JP2010098832A - Dynamo electric machine for vehicles - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a dynamo electric machine for vehicles wherein it is possible to achieve both the performance and reliability of stator winding using aluminum material. <P>SOLUTION: An AC power generator 1 for vehicles includes: a rotor 2 rotationally driven; a stator 3 having a stator core 31 placed opposite to the rotor 2 and stator winding 32 fit to the stator core 31; and a frame 4 that supports the rotor 2 and the stator 3. The stator winding 32 is formed by joining together multiple segment conductors 30, 30'. A segment conductor 30' as a leader used to connect the stator winding 32 and a rectifier 5 and the other segment conductors 30 are formed of different aluminum materials. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a rotating electrical machine for a vehicle mounted on an automobile, a truck, or the like.

  Conventionally, a segment type stator winding using a large number of U-shaped electric conductors is known. Copper is generally used as the material of the electrical conductor, but there is also known one using aluminum as the material of the electrical conductor for the purpose of reducing the weight and preventing coil corrosion due to moisture (for example, see Patent Document 1). .)

Also, in order to facilitate joining (assembly) with a rectifier having a copper terminal and ensure sufficient serviceability in the market, only the lead conductor joined to the rectifier is made of copper and the others are made of aluminum. A conventional structure is also known (see, for example, Patent Documents 2 and 3).
JP 11-191946 A (page 5-7, FIG. 1-12) JP 2007-20302 A (page 4-7, FIG. 1-12) JP 2007-181396 A (page 3-7, FIG. 1-12)

  In general, when an aluminum material is used as an electrical conductor, the electrical conductivity is lower than when a copper material is used, so that the resistance value of the stator winding increases and the output performance deteriorates. Therefore, it is desirable to use a material having as high an electrical conductivity as possible, specifically, pure aluminum (1000 series) as an electrical conductor formed of an aluminum material. The lead wire of the stator winding is connected to a rectifier, and stress such as engine vibration and heat (self-heating) is applied to this connection portion. When the lead wire is an electrical conductor made of aluminum, the strength (tensile strength and fatigue strength) is lower than that of a copper material, and there is a concern that the reliability may be lowered. As a countermeasure for this, a method using a high-strength aluminum alloy is conceivable. However, since an aluminum alloy generally has a low electrical conductivity, the resistance value as a stator winding increases, leading to a decrease in performance. . As described above, when the stator winding is made of an aluminum material as disclosed in Patent Document 1, there is a problem that it is impossible to achieve both performance and reliability.

  In addition, in the stator winding | coil disclosed by patent document 2, since it is necessary to join the dissimilar metal of an aluminum material and a copper material in the middle, it is compared with the case where copper materials are joined or the case where aluminum materials are joined. There was a problem that joining was not easy. In order to perform bonding while ensuring sufficient strength, a special bonding apparatus is required, and the equipment is increased in size. For this reason, if a stator winding can be comprised only with aluminum material, it is convenient from a viewpoint of cost reduction.

  The present invention was created in view of the above points, and an object thereof is to provide a vehicular rotating electrical machine capable of achieving both the performance and reliability of a stator winding using an aluminum material. It is in.

  In order to solve the above-described problems, a rotating electrical machine for a vehicle according to the present invention includes a rotor that is rotationally driven, a stator core that is disposed to face the rotor, and a stator winding that is provided on the stator core. And a frame that supports the rotor and the stator, and the stator winding is formed by joining a plurality of segment conductors, and the stator winding and other components The segment conductors used as the lead wires used for the connection and the other segment conductors are formed of aluminum material, and their materials are different. By combining different aluminum materials, the conflicting requirements of performance and reliability when a stator winding is formed using an aluminum material can be satisfied.

  In addition, it is desirable that the material strength of the segment conductor as the lead wire described above is higher than that of the other segment conductors. Alternatively, it is desirable to lower the conductivity of the other segment conductors than the segment conductors as the lead lines described above. Specifically, it is desirable to form the segment conductor as the above-described lead wire from a 1000 series aluminum material and form the other segment conductors from a 5000 series or 6000 series aluminum material. As a result, it is possible to improve the output by lowering the overall resistance value while ensuring the strength of the leader line portion.

  In addition, the other component described above is desirably a rectifier that rectifies an alternating current output from the stator winding. As a result, the strength of the segment conductor connected to the rectifier can be ensured, and the reliability can be ensured by preventing the deterioration of the durability due to vibration or the like.

  In addition, the segment conductor as the lead-out line described above is partially arranged in the slot formed in the stator core, and the end opposite to the other parts across the stator core is the other segment. It is desirable to be joined to a conductor. Accordingly, since the segment conductor corresponding to the lead wire can be held in the slot of the stator core, stress such as vibration can be prevented from acting on the joint portion between the segment conductors. The reliability of the lead line of the line can be further increased.

