, and the controlled object provide a control system. Control systems provide a variety of elements. At least some of those elements can be called blocks for performing functions. From another point of view, at least some of those elements can be referred to as modules or sections that are interpreted as a configuration. Further, the elements included in the control system can be called the means for realizing the function only intentionally.

The means and / or functions provided by the control system can be provided by the software recorded in the substantive memory device and the computer, software only, hardware only, or a combination thereof running the software. For example, if the control device is provided by an electronic circuit that is hardware, it can be provided by a digital circuit containing a large number of logic circuits, or an analog circuit.

In FIG. 2, the upper row shows the torque TQ (Nm) in the engine 2, and the lower row shows the force F (N) acting on the piston in the engine 2. The horizontal axis is the crank angle CA. The engine 2 repeats a combustion stroke (POW), an exhaust stroke (EXH), an intake stroke (INT), and a compression stroke (COM) in this order. The engine 2 passes through the combustion bottom dead center (P-BDC), the exhaust top dead center (ETDC), the intake bottom dead center (ITDC), and the compression top dead center (C-TDC) in this order. In the following description, the compression top dead center is mainly referred to as top dead center (TDC). The crank angle CA has the exhaust top dead center E-TDC as 0 degree.

The engine torque TQe shows a waveform in a typical operating state of the engine 2. A typical operating state is, for example, a state in which a predetermined load is applied to the engine 2 and the engine 2 is operated at a frequently used rotation speed (for example, 3000 rpm). The waveform of the engine torque TQe changes depending on the operating state. The phase of the engine torque TQe with respect to the crank angle CA is fixed with respect to the crank angle CA. The typical operating state may be an operating state in which the variable element of the engine 2 appears most prominently.

The torque TQ of the engine 2 is observed as a rotational torque on the rotary shaft 5. By combining the inertial torque shown by the alternate long and short dash line and the gas pressure torque shown by the broken line, the engine torque TQe shown by the solid line is generated. The engine torque TQe is also called a combined torque. The alternate long and short dash line indicates the average torque. At this time, the force F acting on the piston is a force acting in the direction of propelling the piston 4. The inertial force shown by the alternate long and short dash line and the force due to the gas pressure shown by the broken line are combined to generate the force F shown by the solid line.

The force F acting on the piston is converted into torque TQ by the crank mechanism of the engine 2. Therefore, near the top dead center (C-TDC), particularly after the top dead center, the torque TQ is small, but the force F acting on the piston 4 is large. In this region (near top dead center (C-TDC), especially after top dead center), combustion has progressed to some extent in the cylinder, and high temperature and high pressure associated with combustion have already occurred. Since this region is a region where high temperature and high pressure are maintained, the cooling loss is large, and the load on the rotating portion of the engine 2, that is, a plurality of bearings is also large. Therefore, the friction loss of the engine 2 is also large. In this region, it is desirable that the torque for driving the rotary electric machine 10 is small. Since the small torque enables the smooth rotation of the engine 2, the engine 2 can smoothly pass through the above region. This smooth passage contributes to loss reduction. On the other hand, even in the region before the top dead center (C-TDC), high temperature and high pressure are generated in the cylinder. However, the region before top dead center is a process in which the temperature and pressure gradually rise due to the gradual progress of combustion. Therefore, even if the torque of the rotary electric machine 10 is high in the region before the top dead center, the influence on the engine 2 is relatively small as compared with the region after the top dead center. In areas other than near top dead center, such characteristic effects are not noticeably observed.

In FIG. 3, the rotor 21 includes a cylindrical rotor core 22 and a plurality of permanent magnets 23. The rotor core 22 has a through hole 21a for receiving the rotating shaft 5. The rotor core 22 has a rotor positioning portion 21b that positions the rotor 21 with respect to the rotation axis 5 in the rotation direction. The rotor positioning portion 21b is provided by a key mechanism that provides meshing between the through hole 21a and the rotating shaft 5. The rotary shaft 5 also has a key mechanism for the rotor positioning portion 21b.

The stator 31 is an external projectile type stator. The stator core 32 has a plurality of magnetic poles. The magnetic poles are also called salient poles or teeth. The stator 31 has a through hole 31a in the center. The stator 31 has a plurality of stator positioning portions 31b. The stator positioning portion 31b is provided by a through hole for receiving a bolt for fixing the stator 31 to the body 9. The body 9 also has a bolt hole for the stator positioning portion 31b.

The plurality of permanent magnets 23 include 12 permanent magnets 23. Thus, the rotor 21 provides 6 to 12 pole poles. The stator 31 provides twelve magnetic poles. The number of poles of the rotor 21 and the number of poles of the stator 31 are not limited to this embodiment, and can be provided by various combinations. The stator coil 33 is a single-phase winding.

In FIG. 3, the mechanical phase of the rotary electric machine 10 with respect to the engine 2 can be changed by various methods. The rotation angle of the engine 2 is indicated by the rotation angle of the rotation shaft 5. The rotation angle of the rotary electric machine 10 can be indicated by the rotation angle of the rotor 21 with respect to the rotation angle of the rotation shaft 5. The rotation angle of the rotary electric machine 10 can be indicated by the fixed angle of the stator 31 with respect to the rotation angle (reference position) of the rotation shaft 5. The rotation angle of the rotary electric machine 10 can be indicated by the position of the stator 31 in the circumferential direction with respect to the rotation shaft 5. The rotation angle of the rotary electric machine 10 can also be indicated by the position of the permanent magnet 23 with respect to the rotor core 22. The rotation angle of the rotary electric machine 10 with respect to the rotation shaft 5 depends on the magnetizing position of the rotor 21 (position in the circumferential direction of the plurality of permanent magnets 23 with respect to the rotor core 22), the position in the rotation direction of the rotor 21, and the position in the circumferential direction of the stator 31. Can be shown.

Similarly, the mechanical phase of the rotary electric machine 10 with respect to the engine 2 can be changed by various methods. For example, the mechanical phase is determined by changing the magnetizing position in the rotor 21 (position in the circumferential direction of the plurality of permanent magnets 23 with respect to the rotor core 22), the position in the rotational direction of the rotor 21, and the position in the circumferential direction of the stator 31. Can be changed. The phase of the rotary electric machine 10 with respect to the engine 2 can be changed by various methods not limited to the methods exemplified here.

The phase of the rotary electric machine 10 with respect to the engine 2 can be changed by shifting the positions of the plurality of permanent magnets 23 in the circumferential direction. For example, the position of one permanent magnet 23 can be changed by changing the position from the position 23a shown by the broken line. The trace of the change in the magnetizing position in the rotor 21 may appear in the deviation 23s in the rotation direction between the rotation direction position of the rotor positioning portion 21b and the actual reference position 23b of the plurality of permanent magnets 23.

The phase of the rotary electric machine 10 with respect to the engine 2 can be changed by changing the position of the rotor positioning portion 21b to the position 21b1. The phase of the rotary electric machine 10 with respect to the engine 2 can be changed by changing to the position of the stator positioning portion 31b and the position 31b1. Two or more of the above-mentioned plurality of methods may be combined.

