JPH08331786A - Coil unit for vehicle and ac generator for the vehicle - Google Patents

Abstract

PURPOSE: To reduce the working cost of the fixing work of a leader and to decrease the product cost of an alternator for a two-wheeled vehicle by preventing the disconnection of the leader of the rotor coil of the alternator and simplifying a method for fixing the leader of the coil. CONSTITUTION: A U-shaped groove 49 having the outer peripheral side groove 50 of the smaller opening size than the wire diameter of the leader 36 of a rotor coil and the inner peripheral side groove 51 of the larger wire diameter than the leader 36 at the inner peripheral side from the groove 50 is formed on the outer periphery of a collar flange 43 of a coil bobbin 9 mounted at the center of a pole core. When the leader 36 of the coil is fixed, the leader 36 covered with a silicon tube 37 is merely inserted to the groove 49 to finish the fixing of the leader 36.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle coil device having a coil bobbin around which a coil such as a rotary electric machine, an ignition coil and an electromagnetic actuator mounted on a vehicle is mounted, and more particularly to a vehicle alternator and the like. The present invention relates to a vehicle alternator including a coil bobbin around which a rotor coil is wound.

[0002]

2. Description of the Related Art Conventionally, for example, in a two-wheeled vehicle AC generator, a rotor is composed of a pole core which constitutes an exciting magnetic pole, and a rotor coil which is wound around an outer circumference of the pole core via a coil bobbin and through which an exciting current flows. Has been done. The coil bobbin has a tubular portion around which the rotor coil is wound, and two collar-shaped portions provided at both ends of the tubular portion.

At least one of the two collar-shaped portions (the collar-shaped portion on the side closer to the slip ring) has a T-shaped holding portion for holding the drawn-out portion of the rotor coil. ing. The lead-out portion of the rotor coil was wound around the T-shaped holding portion for one to two turns and fixed.

[0004]

However, in the two-wheeled vehicle AC generator, the vibration and rotation fluctuation of the two-wheeled vehicle is large, and the resonance of the holding portion is large, which causes a problem that the lead-out portion of the rotor coil is disconnected. ing. To prevent this, do not wrap the rotor coil drawer around the holder, insert the rotor coil drawer into the tube, and wind the tape coil around the rotor coil drawer to hold the drawer. There is also a method of fixing to the part. However, since it is difficult to wind a tape-shaped object around the outer circumference of the rotor coil withdrawal portion, the product cost of a two-wheeled vehicle AC generator increases significantly due to an increase in the number of man-hours and a longer working time. The problem has arisen.

The object of the invention described in claims 1 to 6 is to reduce the product cost by preventing disconnection of the coil lead-out portion and simplifying the method of fixing the coil lead-out portion. Another object of the present invention is to provide a coil device for a vehicle. Further, an object of the invention described in claim 3 is to provide a coil device for a vehicle in which a notch portion can be easily manufactured and vibration can be mitigated.

The object of the invention described in claim 4 is to:
It is an object of the present invention to provide a coil device for a vehicle, which can easily fix the drawn-out portion of the coil to the cutout portion even if the wire diameter of the coil is various. Further, an object of the invention described in claim 6 is to provide a coil device for a vehicle capable of preventing the lead-out portion of the coil from coming out of the cutout portion. Further, the object of the invention described in claim 7 is to prevent the disconnection of the drawn-out portion of the rotor coil and to simplify the method for fixing the drawn-out portion of the rotor coil, thereby reducing the working cost. To provide an alternator for a vehicle.

[0007]

According to a first aspect of the present invention, there is provided a coil bobbin having a tubular portion extending in the tubular direction, and a flanged portion formed at one end of the tubular portion in the tubular direction. A coil device for a vehicle, comprising: a coil portion wound around an outer periphery of a tubular portion of the coil bobbin; and a coil having a lead-out portion pulled out from one end of the coil portion. The technical means having a cutout portion into which the lead-out portion of the coil is inserted is adopted on the outer periphery of the portion.