  Hereinafter, an automotive alternator according to an embodiment to which a rotating electrical machine for a vehicle of the present invention is applied will be described in detail with reference to the drawings.

  FIG. 1 is a cross-sectional view of an automotive alternator 1 according to an embodiment. As shown in FIG. 1, the vehicle alternator 1 of this embodiment includes a rotor 2, a stator 3, a frame 4, a rectifier 5, a regulator 11, and the like. This vehicle alternator 1 has a pulley 20 that receives a rotational force from an engine (not shown). The pulley 20 is fixed to the shaft 6 together with the rotor 2. The rotor 2 has a pair of Landel-type iron cores 21 and field windings 24 and is driven to rotate by the engine. Cooling fans 22 and 23 are provided on the end face in the axial direction of the Landel iron core 21. The cooling fans 22 and 23 take in the cooling air from the opening 41 in the axial direction of the frame 4 and blow out the taken cooling air toward the opening 42 in the radial direction. By this cooling air, the stator winding 32 of the stator 3, the rectifier 5 that rectifies the alternating current output from the stator winding 32 connected to the stator winding 32, the regulator 11 that adjusts the output voltage, etc. Is cooled. The shaft 6 is rotatably supported by the frame 4 and a slip ring is provided in the vicinity of the end on the side opposite to the pulley. The stator 3 is fixed to the frame 4 on the outer peripheral side of the rotor 2.

  Next, details of the stator 3 will be described. FIG. 2 is a perspective view of the segment conductor 30 constituting the stator winding 32. 3 is a perspective view showing an assembled state of the segment conductor 30 shown in FIG. The stator 3 includes a stator winding 32 constituted by a plurality of segment conductors 30 as electrical conductors, a stator core 31 in which a plurality of slots 310 in which the stator windings 32 are provided, and It has an insulating sheet 34 sandwiched between a stator winding 32 and a stator core 31. The rotor 2 and the stator 3 described above are supported by a frame 4.

  The stator winding 32 provided in the slot 310 of the stator core 31 is composed of a plurality of electric conductors, and each slot 310 accommodates an even number (four in this embodiment) of electric conductors. Each of these electrical conductors has a substantially rectangular cross-sectional shape. Further, the four electric conductors in one slot 310 are arranged in the order of the inner end layer, the inner middle layer, the outer middle layer, and the outer end layer from the inside along the radial direction of the stator core 31 as shown in FIG. Is arranged.

  The electric conductor 331a in the inner end layer in one slot 310 is paired with the electric conductor 331b in the outer end layer in another slot 310 that is one magnetic pole pitch away in the clockwise direction of the stator core 31. . Similarly, the inner and middle layer electric conductors 332a in one slot 310 are paired with the outer and middle layer electric conductors 332b in the other slots 310 that are one magnetic pole pitch away in the clockwise direction of the stator core 31. . And the electric conductors which make these pairs are connected through the turn parts 331c and 332c by using a continuous line in the one end surface side of the axial direction of the stator core 31. FIG.

  Therefore, on one end face side of the stator core 31, a continuous line connecting the outer middle layer electric conductor 332b and the inner middle layer electric conductor 332a via the turn portion 332c is connected to the outer end layer electric conductor 331b. A continuous line connecting the electric conductor 331a of the inner end layer via the turn portion 331c is included. As described above, on one end face side of the stator core 31, the turn portion 332 c as a connecting portion of the paired electric conductors serves as a connecting portion of the other pair of electric conductors accommodated in the same slot 310. Is surrounded by the turn part 331c. The middle layer coil end is formed by the connection between the outer middle layer electrical conductor 332b and the inner middle layer electrical conductor 332a, and the end layer coil end is formed by the connection between the outer end layer electrical conductor 331b and the inner end layer electrical conductor 331a. The

  On the other hand, the inner middle layer electric conductor 332a in one slot 310 is also paired with the inner end layer electric conductor 331a 'in the other slot 310 which is one magnetic pole pitch away in the clockwise direction of the stator core 31. ing. Similarly, the outer-layer electric conductor 331b ′ in one slot 310 is paired with the outer-middle electric conductor 332b in another slot 310 that is one magnetic pole pitch away in the clockwise direction of the stator core 31. There is no. These electrical conductors are connected on the other end face side in the axial direction of the stator core 31.