The phase of the rotation angle of the rotor 21 with respect to the rotation angle of the rotation shaft 5 is relatively adjusted by the planned arrangement of the position of the rotor positioning portion 21b. By systematically arranging the position of the stator positioning portion 31b, the phase of the circumferential angle of the stator 31 with respect to the rotation angle of the rotation shaft 5 is relatively adjusted. Due to the planned arrangement of the positions of the plurality of permanent magnets 23 (positions of the magnetic poles) with respect to the rotor core 22, the phase of the circumferential angle of the rotor 21 with respect to the rotation angle of the rotation shaft 5 is relatively adjusted. As a result, the phase of the rotation angle of the rotary electric machine 10 with respect to the rotation angle of the rotation shaft 5 is relatively adjusted. As a result, the phase of the electric torque consumed to drive the rotary electric machine 10 with respect to the engine torque generated by the engine 2 is set to a predetermined value.

For one mass-produced model, the mechanical phase of the rotary machine 10 with respect to the engine 2 is defined at the design stage. The mechanical phase of the rotary electric machine 10 with respect to the engine 2 may differ among a plurality of models. This is because there are differences in the characteristics of the variable elements required for multiple models. For example, in one model, the mechanical phase of the rotary electric machine 10 with respect to the engine 2 is defined so as to suppress variable elements including engine torque. For example, in one other model, the phase of the rotary electric machine 10 with respect to the engine 2 is defined so as to emphasize or amplify the variable element including the engine torque.

The phase of the rotary electric machine 10 with respect to the engine 2 is specified so as to intentionally suppress or emphasize the variable element of the engine 2. The phase of the rotary electric machine 10 with respect to the engine 2 is defined to give a suitable change to the variable element of the engine 2.

In this embodiment, the phase of the rotary electric machine 10 with respect to the engine 2 is adjusted so as to suppress a decrease in the output torque of the engine 2. The term adjustment refers to adjustment at the pre-manufacturing planning stage. The term regulation may include post-manufacturing variable mechanism regulation. The phase of the rotary electric machine 10 includes the mechanical phase of the rotary electric machine 10 with respect to the rotary shaft 5 of the engine 2, the phase in the electric action of the rotary electric machine 10, and the phase in the magnetic action of the rotary electric machine 10. .. Here, the phase of the variable element generated in the engine 2 is invariant. The phase of the variable element generated in the rotary electric machine 10 is set to the planned value by adjusting the relative positional relationship between the rotor 21 and the stator 31.

The method for manufacturing a rotary electric machine for an internal combustion engine includes an assembly stage in which the rotor 21 and the stator 31 are fixed to the engine 2. The manufacturing method includes a component manufacturing step including a step of manufacturing the rotor 21 and a step of manufacturing the stator 31 before the assembly step. The manufacturing method has a planning step of planning the phase of the rotary electric machine 10 with respect to the engine 2 before the component manufacturing step.

The planning stage plans the electric torque TQg consumed to rotate the rotor 21. In the planning stage, the electric torque TQg is planned so as to suppress the behavior that hinders the rotation of the internal combustion engine 2 at the compression top dead center C-TDC of the internal combustion engine 2. The planning stage may be a stage of planning the phase of the rotary electric machine 10 with respect to the engine 2 so as to suppress or emphasize the variable element of the engine 2. For example, the position of the magnetic pole of the rotor 21 with respect to the rotation angle of the rotation shaft 5 is planned. This is achieved by planning the positions of the plurality of permanent magnets 23 with respect to the rotor core 22 or the positions of the rotor positioning portions 21b. For example, the position of the magnetic pole of the stator 31 with respect to the rotation angle of the rotation shaft 5 is planned. This is achieved by planning the fixed position of the stator 31, that is, the position of the stator positioning portion 31b with respect to the rotation angle of the rotation shaft 5.

The component manufacturing step after this planning step includes a forming step of forming the rotor 21 and the stator 31 so as to realize the phase of the rotary electric machine 10 with respect to the engine 2 planned in the planning step. The forming stage is also a stage of forming the rotary electric machine 10 so that the electric torque TQg planned in the planning stage is generated. The forming step may include a step of fixing the permanent magnet 23 to the rotor core 22 at a planned position (a step of determining a magnetizing position that provides a plurality of magnetic poles). The forming step may include forming the rotor positioning portion 21b at a planned position. The forming step may include forming the stator positioning portion 31b at a planned position. As a result, the forming stage forms the rotor and / or the stator of the rotating electric machine so that the rotating electric machine rotates in the phase planned in the planning stage.

The forming step can be provided by the step of forming the magnetic poles in the rotor 21. The forming stage is also a stage of forming a deviation 23s in the rotation direction between the rotation direction position of the rotor positioning portion 21b and the reference position 23b of the permanent magnet 23 (magnetic pole). This deviation 23s is also a trace of a change in the magnetizing position in the rotor 21.

FIG. 4 is a waveform diagram showing an engine torque TQe output by the engine 2 and an electric torque TQg consumed for generating electricity by the rotary electric machine 10. In the figure below, the compression top dead center C-TDC is the origin. Therefore, the crank angle CA starts from 540 degrees.

The waveform of the electric torque TQg changes depending on the operating state of the rotary electric machine 10. The phase of the electric torque TQg with respect to the crank angle CA can be adjusted by changing the fixed position of the rotor 21 and / or the stator 31 to the engine 2. These fixed positions are set to intentionally suppress or emphasize the variable elements of the engine 2.

The engine torque TQe rises sharply during the period including the compression top dead center C-TDC. Immediately after the compression top dead center C-TDC, the engine torque TQe reaches the maximum engine peak point PKe by explosive combustion.

The electric torque TQg has a periodic AC component due to a plurality of magnetic poles of the rotor 21 and the stator 31. The electric torque TQg repeats a plurality of electric peak points PKg having a maximum value and a plurality of electric bottom points BTg having a minimum value during the operation cycle of the internal combustion engine 2 of 720CA. The electric torque TQg is reversed positively and negatively at the zero cross point ZCg. The plurality of zero cross points ZCg have a zero cross point ZCg in the process of decreasing the electric torque TQg and a zero cross point ZCg in the process of increasing the electric torque TQg.

In this embodiment, the phase of the rotary electric machine 10 with respect to the engine 2 is adjusted in order to smooth the rotation of the engine 2 immediately after the compression top dead center C-TDC. The engine torque TQe is in the process of rising between the compression top dead center C-TDC and the engine peak point PKe, and at a position where the crank angle CA is slightly past the compression top dead center C-TDC. Very small. In this region, the effect of the electric torque TQg may deprive the effective engine torque TQe and hinder the smooth rotation of the engine. Therefore, the most preferable state is to keep the electric torque TQg in a relatively low state until the engine torque TQe becomes sufficiently large. For example, in the crank angle CA, the electric torque TQg is adjusted to the phase that can make the period below the average value the longest in the period after the compression top dead center C-TDC including the compression top dead center C-TDC. Is the most preferable.

In this embodiment, the phase adjustment is performed so that one of the zero cross points ZCg in the process of lowering the electric torque TQg is generated at the compression top dead center C-TDC. As a result, the electric torque TQg in the vicinity of the compression top dead center C-TDC is suppressed. In particular, the electric torque TQg is suppressed immediately after the compression top dead center C-TDC. Suppression of the electric torque TQg indicates suppression of the torque consumed by the rotary electric machine 10. Therefore, immediately after the compression top dead center C-TDC, the rotation of the engine 2 proceeds smoothly.

As a result, smooth rotation of the engine 2 can be obtained in the vicinity of the compression top dead center C-TDC. The smooth rotation of the engine 2 also contributes to suppressing knocking and suppressing the progress of excessive combustion.

FIG. 5 shows a waveform when the output of the rotary electric machine 10 is open. Even when the output of the rotary electric machine 10 is in the open state, the same waveform as described above is observed.

