JPS63194543A - Stator of ac generator for vehicle and manufacture thereof - Google Patents

Abstract

PURPOSE:To improve a space factor in a slot by press-molding the part of a winding to be filled in a stator slot so as to have a substantially rectangular section. CONSTITUTION:A stator core 2 has a back high core 6 of outer peripheral side and a toothlike core 7 extending toward a circumferential direction, a plurality of slots 3 are formed between the cores 7, and a substantially rectangular-section stator winding 4 is inserted into the slot 3. An insulating sheet 8 is provided between the core 2 and the winding 4. The winding 4 is formed in a rectangular section at a slot insertion unit, and in a circular section at the other part, i.e., the coil end.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to an alternating current generator, and is particularly suitable for fixing an alternating current generator for a vehicle that can be made smaller and have a higher output, and is suitable for being mounted on an automobile or the like. related to the product and its manufacturing method.

[Conventional technology]

Conventionally, in the stator of this type of vehicle alternator, electric wires having a solid circular cross section are inserted into stator slots while maintaining the cross-sectional shape, as is known from, for example, Japanese Patent Laid-Open No. 55-79660. After filling, a protrusion provided at the tip of the teeth of the stator core is bent to form a half-opening.

Also, for example, according to Japanese Patent Application Laid-Open No. 59-12231,
After filling the slots of the generator stator with solid circular cross-section electric wires, the windings are placed at the slot depth in order to improve the occupied area ratio of the windings in the slots (hereinafter simply referred to as space ratio). It is known that the tip of the tooth part is expanded to both sides by applying pressure in the direction of the opening, making it half open.

[Problem that the invention seeks to solve]

However, in the above-mentioned conventional technology, if the solid circular cross-section electric wire is directly filled into the slot, the above-mentioned space factor cannot be improved due to the space that inevitably occurs between the windings. Unable to improve output. 1. In addition, if the windings are pressed after being filled into the slot, the windings may cross each other in the slot, making it impossible to ensure that the windings are aligned. This can easily damage the insulation coating on the surface of the winding and cause a short circuit in one winding. Therefore, in such a method, the defect rate in mass production increases and the productivity decreases.

In addition, it is widely known that rectangular wires are used instead of round wires, especially in large rotating electric machines, etc. However, the use of such rectangular wires as they are in small generators, etc. to which the present invention pertains is as follows. This will cause significant disadvantage. In other words, the winding is formed into a predetermined shape before being filled into the slot, but in order to form a large amount of winding in a short time using a winding machine, it is necessary to take into account the curvature, twist, etc. of the end coil part. The use of flat wire is inferior to round wire in terms of workability and is unsuitable for mass production.

SUMMARY OF THE INVENTION In view of the above-mentioned prior art, it is an object of the present invention to significantly improve the space factor of the windings to increase output, and to increase productivity by eliminating damage to the winding coating during assembly. An object of the present invention is to provide an excellent stator structure for a vehicle alternator and its production direction.

[Means for Solving the Problems] An object of the present invention is to have a stator core having a plurality of slots and a winding filled in the slot, the winding having at least a circular outer diameter. This is achieved by a stator for an alternator for a vehicle, which is made of an electric wire having a cross section of , and the portion filled in the slot is press-formed to have a substantially rectangular cross section.

[Effect]

According to the present invention, of the windings filled in the stator slots, the portions filled in the slots are pressurized to have a substantially rectangular cross section, so that the space inside the slots is reduced. The winding ratio is greatly improved, and since the winding wire is made of a winding wire whose outer diameter at least has a circular cross section, disadvantages in forming the winding wire can be solved at the same time.

〔Example〕

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A stator for a vehicle alternator and a method for manufacturing the same, which is an embodiment of the present invention, will be described below.

In FIG. 1, a partial cross section of a cylindrical stator (armature) 1 of a vehicle alternator is shown. The stator 1 is formed by punching a plurality of steel plates into a predetermined shape and stacking them.The stator core 2 includes a tall core portion 62 on the outer peripheral side and a toothed core extending in the circumferential direction. 7, and a plurality of slots 3 are formed between the toothed cores 7. In the stator of the vehicle alternator according to this embodiment, the stator 1
Although 12 slots are formed on the inner circumferential surface of the holder, only three of them are shown in FIG. 1 above. In addition, protrusions serving as magnetic flux collecting portions 5 are formed at both ends of the tip of the toothed core 7, which serves to collect magnetic flux and to prevent the winding from popping out as described below. , forming a so-called semi-closed slot.