  Therefore, on the other end face side of the stator core 31, the outer joint portion 333b connecting the outer end layer electric conductor 331b 'and the outer middle layer electric conductor 332b, the inner end layer electric conductor 331a' and the inner middle layer. The inner joint portion 333a that connects to the electrical conductor 332a is disposed in a state of being shifted from each other in the radial direction and the circumferential direction. As shown in FIG. 4, the outer end layer electric conductor 331b ′ and the outer middle layer electric conductor 332b are connected to each other, and the inner end layer electric conductor 331a ′ and the inner middle layer electric conductor 332a are connected to each other as shown in FIG. Two adjacent layer coil ends are formed.

  Further, as shown in FIG. 2, the inner end layer electric conductor 331a and the outer end layer electric conductor 331b are provided by a large segment 331 formed by forming a series of electric conductors in a substantially U shape. Also, the inner middle layer electric conductor 332a and the outer middle layer electric conductor 332b are provided by a small segment 332 formed by forming a series of electric conductors in a substantially U shape. The basic U-shaped segment conductor 30 is formed by a large segment 331 and a small segment 332. Each of the segments 331 and 332 includes a portion that is accommodated in the slot 310 and extends along the axial direction, and also includes oblique portions 331f, 331g, 332f, and 332g as bending portions that extend at an angle with respect to the axial direction. Is provided. These skewed portions form a rear side coil end group 32R and a front side coil end group 32F that protrude from the stator core 31 to both end faces in the axial direction, and are attached to both end faces in the axial direction of the rotor 2. The ventilation path of the cooling air generated when the cooling fans 22 and 23 are rotated is mainly formed between the inclined portions. Further, a lead wire for the stator winding 32 is also arranged in the cooling air ventilation path.

  The above configuration is repeated for the segment conductors 30 of all slots 310. In the front-side coil end group 32F on the counter-turn portion side, the outer end layer end 331e ′, the outer middle layer end 332e, the inner middle layer end 332d, and the inner end layer end 331d ′ are respectively formed. The outer joint 333b and the inner joint 333a are formed by means of TIG welding, ultrasonic welding, or the like, and are electrically connected.

  In the present embodiment, by using the segment conductor 30 described above, two types of three-phase windings 32A and 32B shown in FIG. 5 are formed, and the stator winding 32 is formed by these three-phase windings 32A and 32B. Is configured. The three-phase windings 32A and 32B are both Y-connected and are 30 degrees out of phase with each other in electrical angle.

  FIG. 6 is a diagram showing the detailed shapes of the lead lines Yb and Zb and the neutral point N1 corresponding to one three-phase winding 32A. FIG. 7 is a perspective view showing an assembled state of segment conductors used as lead lines and neutral points. As shown in FIG. 7, the lead wires and the like protruding from the rear side coil end group 32R side are formed using a linear segment conductor 30 'having no turn portion. The segment conductor 30 ′ has a shape in which one straight line portion of the segment conductor 30 is extended as it is without being folded at the turn portion. Therefore, as shown in FIG. 7, by inserting the segment conductor 30 into the slot 310 of the stator core 31 and bending the tip end side, the end of the segment conductor 30 ′ is connected to another segment as shown in FIG. It can be joined to the end of the conductor 30, and the lead line Xb and the like can be easily formed. Since the joining of the end portions is the joining of the same aluminum-based segment conductors 30 and 30 ′, it can be performed by TIG welding or the like generally performed in the same manner as the joining of the segment conductors 30. There is no need for special equipment for joining copper and aluminum.

  In the present embodiment, both the segment conductor 30 ′ corresponding to the six lead lines Xb, Yb, Zb, Ub, Vb, and Wb formed in this way and the other segment conductors 30 are formed of an aluminum material. The materials are different. Specifically, the material is selected such that the material strength of the segment conductor 30 ′ as the lead line is higher than that of the other segment conductors 30. Further, the material is selected so that the electrical conductivity of the other segment conductors 30 is lower than that of the segment conductors 30 'as the lead lines. More specifically, the segment conductor 30 'as the lead wire is formed of a 1000 series aluminum material, and the other segment conductors 30 are formed of a 5000 series or 6000 series aluminum material.

  FIG. 8 is a diagram comparing the characteristics of aluminum materials. The horizontal axis shows the tensile strength as the material strength, and the vertical axis shows the conductivity. As shown in FIG. 8, pure aluminum (1000 series) aluminum material has high electrical conductivity, thereby forming a segment conductor 30 other than the lead wire to lower the resistance value of the stator winding 32 as a whole. Output performance can be improved. In addition, the 5000 series or 6000 series aluminum material has a lower electrical conductivity than the 1000 series aluminum material, but has a high tensile strength. By using this, the segment conductor 30 'as a lead wire is formed. A stator winding 32 that is resistant to stress such as engine vibration can be realized. For example, when the total number of segment conductors is 196, the ratio of the number of the six segment conductors 30 ′ as the lead lines is 3.1% (4.2% when the total number is 144), Even if these six segment conductors 30 'are made of a 5000 or 6000 series aluminum material having a low electrical conductivity, the overall increase in resistance value is slight, and the output is not lowered.