FIG. 6 shows a waveform when the output of the rotary electric machine 10 is controlled by the rectifier circuit 11a and power is supplied. The electric torque TQg fluctuates violently due to the switching of the switching elements 10d and 10e. The electric torque TQg fluctuates significantly due to fluctuations in output. The electric torque TQg reaches the electric bottom point BTg immediately after the compression top dead center C-TDC even when the electric power is being supplied. Therefore, even if the output is controlled by the electric circuit 11, the electric torque TQg is suppressed immediately after the compression top dead center C-TDC.

FIG. 7 is an enlarged waveform diagram immediately after the compression top dead center C-TDC. One of the zero cross points ZCg in the process of decreasing the electric torque TQg is generated at the compression top dead center C-TDC. Further, the first bottom point BTg immediately after the compression top dead center C-TDC occurs before the engine peak point PKe. As a result, the electric torque TQg decreases immediately after the compression top dead center C-TDC in which the absolute value of the engine torque TQe is small. Therefore, the electric torque TQg does not hinder the rotation of the engine 2. Moreover, in the process in which the absolute value of the engine torque TQe gradually increases immediately after the compression top dead center C-TDC, the electric torque TQg further decreases. Therefore, the electric torque TQg does not hinder the rotation of the engine 2 more and more. Further, since the electric bottom point BTg is reached before the engine peak point PKe is reached, the engine torque TQe rises smoothly toward the engine peak point PKe.

This embodiment provides an operation method for operating a rotary electric machine 10 rotated by a rotary shaft 5 of an internal combustion engine 2. The operation method includes a stage of operating the internal combustion engine 2 and a stage of rotating the rotary electric machine 10 by the internal combustion engine 2. The stage of rotating the rotary electric machine 10 is also a stage of rotating the rotor 21. The operation method is a step of adjusting the electric torque TQg and an adjusted electric torque TQg so as to suppress the behavior that hinders the rotation of the internal combustion engine 2 at the compression top dead center C-TDC of the internal combustion engine 2. Including stages. The adjustment step is adjusted by the phase associated with the rotor 21 and / or the stator 31 and / or the current flowing through the stator 31. The phase associated with the rotor 21 and / or the stator 31 can be represented by a mechanical phase or an electrical phase with respect to the rotating shaft 5. The current flowing through the stator 31 can be adjusted by the impedance of the electric circuit 11.

This embodiment provides a rotary electric machine 10. The rotary electric machine 10 is connected to the rotary shaft 5 of the internal combustion engine 2. The rotary electric machine 10 has a rotor 21 and a stator 31 facing the rotor 21. Further, the rotary electric machine 10 defines an electric torque TQg consumed for rotating the rotor 21. The electric torque TQg is adjusted so as to suppress the behavior of inhibiting the rotation of the internal combustion engine 2 at the compression top dead center C-TDC of the internal combustion engine 2. As a result, the electric torque TQg is suppressed before and after the compression top dead center C-TDC, and the behavior of the electric torque TQg that hinders the rotation of the internal combustion engine 2 is suppressed.

In this embodiment, the electric torque TQg is adjusted to be lower than the maximum electric peak point PKg immediately after the compression top dead center C-TDC of the internal combustion engine 2. As a result, the situation where the electric peak point PKg hinders the rotation of the internal combustion engine 2 is avoided. The period immediately after the compression top dead center C-TDC is the period until the engine torque TQe of the internal combustion engine 2 reaches the maximum engine peak point PKe. As a result, in the process in which the engine torque TQe rises from a small absolute value, the situation in which the rotary electric machine 10 hinders the rotation of the internal combustion engine 2 is suppressed.

In one aspect, the electric torque TQg fluctuates via a plurality of zero crossing points ZCg that intersect the mean value. The electric torque TQg is adjusted so that one of the zero cross points ZCg in the process of lowering the electric torque TQg is generated at the compression top dead center C-TDC. As a result, the electric torque TQg is suppressed before and after the compression top dead center C-TDC, and the behavior of the electric torque TQg that hinders the rotation of the internal combustion engine 2 is suppressed. From another aspect, the electric torque TQg has a period T in which a plurality of increases and decreases are repeated during the operation cycle (720CA) of the internal combustion engine 2. The electric torque TQg is positioned at a low torque period in which the electric torque TQg is relatively low immediately after the compression top dead center C-TDC of the internal combustion engine 2.

The electric torque TQg is adjusted by the phase associated with the rotor 21 and / or the stator 31. The electric torque TQg can be adjusted by the current flowing through the stator 31. The electric torque TQg is adjusted by the position of the magnetic pole in the rotor 21. The electric torque TQg can be adjusted by the position of the rotor positioning portion 21b that positions the rotor 21 with respect to the internal combustion engine 2. The electric torque TQg can be adjusted by the position of the stator positioning portion 31b that positions the stator 31 with respect to the internal combustion engine 2.

According to the embodiment described above, by adjusting the phase of the rotary electric machine 10 with respect to the engine 2, a rotary electric machine for an internal combustion engine that supports smooth rotation of the engine 2 is provided.

Second Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In the above embodiment, one of the zero cross points ZCg in the process of lowering the electric torque TQg is generated at the compression top dead center C-TDC. Instead of this, one of the electric bottom points BTg may be generated at the compression top dead center C-TDC. Also in this embodiment, the configurations of FIGS. 1, 2, and 3 are adopted.

In FIG. 8, in this embodiment, the phase of the rotary electric machine 10 with respect to the engine 2 is adjusted in order to smooth the rotation of the engine 2 before and after the compression top dead center C-TDC. In this embodiment, the phase adjustment is performed so that one of the plurality of electric bottom points BTg occurs at the compression top dead center C-TDC.

FIG. 9 is an enlarged waveform diagram immediately after the compression top dead center C-TDC. One of the electric bottom points BTg is generated at the compression top dead center C-TDC. Further, the first zero crossing point ZCg immediately after the compression top dead center C-TDC occurs before the engine peak point PKe. As a result, the absolute value of the electric torque TQg is small immediately after the compression top dead center C-TDC where the absolute value of the engine torque TQe is small. Therefore, the electric torque TQg does not hinder the rotation of the engine 2. Moreover, in the process in which the absolute value of the engine torque TQe gradually increases immediately after the compression top dead center C-TDC, the absolute value of the electric torque TQg is still small. Therefore, the electric torque TQg still does not hinder the rotation of the engine 2.

In this embodiment, the electric torque TQg fluctuates via a plurality of electric bottom points BTg as minimum values. The electric torque TQg is adjusted so that one of the electric bottom points BTg is generated at the compression top dead center C-TDC. As a result, after the compression top dead center C-TDC, the electric torque TQg is suppressed, and the behavior of the electric torque TQg that hinders the rotation of the internal combustion engine 2 is suppressed.

According to the embodiment described above, by adjusting the phase of the rotary electric machine 10 with respect to the engine 2, a rotary electric machine for an internal combustion engine that supports smooth rotation of the engine 2 is provided.

Third Embodiment This embodiment is a modification based on the preceding embodiment. In the above embodiment, the zero cross point ZCg or the electric bottom point BTg in the process of lowering the electric torque TQg is generated at the compression top dead center C-TDC. Instead of this, a zero cross point ZCg in the process of increasing the electric torque TQg may be generated immediately after the compression top dead center C-TDC. Also in this embodiment, the configurations of FIGS. 1, 2, and 3 are adopted.