According to a second aspect of the invention, in addition to the coil device for a vehicle according to the first aspect, the opening size of the notch is smaller than the wire diameter of the coil. The invention described in claim 3 is claim 1 or claim 2.
In addition to the coil device for a vehicle described in (1) above, the coil bobbin is integrally formed of resin, and the cutout portion is formed in a portion protruding in the radial direction from the collar-shaped portion.

According to a fourth aspect of the present invention, in addition to the coil device for a vehicle according to any one of the first to third aspects, the notch portion has an outer peripheral side with respect to an inner peripheral side opening size. It is characterized in that it is formed in a taper shape by increasing the opening size. The invention according to claim 5 is
In addition to the vehicle coil device according to any one of claims 1 to 4, a tubular covering material that covers the lead-out portion of the coil, which is sandwiched between the cutout portions, is provided. According to a sixth aspect of the present invention, in addition to the vehicle coil device according to any one of the first to fifth aspects, a locking portion that locks the lead-out portion of the coil is provided in the cutout portion. It is characterized by being provided.

According to a seventh aspect of the present invention, a rotary shaft that is rotationally driven by a drive source mounted on a vehicle, a rotor core that rotates integrally with the rotary shaft, and a rotor core that is held by the rotor core, A coil bobbin having a tubular portion extended in the tubular direction, and a collar-shaped portion formed at one end of the tubular portion in the tubular direction, a coil portion wound around the outer periphery of the tubular portion of the coil bobbin, and this A vehicle alternator including a rotor coil having a lead-out portion drawn out from one end of the coil portion, wherein the coil bobbin has an outer periphery of a collar-like portion,
Technical means having a notch part into which the lead-out part of the rotor coil is inserted is adopted.

[0011]

According to the invention described in claim 1, the coil lead-out portion is inserted into the notch portion by inserting the coil lead-out portion into the notch portion formed on the outer periphery of the collar-shaped portion of the coil bobbin. Fixed in the locked state. As described above, since the fixing of the coil lead-out portion is simplified, the tape-shaped material wound around the coil lead-out portion can be eliminated. Therefore, the number of man-hours for fixing the coil lead-out portion can be reduced and the working time can be shortened, so that the working cost of the vehicle coil device can be significantly reduced. Further, since the coil lead-out portion is not wound around the collar-shaped portion of the coil bobbin, damage or disconnection of the coil lead-out portion can be suppressed even when the vehicle is greatly vibrated.

According to the second aspect of the invention, by making the opening size of the notch smaller than the wire diameter of the coil,
The coil lead-out portion can be firmly fixed to the notch. According to the invention described in claim 3, the notch can be easily formed on the outer periphery of the collar-shaped portion of the coil bobbin, and the vibration of the vehicle transmitted to the coil bobbin and the like can be mitigated. According to the invention as set forth in claim 4, the wire diameter of the coil can be variously varied by making the outer peripheral side opening dimension of the cutout portion larger than the inner peripheral side opening dimension so that the notch portion has a tapered shape. Is changed to
Since the coils can be inserted into the notches of the coil bobbins having the same shape, it is not necessary to prepare many types of coil bobbins.

According to the fifth aspect of the present invention, by covering the drawer portion to be inserted into the cutout portion with the tubular covering material, the drawer portion can be prevented from being damaged or broken. Claim 6
According to the invention described in (1), by providing the engaging portion that engages the lead-out portion of the coil in the notch, it is possible to prevent the lead-out portion once inserted into the notch from coming out.

According to the invention described in claim 7, by inserting the lead-out portion of the rotor coil into the cutout portion formed on the outer periphery of the collar-shaped portion of the coil bobbin, the lead-out portion of the rotor coil is sandwiched between the cutout portions. Fixed in the locked state. As described above, since the fixing of the drawn-out portion of the rotor coil is simplified, the tape-shaped object wound around the drawn-out portion of the rotor coil can be eliminated. Therefore, it is possible to reduce the work man-hours for fixing the lead-out portion of the rotor coil and shorten the working time, so that the working cost of the vehicle alternator can be significantly reduced. In addition, since the lead-out portion of the rotor coil is not wound around the collar-shaped portion of the coil bobbin, damage and disconnection of the lead-out portion of the rotor coil can be suppressed even if the vehicle vibration or rotation fluctuation is large.

