Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
  • H02K1/22—Rotating parts of the magnetic circuit
  • H02K1/24—Rotor cores with salient poles ; Variable reluctance rotors
  • H02K1/243—Rotor cores with salient poles ; Variable reluctance rotors of the claw-pole type
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
  • B60L1/00—Supplying electric power to auxiliary equipment of vehicles
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
  • H02K1/22—Rotating parts of the magnetic circuit
  • H02K1/27—Rotor cores with permanent magnets
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
  • H02K15/021—Magnetic cores
  • H02K15/022—Magnetic cores with salient poles
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
  • H02K21/02—Details
  • H02K21/04—Windings on magnets for additional excitation ; Windings and magnets for additional excitation
  • H02K21/042—Windings on magnets for additional excitation ; Windings and magnets for additional excitation with permanent magnets and field winding both rotating
  • H02K21/044—Rotor of the claw pole type

Definitions

• the invention relates to forged pole wheels for the rotor of a Lundell-type rotary electric machine, such as an alternator or a starter-motor vehicle. More particularly, the invention relates to forged pole wheels for a rotor equipped with interpolar permanent magnets.
• Rotors equipped with interpolar permanent magnets require the realization of magnet housing grooves and magnet lips in the teeth of the pole wheels.
• the magnet lips provide for holding in place permanent magnets which are subjected to the effects of centrifugal force when the rotor is rotating.
• the pole wheel according to the invention is intended for the rotor of a Lundell-type rotary electric machine.
• the pole wheel is obtained entirely by forging and comprises a central core, a plurality of pole teeth distributed evenly around the circumference of the pole wheel, the pole teeth extending substantially parallel to a central axis of the pole wheel and comprising magnet accommodating grooves and magnet lips, and an annular plate portion and extending between the central core and base portions of the pole teeth.
• the pole wheel comprises a plurality of reservoirs arranged in the base portions of the pole teeth. These tanks located at the base of the teeth provide a space for the material repressed during cold forging strikes and make possible the complete manufacture of the part by forging, with cold forging in the axial direction.
• the reservoirs are two in number for each polar tooth.
• the tanks are located on either side of the polar teeth.
• the tanks are made below an inner surface of the annular portion forming a plate.
• a shape at the base of the magnet lips, near an intersection between two perpendicular planes, is included in a square (SQ) of 3 mm ⁇ 3 mm centered on said intersection.
• the shape at the base of the magnet lips has a radius of between 0.01 and 4 mm.
• Fig.1 which is a view showing a claw rotor of a motor vehicle alternator
• FIG.2 which is a perspective view of a pole wheel equipped with permanent magnets, included in the rotor of Fig.1;
• FIGS. 3a to 3d which show the progressive formation of a basic polar wheel in a hot forging step
• FIG. 3e which shows a tooth section of the base pole wheel of FIG. 3d obtained at the end of the hot forging step
• - Fig.4a is a sectional view of a matrix used in the cold forging step
• FIG.4b is a perspective view of the pole wheel according to the invention obtained at the end of the cold forging step;
• FIGS. 5a to 5d which show the polar wheel according to the invention as well as details of embodiment thereof:
• FIG. 5a is an enlarged representation of the polar wheel according to the invention
• - Fig.5b is a partial perspective view showing a reservoir provided at the base of the pole teeth of the polar wheel according to the invention
• - Fig.5c is a partial perspective view showing a tooth end configuration of the magnet housing groove and the magnet lip;
• Fig. 5d is a schematic sectional view showing an inner radius provided in the magnet accommodating groove at the base of the magnet lip.
• the rotor 1 of a Lundell-type rotary electric machine essentially comprises two pole wheels 10 and 11, interpolar permanent magnets 12, an excitation coil (not visible), a shaft 13, a manifold 14, and two fans 15a, 15b for cooling the machine.
• the pole wheels 10, 11 are mounted on the shaft 13 in such a way that their respective teeth 10g, 11g are nested and form an alternation of south (S) and north (N) magnetic poles. These magnetic poles S and N are produced by supplying electric current to the excitation coil inserted in a central core 107 (FIG. 2) of the pole wheels 10 and 11. The excitation coil is energized through the collector 14. A tray portion 109 (Fig.2) is present between the central core 107 and the base of the claws 10, 1 1, and allows a space to be occupied by the excitation coil.
• the interpolar magnets 12 are housed in the spaces between the teeth N and S of the pole wheels 10, 1 1. In the particular embodiment of the rotor 1 shown in FIG. 1, the set of interdental spaces are occupied by the magnets 12. In other embodiments, the magnets 12 occupy only a part of the interdental spaces. available.
• the pole wheel 10, 1 1 is shown with the permanent magnets 12.
