Alternator

Details Alternator Alternator

2000-05-23

2002-08-27

Nguyen, Tran (Department: 2834)

Electrical generator or motor structure

Dynamoelectric

Rotary

C310S201000, C310S208000

Reexamination Certificate

active

06441526

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an alternator driven by an internal combustion engine, for example, and in particular relates to a construction of a stator therein.
2. Description of the Related Art
FIG. 9
is a cross-section of a conventional automotive alternator,
FIG. 10
is a partial enlargement of the automotive alternator in
FIG. 10
,
FIG. 11
is a partial perspective of a stator in
FIG. 9
viewed from a rear bracket
2
end, and
FIG. 12
is a partial perspective of the stator in
FIG. 9
viewed from a front bracket
1
end.
This alternator includes: a case
3
composed of an aluminum front bracket
1
and an aluminum rear bracket
2
; a shaft
6
disposed within the case
3
having a pulley
4
secured to a first end thereof; a Lundell-type rotor
7
secured to the shaft
6
; fans
5
a
and
5
b
secured to both end surfaces of the rotor
6
; a stator
8
secured to an inner wall of the case
3
; slip rings
9
secured to a second end of the shaft
6
for supplying electric current to the rotor
7
; a pair of brushes
10
sliding on the slip rings
9
; brush holders
11
accommodating the brushes
10
; a rectifier
12
in electrical contact with the stator
8
for converting alternating current generated in the stator
8
into direct current; a heat sink
17
fitted over the brush holder
11
; and a regulator
18
fastened to the heat sink
17
by adhesive for adjusting the magnitude of the alternating voltage generated in the stator
8
.
The rotor
7
is composed of a rotor coil
13
for generating magnetic flux on passage of electric current, and a pair of first and second pole cores
20
and
21
disposed so as to cover the rotor coil
13
, magnetic poles being produced in the pair of pole cores
20
and
21
by the magnetic flux. The pair of pole cores
20
and
21
are made of iron and each has eight claw-shaped magnetic poles
22
and
23
secured to the shaft so as to be spaced at even pitch circumferentially around a circumferential edge, facing each other so as to intermesh.
The stator
8
includes a stator core
15
composed of a cylindrical laminated iron core in which a number of slots extending longitudinally are formed at a predetermined pitch in a circumferential direction, and a three-phase stator winding
16
wound into the stator core
15
.
Air intake vents
1
a
and
2
a
are formed in central portions of the front bracket
1
and the rear bracket
2
, respectively, and air discharge vents
1
b
and
2
b
are formed in outer circumferential shoulder portions of the front bracket
1
and the rear bracket
2
, respectively.
Next, the wiring construction of the a-phase stator winding portion
16
a
of the three-phase stator winding
16
will be-explained with reference to the winding diagram in FIG.
13
. Moreover, this diagram shows the wiring construction when the stator
8
is viewed from the rear bracket
2
end, and in the figure solid lines indicate wire at the rear bracket
2
end (explained below as connecting portions), and dotted lines indicate wire at the front bracket
1
end (explained below as joining portions).
The a-phase stator winding portion
16
a
includes first and second winding portions
31
and
32
. The first winding portion
31
, which is connected to an a-phase lead wire
100
, has its starting point at the third position from an inner circumferential side (hereinafter the positions counted in order from the inner circumferential side will be called the first, second, third, and fourth positions, respectively) inside a slot
15
a
whose slot number is number
1
, extends counterclockwise at the front bracket
1
end and enters a slot
15
a
at the fourth position of slot number
4
. Then, the first winding portion
31
extends clockwise at the rear bracket
2
end, enters a slot
15
a
at the first position of slot number
1
, and passes through to the front bracket
1
end. Next, the first winding portion
31
extends counterclockwise at the front bracket
1
end, enters a slot
15
a
at the second position of slot number
4
, and passes through to the rear bracket
2
end. Then, the first winding portion
31
extends counterclockwise and enters a slot
15
a
at the third position of slot number
7
, and passes through to the front bracket
1
end.
In this manner, wires leading out at the rear bracket
2
end from the fourth position in each of the slots
15
a
each turn towards the front bracket
1
end and enter the first position in a slot
15
a
three slots away in a clockwise direction. Wires leading out at the rear bracket
2
end from the second position in each of the slots
15
a
each turn towards the front bracket
1
end and enter the third position in a slot
15
a
three slots away in a counterclockwise direction.
Then, finally, a wire projecting towards the rear bracket
2
end from the second position of slot number
34
extends in a counterclockwise direction and arrives at the fourth position of slot number
1
, and this becomes the end point of the first winding portion
31
.
The end point of the first winding portion
31
is also the starting point of the second winding portion
32
, and the second winding portion
32
extends clockwise at the front bracket
1
end and enters a slot
15
a
at the third position of slot number
34
. Then, the wire leading out at the rear bracket
2
end extends clockwise at the rear bracket
2
end, enters a slot
15
a
at the second position of slot number
31
, and passes through to the front bracket
1
end. Next, the wire extends clockwise at the front bracket
1
end, enters a slot
15
a
at the first position of slot number
28
, and passes through to the rear bracket
2
end. Then, the wire extends counterclockwise and enters a slot
15
a
at the fourth position of slot number
31
, and passes through to the front bracket
1
end. This wire extends clockwise and enters a slot
15
a
at the third position of slot number
28
.
In this manner, wires leading out at the rear bracket
2
end from the first position in each of the slots
15
a
each turn towards the front bracket
1
end and enter the fourth position in a slot
15
a
three slots away in a counterclockwise direction. Wires leading out at the rear bracket
2
end from the third position in each of the slots
15
a
each turn towards the front bracket
1
end and enter the second position in a slot
15
a
three slots away In a clockwise direction.
Then, finally, a wire projecting towards the front bracket
1
end from the second position of slot number
1
extends in a clockwise direction and arrives at the first position of slot number
34
, and this becomes the end point of the second winding portion
32
. A neutral point lead wire
101
is connected to this end point.
In this manner, in the a-phase stator winding portion
16
a, the first winding portion
31
, which is connected to the a-phase lead wire
100
, makes one lap in a generally counterclockwise direction in every third slot while changing direction to a clockwise direction at a number of places, and then the second winding portion
32
makes one lap in a generally clockwise direction in every third slot while changing direction to a counterclockwise direction at a number of places, constituting a four-turn a-phase stator winding portion
16
a.
Similarly, a b-phase stator winding portion and a c-phase stator winding portion are formed by offsetting by one slot
15
a
and, together with the a-phase stator winding portion, constitute the star-connected three-phase stator winding
16
.
The three-phase stator winding
16
of the above construction is formed by joining a number of short conductor segments
50
such as the one shown in FIG.
11
.
The conductor segments
50
, which are component elements of the wires, are each formed into a U shape from copper wire material having a circular cross section coated with insulation, and each includes a pair of first and second straight portions
51
a
and
51
b
housed inside the slots
15
a
, a connecting portion
52
connecting the straight portions

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