[0015]

【Example】

[Configuration of Embodiment] Next, a coil device for a vehicle according to the present invention,
A vehicle AC generator will be described based on an embodiment applied to a two-wheeled vehicle alternator. 1 and 2 are views showing a coil bobbin and a coil, FIG. 3 is a view showing a main part of the coil bobbin, and FIG. 4 is a view showing an entire structure of an alternator for a motorcycle.

The two-wheeled vehicle alternator 1 is a rotating field type AC generator. This two-wheeled vehicle alternator 1 is composed of a housing 2, a stator (stator) 3 fixed to the inner peripheral surface of the housing 2, and a rotor (rotor) 5 that rotates integrally with a shaft (rotating shaft) 4. Has been done.

Next, the housing 2 will be described with reference to FIG. The housing 2 is composed of a drive frame 11, a rear frame 12 and a rear cover 13. The drive frame 11 and the rear frame 12 hold and fix the stator 3 and the rotor 5, and at the same time, are attached to the engine.

The drive frame 11 and the rear frame 12 have a plurality of stud bolts 14 and nuts 15.
It is directly joined by the tightening tool such as. The drive frame 11 and the rear frame 12 are provided with a large number of holes 16 and 17 for ventilation of cooling air. Further, the shaft 4 is rotatably supported on the inner peripheral sides of the drive frame 11 and the rear frame 12 via ball bearings 18 and 19. An oil seal 20 is mounted on the tip side of the shaft 4 with respect to the front side ball bearing 18.

Between the rear frame 12 and the rear cover 13, two brushes 21, a rectifying device 22, an output terminal (not shown) and the like are attached. A rectifying device (rectifier) 22, an IC regulator (output voltage adjusting device) 23, and the like are mounted between the rear frame 12 and the rear cover 13 by means of screws or the like. The two brushes 21 are housed and held in a brush holder 24 fixed inside the rear cover 13.

Next, the rectifying device 22 will be described with reference to FIG. This rectifying device 22 is a collection of a plurality of rectifying elements (not shown) such as diodes, and converts (rectifies) an alternating current output from a three-phase stator coil 26 described later into a direct current. is there. The rectifying device 22 is electrically connected to an electric load and a battery (neither shown) mounted on the motorcycle.

Next, the IC regulator 23 will be described with reference to FIG. This IC regulator 23 turns on a switching element (not shown) such as a transistor inserted between a rotor coil 7 and a ground (not shown) described later,
By turning off, the exciting current flowing through the rotor coil 7 is controlled to make the output voltage of the two-wheeled vehicle alternator 1 constant.

Next, the stator 3 will be described with reference to FIG. The stator 3 is composed of a stator core (armature iron core) 25 arranged to face the outer periphery of the rotor 5, a three-phase stator coil (armature winding) 26 wound around the stator core 25, and the like. . Stator core 25
Is a laminate of a plurality of thin plates made of magnetic material, and is press-fitted into the inner periphery of the housing 2 to be integrated.

Further, the stator core 25 is the pole core 6
A magnetic flux path is formed so that the magnetic flux emitted from the claw-shaped magnetic pole portions 31 and 32 of FIG. A large number of slots (not shown) are formed on the inner peripheral side of the stator core 25 at equal intervals.
The three-phase stator coils 26 are connected by Y connection or Δ connection, and three-phase AC output is induced as the rotor 5 rotates.

The tip of the shaft 4 is directly connected to a rotating shaft (not shown) such as a crankshaft of the engine.
Further, two slip rings 27 are attached to the outer circumference of the other end (rear end) of the shaft 4. These slip rings 27 have two brushes 21 each having an outer circumference.
Are electrically connected by making sliding contact with each.