In FIG. 10, in this embodiment, the phase of the rotary electric machine 10 with respect to the engine 2 is adjusted in order to smooth the rotation of the engine 2 before and after the compression top dead center C-TDC.

In this embodiment, the phase adjustment is performed so that the zero cross point ZCg in the process of increasing the electric torque TQg is generated immediately after the compression top dead center C-TDC. The zero cross point ZCg is advanced by 7 / 8T as compared with the first embodiment. Therefore, immediately after the compression top dead center C-TDC, the electric torque TQg shows a value smaller than the average value. Also in this embodiment, the absolute value of the electric torque TQg is small immediately after the compression top dead center C-TDC where the absolute value of the engine torque TQe is small. Therefore, the electric torque TQg does not hinder the rotation of the engine 2. Moreover, the electric torque TQg is small in front of the compression top dead center C-TDC. Therefore, the electric torque TQg does not hinder the rotation of the engine 2 from before the compression top dead center C-TDC to immediately after the compression top dead center C-TDC.

In this embodiment, the electric torque TQg fluctuates via a plurality of zero cross points ZCg that intersect the mean value. The electric torque TQg is adjusted so that one of the zero cross points ZCg in the process of increasing the electric torque TQg is generated after the compression top dead center C-TDC. In other words, the compression top dead center C in the 1/2 cycle between the zero cross point ZCg in the process in which the electric torque TQg decreases and the zero cross point ZCg in the process in which the electric torque TQg subsequently generated in the zero cross point ZCg increases. -TDC is positioned. As a result, after the compression top dead center C-TDC, the electric torque TQg is suppressed, and the behavior of the electric torque TQg that hinders the rotation of the internal combustion engine 2 is suppressed.

According to the embodiment described above, by adjusting the phase of the rotary electric machine 10 with respect to the engine 2, a rotary electric machine for an internal combustion engine that supports smooth rotation of the engine 2 is provided.

Fourth Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In the above embodiment, the number of magnetic poles of the rotor 21 and the number of magnetic poles of the stator 31 are 12-12. Instead of this, various numbers can be adopted as the number of magnetic poles of the rotor 21 and the number of magnetic poles of the stator 31. For example, various pole numbers such as 6 poles, 8 poles, 10 poles, 12 poles, 14 poles, 16 poles, and 18 poles, and combinations of these pole numbers can be used.

FIG. 11 shows a fourth embodiment. The rotary electric machine 410 has a rotor 21 and a stator 31. The rotor 21 has six magnetic poles. The stator 31 has six magnetic poles. According to the rotary electric machine 410, a waveform of electric torque TQg having a period T longer than that of the above-described embodiment is provided.

12 and 13 correspond to FIGS. 4 and 5. In FIGS. 12 and 13, the phase of the rotary electric machine 410 is adjusted so that one of the zero cross points ZCg in the process of lowering the electric torque TQg is generated at the compression top dead center C-TDC. In this embodiment, after the compression top dead center C-TDC, the electric torque TQg is smaller for a long period of time as compared with the preceding embodiment. In this embodiment, the first electric bottom point BTg occurs before the engine peak point PKe. Moreover, the second zero cross point ZCg is generated after the engine peak point PKe. Therefore, the electric torque TQg is suppressed to the average value or less in the period until the engine torque TQe reaches the engine peak point PKe. Therefore, the electric torque TQg supports the smooth rotation of the engine 2. Further, after the engine peak point PKe, the first electric peak point PKg is generated. Therefore, for a long period of time, the electric torque TQg supports the smooth rotation of the engine 2.

In the plurality of embodiments described above, the stator core disclosed in the plurality of embodiments described later can be further adopted. Among the plurality of embodiments described later, some embodiments produce variations in electric torque suitable for combination with the above-described embodiments. Even if the torque phase associated with the engine rotation and the electric torque phase are synchronized with each other in a predetermined relationship, if the electric torque pulsation width is small, the effect in the above-described embodiment is small. On the other hand, as in the embodiment described later, by combining the stator core that produces a pulsating width of a relatively large electric torque with the above-described embodiment, the desired effect can be expected.

Fifth Embodiment FIG. 14 shows a power system 510 for an internal combustion engine. The electric power system 510 includes a rotary electric machine 511 for an internal combustion engine (hereinafter, simply referred to as a rotary electric machine). In the figure, the cross section of the rotary electric machine 511 in the cross section including the rotary shaft AX is shown. The rotary electric machine 511 is assembled to the internal combustion engine 512. The internal combustion engine 512 has a body 513 and a rotating shaft 514 that is rotatably supported by the body 513 and rotates in conjunction with the internal combustion engine 512. The rotary electric machine 511 is assembled to the body 513 and the rotary shaft 514. The body 513 is a structure such as a crankcase and a mission case of the internal combustion engine 512. In the illustrated example, the body 513 has a base on the right side and a cover on the left side. The rotary shaft 514 is a crank shaft of the internal combustion engine 512, or a rotary shaft interlocking with the crank shaft. The rotary shaft 514 rotates by operating the internal combustion engine 512, and drives the rotary electric machine 511 to function as a generator. The rotary shaft 514 is rotationally driven by the rotary electric machine 511 when the rotary electric machine 511 functions as an electric machine.

The power system 510 has an electrical circuit (CNT) 515. The rotary electric machine 511 and the electric circuit 515 are connected by a power line 516. The power line 516 outputs the generated power to the electric circuit 515 when the rotary electric machine 511 is used as a generator. The electric circuit 515 includes a rectifier circuit for rectifying the generated power. The electric circuit 515 includes the electric circuit of the vehicle and the battery. An example of an application of the rotary electric machine 511 is a generator driven by an internal combustion engine 512 for a vehicle. The rotary electric machine 511 can be used for, for example, a saddle-riding vehicle.

The rotary electric machine 511 may be used as an electric motor for supporting an internal combustion engine 512 for a vehicle. In this case, the electric circuit 515 includes an inverter circuit and a control device. In this case, the rotary electric machine 511 includes one or a plurality of rotation position sensors in order to output a signal indicating the rotation position. The rotation position sensor outputs a reference position signal of the rotation electric machine 511 and / or a rotation position signal of the rotation electric machine 511 to the electric circuit 515. The control device uses the rotation position signal to execute control so that the rotary electric machine 511 functions as an electric motor.

The rotary electric machine 511 has a rotor 521 and a stator 531. The rotor 521 is a field magnet. The stator 531 is an armature. The rotor 521 is entirely cup-shaped. The rotor 521 is a member extending over the end surface and the radial outer surface of the stator 531. The rotor 521 is fixed to the end of the rotating shaft 514. The rotor 521 and the rotation shaft 514 are connected via a positioning mechanism related to the rotation direction such as key fitting. The rotor 521 is fixed by being fastened to the rotating shaft 514 by a fixing bolt. The rotor 521 rotates together with the rotation shaft 514. The rotor 521 is rotatably supported facing a plurality of magnetic poles.

The rotor 521 has a cup-shaped rotor core 522. The rotor core 522 is connected to the rotating shaft 514 of the internal combustion engine 512. The rotor core 522 provides a yoke for the permanent magnet 523 described below. The rotor core 522 is made of magnetic metal.