  As described above, in the stator winding 32 included in the stator 3 of the vehicle alternator 1 of the present embodiment, the segment conductor 30 ′ serving as the lead wire used for connection to the rectifier 5 and the other segments The conductors 30 are both formed of an aluminum material, and their materials are different. By combining different aluminum materials, the conflicting requirements of performance and reliability when the stator winding 32 is formed using an aluminum material can be satisfied.

  In particular, the material strength of the segment conductor 30 ′ as the lead line is higher than that of the other segment conductors 30, or the conductivity of the other segment conductors 30 is lower than that of the segment conductor 30 ′ as the lead line. . Specifically, the segment conductor 30 'as the lead wire is formed of 1000 series aluminum material, and the other segment conductors 30 are formed of 5000 series or 6000 series aluminum material. As a result, it is possible to improve the output by lowering the overall resistance value while ensuring the strength of the lead wire portion.

  Further, a segment conductor 30 ′ serving as a lead-out wire is partially disposed in a slot 310 formed in the stator core 31, and the end on the side opposite to the rectifier 5 (pulley side) across the stator core 31. The part is joined to another segment conductor 30. As a result, the segment conductor 30 ′ corresponding to the lead wire can be held in the slot 310 of the stator core 31, thereby preventing stress such as vibration from acting on the joint portion of the segment conductors 30, 30 ′. The reliability of the lead wire of the stator winding 32 can be further increased.

  In addition, this invention is not limited to the said embodiment, A various deformation | transformation implementation is possible within the range of the summary of this invention. In the embodiment described above, the stator winding 32 is configured by combining two types of three-phase windings 32A and 32B as shown in FIG. 5, but the stator winding is configured by one type of three-phase winding. You may make it do. In addition, the present invention can be applied to a staggered stator winding in which two types of Y connections are serialized, or a stator winding in which a Δ connection and a staggered connection are combined. All other segment conductors may be formed of an aluminum material, and these materials may be different from those of the present embodiment.

  In the above-described embodiment, the present invention is applied to the vehicular AC generator 1. However, the present invention can also be applied to a vehicular rotating electrical machine (such as an electric motor) other than the vehicular AC generator.

It is sectional drawing of the alternating current generator for vehicles of one Embodiment. It is a perspective view of the segment conductor which comprises a stator winding | coil. It is a perspective view which shows the assembly | attachment state of the segment conductor shown in FIG. It is a perspective view which shows the joining edge part of a front side coil end group. It is explanatory drawing of this embodiment other stator winding. It is a figure which shows the detailed shape of the leader line corresponding to a three-phase winding, and a neutral point. It is a perspective view which shows the assembly | attachment state of the segment conductor used as a leader line and a neutral point. It is the figure which compared the characteristic of the aluminum material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Vehicle AC generator 2 Rotor 3 Stator 4 Frame 5 Rectifier 11 Regulator 20 Pulley 30 Segment conductor (Most part of stator winding)
30 'segment conductor (constituting the lead wire of the stator winding)
31 Stator core 32 Stator winding

Claims (6)

A stator having a rotor to be driven to rotate, a stator core disposed opposite to the rotor, and a stator winding mounted on the stator core, and a frame for supporting the rotor and the stator In a vehicular rotating electrical machine comprising:
The stator winding is formed by joining a plurality of segment conductors,
The segment conductor as a lead wire used for connection between the stator winding and other components and the other segment conductor are both formed of an aluminum material, and the materials thereof are different. Rotating electric machine for vehicles. In claim 1,
A rotating electrical machine for a vehicle, wherein the material strength of the segment conductor as the lead wire is higher than that of the other segment conductors. In claim 1 or 2,
A rotating electrical machine for a vehicle, wherein the electrical conductivity of the other segment conductors is lower than that of the segment conductors as the lead wires. In any one of Claims 1-3,
A vehicular rotating electrical machine characterized in that the segment conductor as the lead wire is formed of a 1000 series aluminum material, and the other segment conductors are formed of a 5000 series or 6000 series aluminum material. In any one of Claims 1-4,
The other component is a rectifier that rectifies an alternating current output from the stator winding. In any one of Claims 1-5,
A part of the segment conductor as the lead-out wire is disposed in a slot formed in the stator core, and an end portion on the opposite side to the other components across the stator core is other A rotating electrical machine for a vehicle characterized by being joined to the segment conductor.

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