Next, the rotor 5 will be described with reference to FIG. The rotor 5 is a portion that acts as a field magnet, and is composed of a Lundell-type pole core (field iron core) 6, a rotor coil (field winding) 7, the above two slip rings 27, and the like. The pole core 6 is press-fitted and fixed to the outer periphery of the central portion of the shaft 4 by spline fitting or the like. On both sides of the pole core 6, a plurality of claw-shaped magnetic pole portions 31 and 32 are provided so as to mesh with each other. Further, two cooling fans 33 and 34 for sucking cooling air into the housing 2 are integrally attached to both end surfaces of the pole core 6.

The rotor coil 7 is the rotor coil of the present invention, and a copper wire having a wire diameter of, for example, 0.5 mm to 2.0 mm is used, and is housed in a coil bobbin 9 arranged at the center of the pole core 6. Coil portion 35 wound in a closed state, and the rear end side of this coil portion 35 (slip ring 27 side)
It has two withdrawing portions 36 that are drawn out. Most of these drawer portions 36 are covered with a silicon tube (covering material) 37 having a circular tube shape, and the ends thereof have two shaft connection bars (slip ring terminals) 38.
Are connected to each other by means such as welding. The ends of the two lead-out portions 36 and the two shaft connection bars 38 are covered and fixed with an impregnating agent (epoxy resin or the like) 39, as shown by hatching in FIG. .

The coil bobbin 9 includes a wound portion 41 around which the coil portion 35 of the rotor coil 7 is wound, and the wound portion 41.
Flange-shaped flange portion 42 provided on the distal end side of the cylinder direction,
And a flange-shaped flange portion 43 provided on the rear end side of the wound portion 41 in the cylinder direction, and integrally formed of nylon resin or the like. The wound portion 41 is the tubular portion of the present invention, is attached to the outer periphery of the central portion of the pole core 6, and has a cylindrical cross section that extends in a direction parallel to the axial direction of the shaft 4.

The flange portion 42 has a plurality of bulging portions 44 bulging in the radial direction on the outer periphery, is provided between two adjacent bulging portions 44, and is made of an epoxy resin (not shown) for fixing the coil portion 35. It has a plurality of insertion holes 45 for inserting the impregnating agent into the coil bobbin 9.

The flange portion 43 is a flange-shaped portion of the present invention, and like the flange portion 42, a plurality of overhanging portions 4 are provided on the outer circumference.
6 and has a plurality of insertion holes 47 for inserting the impregnating agent into the coil bobbin 9 between two adjacent overhanging portions 44. Further, at two locations on the outer periphery of the flange portion 43, thick-walled portions 48 having a larger wall thickness than other portions are formed. The thickened portion 48 includes a lead-out portion 3 of the rotor coil 7.
A U-shaped groove 49 for inserting the silicon tube 37 covering 6 is formed.

The U-shaped groove 49 is a notch portion of the present invention, and as shown in FIG. 2, the shaft 4 of the flange portion 43.
Is formed in a portion protruding in a radial direction (longitudinal direction) substantially orthogonal to the axial direction of. The U-shaped groove 49 is shown in FIG.
As shown in, the outer peripheral side groove portion 50 having parallel wall surfaces,
Further, an inner peripheral side groove portion (locking portion) 51 which is provided on the inner peripheral side of the outer peripheral side groove portion 50 and has a substantially circular wall surface is provided. The opening size of the outer peripheral side groove portion 50 is determined by the rotor coil 7
Is smaller than the wire diameter of the lead-out portion 36, and the opening dimension of the inner circumferential side groove portion 51 is larger than the wire diameter of the lead-out portion 36 of the rotor coil 7 and is substantially the same as the outer diameter of the silicon tube 37. The wall surface of the U-shaped groove 49 may be formed in a tapered shape in which the opening size on the outer peripheral side is larger than the opening size on the inner peripheral side.

The flange portion 43 is formed with a positioning groove 52 which is inclined from the thick portion 48 on one side toward the wound portion 41 by a predetermined inclination angle and has a substantially semi-circular cross section. . The positioning groove 52 is positioned by inserting the winding start portion of the coil portion 35 of the rotor coil 7.

[Fixing Method of the Embodiment] Next, a fixing method of the extraction portion 36 of the rotor coil 7 will be briefly described with reference to FIGS. 1 to 4.