The rotor 521 has a permanent magnet 523 arranged on the inner surface of the rotor core 522. The rotor 521 provides a field magnet by means of a permanent magnet 523. The permanent magnet 523 is fixed to the inside of the cylinder of the rotor core 522. The permanent magnet 523 has a plurality of segments. Each segment is partially cylindrical. The permanent magnet 523 provides a plurality of N poles and a plurality of S poles inside the permanent magnet 523. The permanent magnet 523 provides at least a field magnet. Permanent magnet 523 provides 6 pairs of N-pole and S-pole, or 12-pole field, with 12 segments. The number of magnetic poles may be another number.

The stator 531 has a stator core 532. The stator core 532 is arranged radially inside the rotor 521 by being fixed to the body 513 of the internal combustion engine 512. The stator core 532 is formed by laminating electromagnetic steel sheets formed into a predetermined shape. The stator 531 has a stator coil 533 wound around a stator core 532. The stator coil 533 provides an armature winding. The stator coil 533 is a single-phase winding or a multi-phase winding. The stator coil 533 provides an armature winding.

The stator 531 has an insulator 534. The insulator 534 is arranged between the stator core 532 and the stator coil 533. The insulator 534 is also called a bobbin. A portion of the insulator 534 provides a flange portion of the bobbin by being positioned adjacent to the magnetic pole. A part of the insulator 534 is arranged on both sides in the axial direction of the magnetic pole. The insulator 534 is also exposed to the annular portion of the stator core 532.

The stator 531 has a bracket 535. The bracket 535 is fixed to the stator core 532. The bracket 535 fixes the power line 516.

The stator 531 is an annular member. The stator 531 is fixed to the body 513 by a plurality of fixing bolts. The stator 531 is arranged between the rotor 521 and the body 513. The stator 531 has an outer peripheral surface facing the inner surface of the rotor 521 via a gap.

The rotation of the rotary electric machine 511 is detected by the rotation sensor 517. The rotation sensor 517 detects a feature portion formed on the outer surface of the rotor 521. The feature section provides, for example, a plurality of protrusions and recesses between them. The waveform detected by the rotation sensor 517 is also called a pulsar waveform. The rotation sensor 517 can be provided by a magnetic sensor such as a magnet pickup, an MRE element, and a Hall effect element.

The stator coil 533 is provided by an aluminum-based metal. The stator coil 533 is provided by a conductor made of aluminum or a conductor made of an aluminum alloy.

FIG. 15 shows a rotor 521 and a stator 531. In the figure, the state where the cover is removed is shown. In the figure, the central opening 531a of the stator 531 is shown. The boss portion 522a of the rotor 521 can be seen in the central opening 531a. In the figure, the open end of the rotor 521 is shown. The shape of the stator coil 533 is schematically shown.

The stator core 532 has a plurality of magnetic poles 536. The stator core 532 has a connecting portion 537. The connecting portion 537 is annular. The connecting portion 537 connects a plurality of magnetic poles 536 at their bases. The connecting portion 537 functions as a yoke for a plurality of magnetic poles 536. The stator core 532 is fixed to the body 513 at the connecting portion 537. The connecting portion 537 may have a seam. The plurality of magnetic poles 536 are arranged on the outer periphery. The magnetic pole 536 is also called a tooth. The stator core 532 has, for example, 12 magnetic poles 536. The number of magnetic poles 536 may be any other number. These magnetic poles 536 are arranged so as to face the field of the rotor 521. One magnetic pole 536 has one single coil 533u. The stator coil 533 includes a plurality of single coils 533u. The single coil 533u is also called a unit coil.

FIG. 16 shows the stator core 532. In the figure, the rotation axis AX of the rotary electric machine 511 and the radial center axis AR of the magnetic pole 536 are shown. The stator core 532 has a plurality of magnetic poles 536 and a common connecting portion 537. One magnetic pole has a tip 536a for facing the rotor 521. The tip portion 536a provides an outer peripheral surface that extends along the circumferential direction. The tip portion 536a is also referred to as a tip enlargement portion. The tip portion 536a provides a magnetic pole surface facing radially outward. One magnetic pole 536 has a rod-shaped portion 536c radially inward from the tip portion 536a. The rod-shaped portion 536c connects the tip portion 536a and the connecting portion 537. The rod-shaped portion 536c extends radially. The rod-shaped portion 536c extends radially inside the stator coil 533. The connecting portion 537 is provided on the inner side in the radial direction, which is the base end side of the plurality of rod-shaped portions 536c.

FIG. 17 is a perspective view of the insulator 534. The insulator 534 is arranged so as to sandwich the stator core 532 from both sides. In the figure, a half of the insulator 534 is shown. The insulator 534 has a flange portion 534a positioned so as to protrude from the tip portion 536a. The flange portion 534a provides a flange for the stator coil 533. The insulator 534 has an accommodating portion 534b. The accommodating portion 534b accommodates the tip portion 536a and exposes the tip surface 536b.

The insulator 534 has a body portion 534c. The flange portion 534a extends radially outward from the axis of the body portion 534c with respect to the axis of the body portion 534c. The body portion 534c has a tubular shape. The body portion 534c is a square cylinder with rounded corners. The body portion 534c extends radially. The body portion 534c accommodates the rod-shaped portion 536c. The body portion 534c wraps the rod-shaped portion 536c. The body portion 534c has an outer surface shape corresponding to the outer surface of the rod-shaped portion 536c. The body portion 534c provides a winding body for the stator coil 533.

The insulator 534 has an annular connecting portion 534d. The connecting portion 534d connects a plurality of body portions 534c. The connecting portion 534d is arranged inside the plurality of body portions 534c in the radial direction. The connecting portion 534d extends radially outward from the axis of the body portion 534c with respect to the axis of the body portion 534c.

The flange portion 534a and the connecting portion 534d are located at both ends of the body portion 534c. The flange portion 534a, the body portion 534c, and the connecting portion 534d provide a winding cylinder for the stator coil 533. The flange portion 534a, the body portion 534c, and the connecting portion 534d are also referred to as bobbins. The flange portion 534a and the connecting portion 534d are also members that define the range of the stator coil 533.

FIG. 18 is a plan view showing one tooth. The numbers shown indicate the dimensions of the teeth. The unit is millimeter (mm). The teeth are straight type that is straight in the radial direction. The thickness of the teeth is 9 (mm). In this example, the stator coil 533 is provided by a copper-based metal. The number of turns of the stator coil 533 in one tooth is 36 turns.

FIG. 19 is a waveform diagram showing transient performance by the rotary electric machine 511 including the stator with the teeth of FIG. A transient waveform in which the number of revolutions gradually increases is shown. The waveform diagram shows a case where the rotation speed changes in the range of about 3000 r / min to 6000 r / min in the period from time t1 to time t2. The internal combustion engine 512 is a 4-stroke single cylinder. One rotation of the rotor 521 corresponds to one rotation of the crankshaft. The number of revolutions of the internal combustion engine 512 causes torque fluctuations caused by the intake valve and / or the exhaust valve, and torque fluctuations caused by a plurality of strokes of intake, compression, combustion, and exhaust.

The pulser waveform PW of the rotation sensor 517 has a plurality of pulses. The interval between multiple pulses indicates the number of revolutions.

The torque waveform TW output by the torque sensor 519 indicates the torque generated in the stator 531. The torque waveform TW may be measured by a fixed portion on the test bench. The torque sensor 519 can be provided by various sensors that detect the torque generated in the stator 531. The torque sensor 519 can be provided by a strain gauge that detects rotational strain in the fixed portion. The torque waveform TW fluctuates violently. The torque waveform TW fluctuates periodically.