• Magnet housing grooves 100 and lips 101 are provided in the teeth 10g, 11g of the pole wheel to allow the mounting the magnets 12 in the interfering spaces and maintain them in position when the rotor 1 is rotating and the effects of the centrifugal force are exerted.
• Magnetic chamfers 102, aeraulic 103 and balancing 104 are also provided in the teeth 10g, 11g.
• the magnetic chamfers 102 are arranged on either side of the longitudinal edges of the tooth 10g, 11 g, as shown in FIG. Aeraulic chamfers 103 and balancing 104 are visible in FIG.
• the forging process comprises two main steps, namely, a hot forging step followed by a cold forging step.
• the hot forging step makes it possible to obtain from a previously crushed iron slug F (FIG. 3a) a base pole wheel 10B (FIG. 3d) in which the chamfers 102, 103 and 104 have been formed. No groove preform and magnet lip are made during this EC step.
• the hot forging step comprises an operation of making a rough EE (Fig.3b), a finishing operation EF (Fig.3c) and a cutting operation surplus material SM (Fig. 3d) to the contours of the base polar wheel 10B.
• the teeth 10g, 11g are formed with the chamfers 102, 103 and 104.
• the cold forging step has the purpose of producing the magnet housing grooves 100 and lips 101 for the magnets 12. For this, grooves are produced under the teeth 10g, 11g, at the longitudinal edges. of these. These grooves are made by repressing the material, by two successive operations of cold stamping, using a matrix MA shown in Fig.4a.
• the matrix MA is formed of a lower matrix MAi and an upper matrix MAs.
• the base pole wheel 10B is placed in a corresponding shape of the lower die MAi, with the teeth pointing upwards.
• the upper matrix MAs comprises the final shape of the tooth 10g, 11g, with the magnet-accommodating grooves 100 and the lips 101.
• the opening Ov has a dimension of between 0.1. L and L, L being the thickness of the tray 109 (Fig.5a). Typically, the opening Ov has a dimension of between 0.1 mm and 6 mm depending on the applications.
• a vertical thrust P is exerted on the matrix MA, up to contact at the joint plane between the upper matrix MAs and the lower matrix MAi.
• the material is pushed back into the preform provided for this purpose in the matrix.
• a locking counter-support is provided on the iron diameter of the workpiece and / or the magnetic bevels 102, a Vogellic 103 and balancing 104.
• the chamfers 102, 103 and 104 are, depending on the applications, shaped and / or maintained.
• the cold stamping operation is carried out in two successive strikes, with equal or different pressures, depending on the application, typically between 150 to 1500 tons.
• a cutting operation surplus material to the contours of the pole wheel 10, 1 1 is performed after the cold stamping operation.
• the manufacture of the polar wheel 10, 1 is then complete and this comprise the magnet housing grooves 100 and lips 101, as well as the chamfers 102, 103 and 104 obtained beforehand in the hot forging step.
• a section of the tooth 10g, 11g, along a cutting axis BB (FIG. 4b), is shown in FIG.
• reservoirs 105 are provided at the base of each of the teeth 10g, 1 1g, the pole wheel 10, 1 1. These tanks 105 are two in number for each tooth 10g, 11 g, and are located on either side thereof. It will be noted in Fig.5b that the tanks 105 are made below an inner surface 106, substantially annular, of the plate portion 109 of the pole wheel 10, 1 January. The tray portion 109 is between the base of the teeth 10g, 11g, and the central core 107 of the pole wheel 10, 11.
• tanks 105 located at the base of the teeth 10g, 1 1 g are necessary in the polar wheel according to the invention because they allow the manufacture thereof by the implementation of the forging process as it has just been described above. Indeed, the tanks 105 provide a space for the material discharged during the two successive strikes of the cold forging step and thus make possible the complete manufacture of the part by forging, with cold forging in the axial direction. Tests have been carried out by the inventive entity and have highlighted the interest of certain particular characteristics detailed below the pole wheel 10, 1 1 according to the invention, in particular for the mechanical strength of the lips 101 at the centrifugation .
• the shape at the base of the lip 101 will preferably be in a square SQ approximately 3 mm x 3 mm which is centered on the intersection of the perpendicular planes E and G.

Landscapes

• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Transportation (AREA)
• Mechanical Engineering (AREA)
• Permanent Field Magnets Of Synchronous Machinery (AREA)
• Manufacture Of Motors, Generators (AREA)
• Forging (AREA)
• Iron Core Of Rotating Electric Machines (AREA)

Priority Applications (4)

Applications Claiming Priority (2)

Publications (2)

Family

ID=51417352

Family Applications (1)

Country Status (6)

Cited By (1)

Families Citing this family (1)

Citations (1)

Family Cites Families (11)

• 2014
  • 2014-03-25 FR FR1452499A patent/FR3019399B1/fr active Active
• 2015
  • 2015-03-02 EP EP15713973.4A patent/EP3123595B1/fr active Active
  • 2015-03-02 WO PCT/FR2015/050504 patent/WO2015145009A2/fr not_active Ceased
  • 2015-03-02 CN CN201580016101.0A patent/CN106104971B/zh not_active Ceased
  • 2015-03-02 US US15/126,654 patent/US10250088B2/en active Active
  • 2015-03-02 JP JP2016554840A patent/JP6621753B2/ja active Active

Patent Citations (1)

Also Published As

Similar Documents

Legal Events