When the rotor coil 7 is wound around the coil bobbin 9, first, the winding start side extraction portion 36 is inserted into the silicon tube 37, and then the silicon tube 37 is inserted.
It is inserted into the U-shaped groove 49 of each flange portion 43. Then
The lead-out portion 36 is inserted into the inner peripheral side groove portion 51 wider than its own wire diameter through the outer peripheral side groove portion 50 narrower than its own wire diameter. As a result, the lead-out portion 36 is firmly fixed by the inner circumferential side groove portion 51, so that it does not come out to the outer circumferential side groove portion 50 side.

Next, after the winding start portion of the coil portion 35 is fitted into the positioning groove 52 and the winding start portion is positioned, the rotor coil 7 is wound around the wound portion 41 for a predetermined number of turns and a predetermined number of turns. The coil portion 35 is wound by the number of winding layers of
To form. Next, after the lead-out portion 36 on the winding end side is inserted into the silicon tube 37, it is inserted into the U-shaped groove 49 of the flange portion 43 together with the silicon tube 37. Then, similarly to the lead-out portion 36 on the winding start side, the inner circumferential groove portion 51 is formed.
It is firmly fixed to. As a result, the fixing of the extraction portion 36 of the rotor coil 7 and the winding of the rotor coil 7 around the coil bobbin 9 are completed.

[Operation of Embodiment] Next, the operation of the alternator 1 for a motorcycle according to this embodiment will be briefly described with reference to FIGS. 1 to 4. When the engine mounted on the motorcycle is driven, the shaft 4 rotates and the rotor 5 rotates. That is, the pole core 6, the rotor coil 7, and the two slip rings 27 rotate.

When a voltage is applied to the rotor coil 7 from the battery and an exciting current flows through the rotor coil 7, the claw-shaped magnetic pole portions 31 and 32 on both sides of the pole core 6 are excited. That is, for example, the claw-shaped magnetic pole portion 31 on the one side is entirely the N pole, and the claw-shaped magnetic pole portion 32 on the other side is the S pole. Then, a rotating magnetic field is generated in the stator core 25 of the stator 3 that rotates relative to the rotor 5, and an alternating current is induced in the three-phase stator coil 26. This three-phase alternating current is converted into a direct current by the rectifier 22, charges the battery, and supplies electric power to the electric load of the motorcycle.

[Effects of Embodiment] As described above, in the two-wheeled vehicle alternator 1, by inserting the lead-out portion 36 of the rotor coil 7 into the U-shaped groove 49 of the coil bobbin 9, the lead-out portion 36 of the rotor coil 7 becomes U. It is firmly fixed on the wall surface around the inner circumferential groove portion 51 of the character groove 49. Thus, by fixing the lead-out portion 36 of the rotor coil 7 by a simple operation, the tape-shaped material wound around the lead-out portion 36 of the rotor coil 7 can be eliminated. As a result, it is possible to reduce the number of work steps for fixing the lead-out portion 36 of the rotor coil 7 and to shorten the work time. Therefore, the work cost for fixing the lead-out portion 36 of the rotor coil 7 can be reduced, so that the rotor coil The price of the rotor 5 including the coil bobbin 7 and the coil bobbin 9 can be suppressed.

As a result, the product cost of the two-wheeled vehicle alternator 1 having the inexpensive rotor 5 can be significantly reduced. Further, since the lead-out portion 36 of the rotor coil 7 is not wound around the flange portion 43 of the coil bobbin 9,
Even if the vibration of the two-wheeled vehicle or the rotation fluctuations of the shaft 4 and the rotor 5 are very large, it is possible to suppress damage and disconnection of the lead-out portion 36 of the rotor coil 7.

[Modification] In this embodiment, the present invention is applied to the alternator 1 for a two-wheeled vehicle, but the present invention is applied to other vehicle alternators, magnet switches for vehicle starters, ignition coils, electromagnetic actuators, etc. It may be applied to a coil device for a vehicle provided with a coil bobbin around which a coil is wound.