The torque waveform TW oscillates between the first reference value TrH and the second reference value TrL lower than the first reference value TrH. The distance between the first reference value TrH and the second reference value TrL is called the reference fluctuation range.

FIG. 20 is an enlarged waveform diagram of a part of FIG. 19. This figure shows a waveform near 5000 r / min. It is possible to read the correspondence between each pulse in the pulser waveform PW and the fluctuation of the torque waveform TW.

FIG. 21 is an enlarged waveform diagram of a part of FIG. 19. This figure shows the torque waveform TW.

FIG. 22 is a plan view showing one tooth. The rod-shaped part of the tooth is thicker at the radial outer end than at the radial inner end. Teeth is called a tapered type. This tooth allows a relatively large number of turns. The teeth have a straight portion and an enlarged portion. The straight portion is located at the base end portion, and the enlarged portion is located at the tip end portion. The thickness of the teeth is 11 (mm). In this example, the stator coil 533 is provided by an aluminum-based metal. The number of turns of the stator coil 533 in one tooth is 30 turns.

FIG. 23 shows the transient performance of the rotary machine 511 with the stator core with the teeth of FIG. FIG. 23 corresponds to FIG. The torque waveform TW fluctuates within the reference fluctuation range. However, the torque waveform TW is closer to the first reference value TrH than in FIG. 19 for a long time. The effective value or the average value or the center value of the torque waveform TW in FIG. 23 is higher than the corresponding value of the torque waveform in FIG. 24 and 25 correspond to FIGS. 20 and 21. The stator core provided with the teeth of FIG. 22 is thinner in the circumferential direction and more flexible in the circumferential direction than the stator core provided with the teeth of FIG.

FIG. 26 is a plan view showing one tooth. The tooth of FIG. 26 has a base end that is thinner than the tooth of FIG. 22. The teeth of FIG. 26 are thinner than the teeth of FIG. The thickness of the teeth is 9 (mm). In this example, the stator coil 533 is provided by an aluminum-based metal. The number of turns of the stator coil 533 in one tooth is 36 turns.

FIG. 27 shows the transient performance of the rotary machine 511 with the stator core with the teeth of FIG. FIG. 27 corresponds to FIG. The torque waveform TW fluctuates within the reference fluctuation range. However, the torque waveform TW is closer to the first reference value TrH than in FIGS. 19 and 22 for a longer period of time. The effective value or the average value or the center value of the torque waveform TW in FIG. 27 is higher than the corresponding value of the torque waveform in FIG. 23. 28 and 29 correspond to FIGS. 20 and 21. The stator core provided with the teeth of FIG. 26 is thinner in the circumferential direction and more flexible in the circumferential direction than the stator core provided with the teeth of FIG. The stator core provided with the teeth of FIG. 26 is thinner in the circumferential direction and more flexible in the circumferential direction than the stator core provided with the teeth of FIG. 22.

FIG. 30 is a plan view showing one tooth. The teeth in FIG. 30 are the same as the teeth in FIG. In this example, the stator coil 533 is provided by an aluminum-based metal. The number of turns of the stator coil 533 in one tooth is 36 turns. However, the amount of magnetism of the permanent magnet 523 is stronger than that of the rotary electric machine having the teeth of FIGS. 18, 22, and 26.

FIG. 31 shows the transient performance of the rotary electric machine 511 including the stator core with the teeth of FIG. FIG. 31 corresponds to FIG. The torque waveform TW fluctuates within the reference fluctuation range. However, the torque waveform TW is closer to the first reference value TrH than in FIGS. 19, 23, and 27. The effective value or the average value or the center value of the torque waveform TW in FIG. 31 is higher than the corresponding value of the torque waveform in FIG. 27.

The tooth and stator coil 533 of FIG. 30 is the same as the tooth and stator coil 533 of FIG. 26. Therefore, it is considered that the difference in the torque waveform TW is caused by the difference in the magnetizing amount of the permanent magnet 523. The strong permanent magnet 523 in this example appears to exert a large torque on the stator 531 on average. Moreover, the strong permanent magnet 523 seems to reduce the amplitude of the torque waveform TW. 32 and 33 correspond to FIGS. 20 and 21.

FIG. 34 is a plan view showing one tooth. The teeth are straight type that is straight in the radial direction. The thickness in the teeth is 12 (mm). In this example, the stator coil 533 is provided by a copper-based metal. The number of turns of the stator coil 533 in one tooth is 32 turns. The amount of magnetism of the permanent magnet 523 is the same as that of the rotary electric machine having the teeth of FIGS. 18, 22, and 26.

FIG. 35 shows the transient performance of the rotary machine 511 with the stator core with the teeth of FIG. FIG. 35 corresponds to FIG. The torque waveform TW fluctuates within the reference fluctuation range. 36 and 37 correspond to FIGS. 20 and 21.

FIG. 38 is a plan view showing one tooth. The rod-shaped part of the tooth is thicker at the radial outer end than at the radial inner end. Teeth is called a tapered type. This tooth allows a relatively large number of turns. The teeth have a straight portion and an enlarged portion. The straight portion is located at the base end portion, and the enlarged portion is located at the tip end portion. The thickness of the teeth is 12 (mm). In this example, the stator coil 533 is provided by an aluminum-based metal. The number of turns of the stator coil 533 in one tooth is 29 turns. The amount of magnetism of the permanent magnet 523 is the same as that of the rotary electric machine having the teeth of FIGS. 18, 22, and 26.

The tooth of FIG. 38 is slightly longer than the tooth of FIG. 34 and is thin at the proximal end. The teeth of FIG. 38 show a reluctance greater than that of FIG. 34. The stator coil 533 using the teeth of FIG. 38 shows an inductance smaller than that of the stator coil 533 using the teeth of FIG. 34.

The tooth of FIG. 38 exhibits a larger amount of deflection in the circumferential direction than the tooth of FIG. 34. So to speak, it can be said that the teeth of FIG. 38 have a softer structure than the teeth of FIG. 34. The amount of deflection of the teeth in FIG. 38 is about 40% larger than the amount of deflection of the teeth in FIG. 34.

FIG. 39 shows the transient performance of the rotary machine 511 with the stator core with the teeth of FIG. 38. FIG. 39 corresponds to FIG. The torque waveform TW fluctuates within the reference fluctuation range. The torque waveform TW is closer to the second reference value TrL than in FIG. 35 for a long time. The amplitude of the torque waveform TW is smaller than that in FIG. 35. The effective value or the average value or the center value of the torque waveform TW in FIG. 39 is lower than the corresponding value of the torque waveform in FIG. 35. 40 and 41 correspond to FIGS. 20 and 21. The stator core provided with the teeth of FIG. 38 is thinner in the circumferential direction and more flexible in the circumferential direction than the stator core provided with the teeth of FIG. 34.

FIG. 42 is a plan view showing one tooth. The rod-shaped portion of the tooth in FIG. 42 is thicker than the tooth in FIG. 38. The thickness in the teeth is 12 (mm). In this example, the stator coil 533 is provided by an aluminum-based metal. The number of turns of the stator coil 533 in one tooth is 29 turns. The amount of magnetism of the permanent magnet 523 is the same as that of the rotary electric machine having the teeth of FIGS. 18, 22, and 26.

The tooth of FIG. 35 is thicker at the base end than the tooth of FIG. 38. The teeth of FIG. 42 show a reluctance smaller than that of FIGS. 34 and 38. The stator coil 533 using the teeth of FIG. 42 shows an inductance smaller than that of the stator coil 533 using the teeth of FIG. 34.