A stator (armature) winding 4 having a substantially rectangular cross section is inserted into the slot 3 of the stator 1, and in this example, a stator winding consisting of six windings is inserted. It goes without saying that this winding is wound so as to obtain a three-phase output, similar to a conventional inter-vehicle alternator. Further, an insulating sheet 8 having high heat resistance, such as Nomex, is provided between the stator core 2 and the stator winding 4.

This ensures electrical insulation between the iron core 2 and the winding 4.

FIG. 2 is a diagram of the generator stator 1 shown in FIG. 1 viewed from below. As is clear from this figure.

The stator winding 4 housed in the slot 3 of the stator core 2 is processed to be flat (rectangular cross section) at the slot insertion part, and the other part, that is, the coil end 4a.
As is clear from the fact that one or more of the slots 3 maintain a circular cross section, a winding wire also having a substantially rectangular cross section is inserted into the slot 3 having a substantially rectangular cross section.

It is clear that the space factor of the windings in the so-called stator slots is improved. Also, in the figure.

The same reference numbers as in FIG. 1 indicate the same parts.

Next, a method of forming the stator winding 4 will be explained.

First, as shown in FIG. 3, the stator winding 4 is formed by winding a solid electric wire material having a circular cross section into a substantially rectangular shape a plurality of times (for example, six times). However, in the example shown in the figure, the coil end 4a of the stator winding 4 wound into a rectangular shape is formed into an arc shape, and is inserted into the stator core slot described later. At this time, it is convenient for processing the coil end portion 4a. In addition, since wire material with a circular cross section is used, there is no need to take into account twisting of the wire, compared to forming the above-mentioned winding wire using so-called square wire. It is clearly suitable for production processes.

The stator winding 4 formed in this manner is firstly formed into a flattened portion at the slot insertion portion using a pressure forming machine as shown in FIG. That is, the slot insertion part of the winding 4 (that is, the part excluding the coil end 4a) formed as shown in FIG. 3 is slidably supported by the spring 10 to form a slider! 11 and a stopper 12, and then pressurized in the direction shown by the arrow by a pusher 13 that moves up and down using hydraulic pressure, for example. As a result of this pressurization, the stator winding 4 is heated at the coil end 4 as shown in FIG.
The section of the coil other than a, that is, the slot insertion portion, is formed into a substantially square shape (for example, rectangular shape). In the above embodiment, one winding is wound once, then one is overlaid, and compression molding is performed at the same time. It may be formed by

Next, the stator winding 4 formed as described above is
The stator core 2 is fixed in slots 3 formed between the toothed cores 7 of the stator core 2 shown in the figure through an insulating sheet or the like. As shown in FIG. 6, the toothed core 7 of the stator core 2 is provided with a substantially elliptical through hole 10 extending in the axial direction at its tip. By pressing the tip surface of the toothed iron core, a protrusion serving as the magnetic flux collecting portion is formed, thereby preventing the winding from coming out from the slot 3. As is clear from this, when using the stator core 2 as described above, the protrusions that serve as magnetic flux collectors are not yet formed at the tips of the slots 3 of the stator core 2; Therefore, even if the winding @4 is formed into a substantially rectangular shape as shown in FIG.
It is clear that this can be done within the same timeframe, and the ease of assembly, especially in mass production processes, is significantly improved.

Next, FIG. 7(a) shows a method of forming protrusions that will serve as magnetic flux collecting parts of the stator. In FIG. 4 is shown. After that, Fig. 7(b)
As shown in , pressure is applied to the tip end surface of the toothed core 7 of the stator core 2 in the direction indicated by arrow F in the figure using an appropriate pressure means (for example, a suppressor, a roller, etc.) = Pressure As a result, the through hole 10 formed at the tip of the toothed core 7 is crushed, as shown by the solid line in the figure.
At the same time, the iron core portions on both sides of the through hole are pushed out, thereby obtaining the magnetic flux collecting portion 5 having an ideal approximately arcuate shape as shown.