In this embodiment, the shaft 4 is directly connected to the output shaft of the engine. However, a pulley is provided on the shaft 4 so that the power of the drive source such as the engine is transmitted to the shaft 4 via the transmission means such as the belt. You can As the drive source, power other than the engine such as an electric motor or a hydraulic motor may be used.

In this embodiment, the shaft 4 is provided as a notch.
Although the U-shaped groove 49 cut out in the radial direction (vertical direction) substantially orthogonal to the axial direction of the shaft 4 is used, the shaft 4 is used as the cutout portion.
Alternatively, a V-shaped groove, a U-shaped groove, or a polygonal groove cut out in a radial direction (vertical direction) substantially orthogonal to the axial direction may be used. Further, a U-shaped groove, a V-shaped groove, a U-shaped groove, a polygonal groove, or the like cut out in the lateral direction substantially orthogonal to the radial direction of the shaft 4 may be used as the cutout portion.

[Brief description of drawings]

FIG. 1 is a front view showing a coil bobbin and a coil (Example).

FIG. 2 is a cross-sectional view taken along the line AA of FIG. 1 (Example).

FIG. 3 is a front view showing a main part of the coil bobbin of FIG. 1 (Example).

FIG. 4 is a cross-sectional view showing an overall structure of a two-wheeled vehicle alternator (embodiment).

[Explanation of symbols]

 1 Alternator for Motorcycle (Vehicle Coil Device) 4 Shaft (Rotating Shaft) 5 Rotor (Rotor) 6 Pole Core (Rotor Iron Core) 7 Rotor Coil (Rotor Coil, Rotor Winding) 9 Coil Bobbin 35 Coil Part 36 Drawer Part 37 Silicon tube (covering material) 41 Rolled part 43 Flange part (flange-shaped part) 49 U-shaped groove (notch part) 51 Inner peripheral groove part (locking part)

Claims (7)

[Claims] 1. A coil bobbin having a tubular portion extending in the tubular direction, and a flange-shaped portion formed at one end of the tubular portion in the tubular direction, and a coil bobbin wound around the outer periphery of the tubular portion of the coil bobbin. A coil device for a vehicle, comprising: a coil portion; and a coil having a lead-out portion pulled out from one end of the coil portion, wherein the coil bobbin has an outer periphery of the collar-shaped portion and a lead-out portion of the coil. A coil device for a vehicle, comprising a notch part to be inserted. 2. The coil device for a vehicle according to claim 1, wherein an opening size of the cutout portion is smaller than a wire diameter of the coil. 3. The coil device for a vehicle according to claim 1 or 2, wherein the coil bobbin is integrally formed of resin, and the cutout portion is formed in a portion protruding radially from the collar-shaped portion. A coil device for a vehicle, wherein the coil device is formed. 4. The coil device for a vehicle according to any one of claims 1 to 3, wherein the notch has a tapered shape in which an opening size on an outer peripheral side is larger than an opening size on an inner peripheral side. A coil device for a vehicle, comprising: 5. The vehicle coil device according to any one of claims 1 to 4, wherein the vehicle coil device is sandwiched between the notches.
A coil device for a vehicle, comprising a tubular covering material that covers the drawn-out portion of the coil. 6. The coil device for a vehicle according to claim 1, wherein the cutout portion has a locking portion that locks a lead-out portion of the coil. Vehicle coil device. 7. A rotary shaft which is rotationally driven by a drive source mounted on a vehicle, a rotor core which rotates integrally with the rotary shaft, and a cylinder which is held by the rotor core and extends in the cylinder direction. -Shaped portion, and a coil bobbin having a collar-shaped portion formed at one end of the tubular portion in the cylinder direction, a coil portion wound around the outer periphery of the tubular portion of the coil bobbin, and outside from one end of the coil portion. A vehicle alternator comprising a rotor coil having a drawn-out lead-out portion, wherein the coil bobbin has a notch portion on the outer periphery of the collar-shaped portion, into which the lead-out portion of the rotor coil is inserted. An alternator for vehicles, which is characterized in that