The teeth of FIG. 42 exhibit a smaller amount of circumferential deflection than the teeth of FIGS. 34 and 38. So to speak, it can be said that the tooth of FIG. 42 has a harder structure than the tooth of FIG. 38. The amount of deflection of the teeth in FIG. 42 is about 10% smaller than the amount of deflection of the teeth in FIG. 34.

FIG. 43 shows the transient performance of the rotary electric machine 511 including the stator core with the teeth of FIG. 42. FIG. 43 corresponds to FIG. The torque waveform TW fluctuates within the reference fluctuation range. However, the torque waveform TW is closer to the first reference value TrH than in FIG. 35 for a long time. The effective value or the average value or the center value of the torque waveform TW in FIG. 43 is higher than the corresponding value of the torque waveform in FIG. 35. 44 and 45 correspond to FIGS. 20 and 21.

According to this disclosure, the torque generated in the stator in the rotary electric machine 511 using the copper-based metal and the torque generated in the stator in the rotary electric machine 511 using the aluminum-based metal can be adjusted to the same extent. As a result, the difference in torque of the rotary electric machine 511, which is a load for the internal combustion engine 512, is suppressed. The torque generated in the stator is (1) as the effective value or mean value or center value of the fluctuating torque, or (2) as the amplitude of the fluctuating torque, or (3) the torque generated in the rotating shaft of the internal combustion engine 512. It can be evaluated by the synchronization relationship (phase relationship) with the fluctuation. The torque generated in the stator is affected by the type of winding and the rigidity of the stator core 532 in the teeth. According to this disclosure, it is possible to suppress the difference in torque caused by the difference between the copper-based metal winding and the winding and the aluminum-based metal winding.

The example of FIG. 46 is a plan view of a stator core having a round fitting portion (embossed mark) 541 at the base of all teeth. The annular portion from which the plurality of teeth protrudes has a plurality of fitting portions 541 for maintaining the plurality of steel plates in a laminated state. The plurality of round fittings contributes to adjusting the stiffness of the plurality of teeth. In this example, the fitting portion increases the rigidity of the plurality of teeth by work hardening.

The example of FIG. 47 is a plan view of a stator core having a square fitting portion 542 (embossed mark) at the base of all teeth. The plurality of square fittings 542 contribute to adjusting the stiffness of the plurality of teeth.

The example of FIG. 48 is a plan view of a stator core having a linear trapezoidal connection 543 at the base of all teeth. A trapezoidal connecting portion 543 whose width changes along the teeth toward the outside in the radial direction is provided between the outer surface of the annular portion and the base end portions of the plurality of teeth. The trapezoidal connection 543 contributes to adjusting the stiffness of the plurality of teeth.

The example of FIG. 49 is a cross-sectional view of a stator in which an aluminum coil winding is wound around the root of the tooth so as to form more layers than the tip of the tooth. The stator coil 533 has a plurality of single coils 544 corresponding to each of the plurality of teeth. One single coil 544 has three layers at the radial outer end and four layers at the radial inner end. The stator coil 533 has a larger number of layers toward the inner side in the radial direction. Since the stator coil 533 is lighter toward the outer side in the radial direction, it suppresses the moment of deforming the teeth. Further, the stator coil 533 itself reinforces the teeth.

The example of FIG. 50 is a plan view of a stator core in which the outer circumferences of a plurality of teeth are continuous and annular. The stator core 532 has a continuous annular magnetic pole portion 545 at the tips of the plurality of teeth. The continuous annular magnetic pole portion 545 contributes to increasing the rigidity of the plurality of teeth.

The example of FIG. 51 is a cross-sectional view of a stator in which a resin spacer 546 is arranged between adjacent teeth. The stator has a resin spacer 546 that connects between the plurality of teeth. The spacer 546 can be provided by a plurality of resin pieces or an annular resin ring.

The example of FIG. 52 is a cross-sectional view of a stator in which resin is packed between a plurality of teeth and a plurality of coils. The stator has a resin molded body 547. The resin molded body 547 fills the space between the plurality of teeth and the plurality of coils. After the stator coil 533 is wound, the resin molded body 547 can be molded so as to insert the stator.

The example of FIG. 53 is a plan view of a stator core having a slit 548 extending radially outward of the teeth. The slit 548 extends radially through the teeth from the radial outer end face of the teeth. The slits 548 are open on both end faces in the axial direction of the stator core. By setting the slit 548, the magnetic path generated in the circumferential direction is divided. There is no problem even if contact is made during winding because the magnetic resistance increases, but ideally, the slit 548 is filled or the winding is performed with a hard bobbin so as not to make contact.

The example of FIG. 54 is a plan view of the stator core 549 of another embodiment. Suppresses the amount of radial outer iron in the teeth. The shape may be tapered in the tooth toward the outside in the radial direction, the width of the brim may be reduced, or the brim may be thinned. Since the linearity deteriorates, the bobbin is formed so that the outer surface is a straight cylinder outer surface. The outer surface of the bobbin should be straight.

Other Embodiments The disclosure in this specification, drawings and the like is not limited to the exemplified embodiments. Disclosures include exemplary embodiments and modifications by those skilled in the art based on them. For example, the disclosure is not limited to the parts and / or combinations of elements shown in the embodiments. Disclosure can be carried out in various combinations. The disclosure can have additional parts that can be added to the embodiment. Disclosures include those in which the parts and / or elements of the embodiment are omitted. Disclosures include the replacement or combination of parts and / or elements between one embodiment and another. The technical scope disclosed is not limited to the description of the embodiments. Some technical scopes disclosed are indicated by the claims description and should be understood to include all modifications within the meaning and scope equivalent to the claims description.

In the above embodiment, a 4-stroke reciprocating engine is exemplified as the engine 2. Instead of this, the engine 2 can be provided by various internal combustion engines such as a two-stroke engine and a rotary engine. Further, in the above embodiment, the engine 2 is a single cylinder. Instead of this, the engine 2 may have multiple cylinders. The multi-cylinder engine 2 produces a complex engine torque TQe waveform, but the phase adjustment of the rotary electric machine 10 allows the variable elements of the engine 2 to be adapted to the application. Also in this case, a rotary electric machine for an internal combustion engine that intentionally suppresses or emphasizes the variable element of the engine 2 is provided.

In the above embodiment, a single-phase generator is exemplified. Instead of this, the rotary electric machine 10 may be a polyphase generator. Further, the rotary electric machine 10 may provide a generator motor. In this case, the rotary electric machine 10 includes a rotary position detector for functioning as a generator motor. The electric circuit 11 can include an inverter circuit and a control device. The electric circuit 11 provides a rectifying circuit that rectifies the AC power output when the rotary electric machine 10 functions as a generator and supplies power to an electric load including a battery. The electric circuit 11 provides a signal processing circuit that receives a reference position signal supplied from the rotary electric machine 10. The reference position signal is used for ignition timing control and / or fuel injection timing control. The electrical circuit 11 may provide a controller that performs engine control, including ignition timing control and / or fuel injection timing control. The electric circuit 11 provides a drive circuit that causes the rotary electric machine 10 to function as an electric machine. The electric circuit 11 receives a rotation position signal from the rotary electric machine 10 for causing the rotary electric machine 10 to function as an electric machine. The electric circuit 11 causes the rotary electric machine 10 to function as an electric motor by controlling the energization of the rotary electric machine 10 according to the detected rotation position.