In the embodiments described above, the electric wire material for forming the stator winding is a solid winding wire whose cross section is circular, that is, a so-called round wire. however,
According to the present invention, instead of the above-mentioned round line, for example, FIG.
) It is also possible to use a hollow conducting wire 40 as shown in FIG. This hollow conducting wire 40 has an annular cross section as shown in the figure, and when pressed, as shown in FIG. 8(b),
The conductive wire has a substantially rectangular cross section. When such a hollow conducting wire 40 is used, in the pressure forming process shown in FIG. It is clear that the deformation of is also easy and reliable.

Further, even when such a hollow conducting wire 40 is used, only the slot insertion portion thereof is formed flat. Furthermore, when using the above-mentioned hollow conductor, the pressing force during the processing process can be reduced compared to solid conductors, so the insulation coating of the winding is less likely to be damaged when pressurized, resulting in an extremely low defect rate. It can be done.

A cross-sectional view of a vehicle alternator incorporating the stator 1 described above is shown in FIG. FIG. 10 shows the output characteristics of the stator of the present invention incorporated into the generator in comparison with the conventional stator. That is, with the configuration of the present invention, it is possible to improve the occupation rate and space factor of the conductor windings in the slots of the stator to about 80%. In addition, compared to the output of a conventional vehicle alternator of the same size (output characteristics are shown by the dotted line), it has become possible to increase the output at almost all generator rotational speeds. In particular, at the rated rotation speed of 5000 rpm, it was confirmed that the output was increased by about 25%, as shown by the solid line in the figure.

〔Effect of the invention〕

As is clear from the above description, according to the present invention, it is possible to obtain a stator for a vehicle alternator with a high space factor, thereby making it possible to reduce the size and increase the output of the vehicle alternating current generator. It becomes possible to obtain an opportunity.

[Brief explanation of the drawing]

FIG. 1 is a partial sectional view of fixing the vehicle alternator according to the present invention, FIG. 2 is a bottom view of the stator shown in FIG. 1, and FIGS. 3 to 6 are stator windings according to the present invention. 7(a) and 7(b) are diagrams for explaining the method for forming the magnetic flux collecting section shown in FIG. 1, and FIG. 8 is for explaining the method for forming the conductor winding material. FIG. 9 is a cross-sectional view of a vehicle alternator incorporating the stator of the present invention, and FIG. 10 is a cross-sectional view of a vehicle alternator incorporating the stator of the present invention. FIG. 3 is a characteristic diagram showing output characteristics. DESCRIPTION OF SYMBOLS 1... Stator, 2... Stator core, 3... Slot, 4... Stator winding, 4a... Coil end, 5...
...Magnetic flux collection part loincloth 1st opening N. '#2 Figure 3 Figure 4 Figure 5 Showatsu Otsu-ku tea 70 (Reno #e mouth Cb) No. q12)

Claims (1)

[Claims] 1. An AC power generator for a vehicle comprising a stator core having a plurality of slots near its circumferential surface, and a stator winding inserted into the slots of the stator core via an insulator. In the stator of the machine, the slot formed in the stator core has a substantially rectangular cross-sectional shape, and the stator winding has a substantially rectangular cross-sectional shape at the slot insertion portion, and other portions of the stator winding have a substantially rectangular cross-sectional shape. A stator for a vehicle alternator, characterized in that at least its outer diameter has a circular cross-sectional shape. 2. The stator for an alternator for a vehicle according to claim 1, wherein a portion of the stator winding other than the slot insertion portion has a hollow cross-sectional shape. 3. Manufacturing a stator for a vehicle alternator comprising a stator core having a plurality of slots near its circumferential surface, and stator windings inserted into the slots of the stator core via an insulator. In the method, after forming the stator winding by winding a winding material having a cross-sectional shape with at least a circular outer diameter into a predetermined winding shape, pressing and deforming the slot insertion part of the stator winding. A method of manufacturing a stator for a vehicle alternator, characterized in that the stator has a substantially rectangular cross-sectional shape. 4. A method for manufacturing a stator for a vehicle alternator according to claim 3, wherein the stator winding is formed of a winding material having a hollow cross-sectional shape.