As exemplified in the above embodiment, this disclosure is applicable to a rotary electric machine having a single-phase or multi-phase stator coil 33. For example, this disclosure can be applied to various connection shapes such as star connection and delta connection. In addition, this disclosure is applicable to rotary electric machines containing a plurality of coils having different electric angles in one phase. For example, two coil elements may be connected in parallel in the same phase. Similarly, three coil elements may be connected in parallel.

In the above embodiment, the stator coil 33 provides a single-phase winding. The single-phase winding produces an electric torque TQg in which the difference between the electric peak point PKg and the electric bottom point BTg is large. Therefore, the amount of change when the engine torque TQe is changed by the electric torque TQg is large. Therefore, the single-phase winding has a relatively remarkable effect. Alternatively, the stator coil 33 may provide polyphase windings. In the case of multi-phase winding, the difference between the electric peak point PKg and the electric bottom point BTg in the electric torque TQg is relatively small.

In the above embodiment, the electric circuit 11 includes an open type regulator. In the open type regulator, a sine wave tends to appear in the power generation output of the stator coil 33. Therefore, an electric torque TQg having a large difference between the electric peak point PKg and the electric bottom point BTg is likely to be generated. As a result, the combination of the single-phase winding and the open type regulator contributes to provide an easy-to-use electric torque TQg. The electric circuit 11 may include a short type regulator. The electrical circuit 11 can include a rectifying circuit provided by a bridge circuit including a plurality of rectifying elements, such as a diode, or a thyristor.

In the above embodiment, the coil wire forming the stator coil 33 is an aluminum-based metal. Instead, the coil wire can be made of a variety of conductor materials. For example, the coil wire may be made of copper or a copper alloy. Further, a part of the coil wire forming the stator coil 33 may be made of an aluminum-based metal, and the other part may be made of a copper-based metal.

In the above embodiment, the phase of the electric torque TQg with respect to the engine torque TQe is adjusted by adjusting the phase of the rotary electric machines 10 and 410. Instead of this, the phase of the electric torque TQg may be adjusted by controlling the outputs of the rotary electric machines 10 and 410. For example, when the output of the rotary electric machine 10 is controlled by the rectifier circuit 11a, the phase of the electric torque TQg shifts due to the change in the impedance component of the electric circuit 11. Therefore, the rectifier circuit 11a can be controlled so that the electric torque TQg becomes low after the compression top dead center C-TDC including the compression top dead center C-TDC. Also in this case, the electric torque TQ is suppressed immediately after the compression top dead center C-TDC in which the absolute value of the engine torque TQe is low. Therefore, a rotary electric machine for an internal combustion engine that supports smooth rotation of the engine 2 is provided.

1 internal combustion engine system, 2 internal combustion engine, 3 cylinders,
4 pistons, 5 rotating shafts, 6 connecting rods,
7 valve drive system, 8 drive system, 9 body,
10 rotary electric machine, 11 electric circuit, 15 wire harness,
21 rotor, 22 rotor core, 23 permanent magnet,
21a, 21b rotor positioning mechanism,
31 stator, 32 stator core, 33 stator coil,
31a, 31b stator positioning mechanism, 410 rotary electric machine,
C-TDC compression top dead center, P-BDC combustion bottom dead center,
E-TDC exhaust top dead center, I-BDC intake bottom dead center,
TQe engine torque, PKe engine peak point,
TQg electric torque, PKg electric peak point,
ZCg zero cross point, BTg electric bottom point,
510 power system, 511 rotary electric machine, 512 internal combustion engine,
521 rotor, 522 rotor core, 523 permanent magnet,
531 stator, 532 stator core,
533 stator coil, 534 insulator,
536 magnetic poles, 537 connections,
517 rotation sensor, 519 strain gauge.

Claims (10)

In a rotary electric machine for an internal combustion engine connected to a rotary shaft (5) of an internal combustion engine (2),
It has a rotor (21) and a stator (31) facing the rotor.
When the internal combustion engine rotary electric machine functions as a generator, the electric torque (TQg) consumed to rotate the rotor to generate power by the internal combustion engine rotary electric machine is compressed and killed by the internal combustion engine. At the point (C-TDC), the electric machine is adjusted so as to suppress the behavior of inhibiting the rotation of the internal combustion engine, and the electric torque is the maximum value immediately after the compression top dead point of the internal combustion engine. A rotating electric machine for an internal combustion engine that is adjusted to be lower than the peak point (PKg). The electric torque is adjusted so as to suppress the behavior that hinders the rotation of the internal combustion engine immediately after the compression top dead center of the internal combustion engine.
The internal combustion engine according to claim 1, wherein immediately after the compression top dead center is a period until the engine torque (TQe) of the internal combustion engine reaches the maximum engine peak point (PKe). Rotating electric machine for engine. The electric torque has a cycle (T) in which a plurality of increases and decreases are repeated during the operation cycle (720CA) of the internal combustion engine.
The rotary electric machine for an internal combustion engine according to claim 1 or 2, wherein a low torque period in which the electric torque is relatively low is positioned immediately after the compression top dead center of the internal combustion engine. The electric torque fluctuates via a plurality of zero cross points (ZCg) intersecting the average value.
The rotary electric machine for an internal combustion engine according to any one of claims 1 to 3, wherein one of the zero cross points is adjusted to occur at the compression top dead center in the process of reducing the electric torque. The electric torque fluctuates via a plurality of electric bottom points (BTg) as minimum values.
The rotary electric machine for an internal combustion engine according to any one of claims 1 to 3, wherein one of the bottom points of the electric machine is adjusted to occur at the compression top dead center. The electric torque fluctuates via a plurality of zero cross points (ZCg) intersecting the average value.
The rotary electric machine for an internal combustion engine according to any one of claims 1 to 3, wherein after the compression top dead center, one of the zero cross points is adjusted to occur in the process of increasing the electric torque. The compression top dead center is positioned in the half cycle between the zero cross point in the process of decreasing the electric torque and the zero cross point in the process of increasing the electric torque that is continuously generated at the zero cross point. The rotary electric machine for an internal combustion engine according to claim 6. The rotary electric machine for an internal combustion engine according to any one of claims 1 to 7, wherein the electric torque is adjusted by a phase related to the rotor and / or the stator, and / or a current flowing through the stator. The electric torque is
The position of the magnetic pole in the rotor,
The position of the rotor positioning unit (21b) that positions the rotor with respect to the internal combustion engine, or
The rotary electric machine for an internal combustion engine according to claim 8, wherein the stator is adjusted by the position of a stator positioning unit (31b) for positioning the stator with respect to the internal combustion engine. In a method for manufacturing a rotary electric machine for an internal combustion engine, which has a rotor (21) rotated by a rotating shaft (5) of the internal combustion engine (2) and a stator (31) facing the rotor.
At the compression top dead center (C-TDC) of the internal combustion engine, it is consumed to rotate the rotor to generate power by the rotary electric machine for the internal combustion engine so as to suppress the behavior of inhibiting the rotation of the internal combustion engine. At the planning stage of planning the electric torque (TQg)
A forming step for forming the rotary electric machine for an internal combustion engine is provided so that the electric torque planned in the planning step is generated.
The forming step is a step of forming a magnetic pole in the rotor.
In the planning stage, when the rotary electric machine for an internal combustion engine functions as a generator, the electric torque is lower than the maximum electric peak point (PKg) immediately after the compression top dead center of the internal combustion engine. A method of manufacturing a rotary electric machine for an internal combustion engine, which is adjusted so as to be.

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