Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
2001-05-17
2004-05-18
Mullins, Burton S. (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C439S884000
Reexamination Certificate
active
06737772
ABSTRACT:
This application is based on Application No. 2000-318075, filed in Japan on Oct. 18, 2000, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to an AC generator for use in a vehicle. More particularly, the present invention relates to a structure for connecting lead wires and neutral leads of a stator winding to a rectifier and also relates to a method for forming such a structure.
2. Description of the Related Art
FIG. 13
is a longitudinal sectional view illustrating a conventional AC generator for use in a vehicle.
FIG. 14
is a perspective view illustrating a stator structure applied to the conventional AC generator.
FIG. 15
is a perspective view of a primary part thereof and illustrates the connection between a metallic terminal and a conductor wire serving as a stator winding of a stator, which is applied to the conventional AC generator for use in a vehicle.
FIG. 16
is a perspective view illustrating a mounting structure for mounting the stator winding of the conventional AC generator on a rectifier.
As shown in
FIG. 13
, the AC generator for use in a vehicle comprises a case
3
consisting of an aluminum front bracket
1
and an aluminum rear bracket
2
, a shaft
6
having an end portion to which a pulley
4
is fixed, a Lundell type rotor fixed to this shaft
6
, fans
5
respectively fixed at both axial end portions of this rotor
7
, a stator
8
fixed to the cased
3
in such a way as to surround the rotor
7
, slip rings
9
, fixed to the other end portion of the shaft
6
, for supplying an electric current to the rotor
7
, a pair of brushes
10
adapted to slide over the surface of the slip rings
9
, a brush holder
11
for accommodating the pair of brushes
10
, a rectifier
12
, electrically connected to the stator
8
, for rectifying an alternating current generated in the stator
8
into a DC current, and a regulator
18
, fitted into the brush holder
11
, for regulating an AC voltage generated in the stator
8
.
The rotor
7
has a field coil
13
adapted to generate magnetic flux when an electric current is fed thereto, and a pair of pole cores
20
and
21
provided in such a manner as to cover this field coil
13
, magnetic poles being formed in the poles
20
and
21
by the magnetic flux. Further, the pair of pole cores
20
and
21
has iron claw-shaped magnetic poles provided with equal angular pitches in the direction of the circumference of the an outer peripheral portion thereof in such a way as to protrude therefrom so that the maximum radial section thereof is nearly trapezoidal. Moreover, the pair of pole cores
20
and
21
is securely fixed to the shaft
6
so that the claw-shaped magnetic poles
22
and
23
are made to face and mesh with each other.
The stator
8
is constituted by a cylindrical stator core
16
formed by using laminated magnetic steel plates and a stator winding
17
wound around the stator core
16
, as illustrated in
FIG. 14. A
plurality of slots
16
a
each extending in an axial direction are formed with a predetermined pitch in the circumferential direction in the stator core
16
. The stator winding
17
is constituted by three winding units
26
each obtained by winding a copper conductor wire
25
having a circular cross section coated with electrical insulation for a predetermined number of turns into a wave-shaped pattern. The three winding units
26
are wound around the stator core
16
in such a way as to be respectively accommodated in every three slots
16
a
by shifting each of the slots, in each of which the corresponding winding unit is accommodated, by one slot. The beginning end portions of the winding units
26
constitute lead wires
26
a
,
26
b
, and
26
c
, respectively. The finishing ends of the winding units
26
constitute neutral points
26
n
. Further, the stator winding
17
is constituted by bringing together the neutral points
26
n
of the three winding units
26
, that is, establishing three phase alternating current connection (Y-connection) among the three winding units
26
. Moreover, a metallic terminal
27
made of, for example, tough pitch copper is connected to each of the lead wires
26
a
,
26
b
, and
26
c
. Furthermore, one end portion of the neutral lead
28
and the three neutral points
26
n
are put together and integrated with one another by solder. Another metallic terminal
27
is connected to the other end portion of the neutral lead
28
.
Incidentally, as shown in
FIG. 15
, the metallic terminal
27
is connected to the conductor wire
25
at a portion A by soldering or welding after the grasping piece
27
a
thereof is caulked and attached to the end portion, from which the insulating coating is removed, of the conductor wire
25
. Additionally, the metallic terminal
27
is similarly connected to the other end portion of the neutral lead
28
.
As illustrated in
FIG. 16
, the rectifier
12
comprises a plurality of positive-electrode-side diodes
30
and negative-electrode-side diodes
31
for performing full-wave rectification on three-phase alternating current, first and second cooling plates
32
and
33
for cooling the positive-electrode-side diodes
30
and the negative-electrode-side diodes
31
, an insulator
34
for insulating the first and second cooling plates
32
and
33
, a circuit board
35
, and an output terminal
36
.
The first cooling plate
32
is formed in a horseshoe shape. The positive-electrode-side diodes
30
are mounted on a principal surface
32
a
thereof in such a way as to be arranged in the direction of the circumference thereof Further, radiating fins
32
b
are erected on the rear surface (that is, the surface opposite to the principal surface) of the first cooling plate
32
. Moreover, flange portions
32
c
radially and outwardly extend from both circumferentially end portions of and a central portion of the first cooling plate
32
. Furthermore, a through hole (not shown) is dug in each of the flange portions
32
c.
The second cooling plate
33
is formed in a horseshoe shape in such a way as to have a diameter, which is larger than that of the first cooling plate
32
. The negative-electrode-side diodes
31
are mounted on a principal surface
33
a
of second cooling plate
33
in such a manner as to be arranged in the direction of the circumference thereof. Moreover, through holes (not shown) are dug in both circumferential end portions of and a central portion of the second cooling plate
33
correspondingly to the through holes dug in the first cooling plate
32
.
The circuit board
35
is a resin molding in which wiring for constructing diode bridges of the positive-electrode-side diodes
30
and the negative-electrode-side diodes
31
are insert-molded. Further, the circuit board
35
is formed in a horseshoe shape, similarly as the second cooling plate
33
. Moreover, through holes
35
a
are dug in both circumferentially end portions of and a central portion of the circuit board
35
correspondingly to the through holes dug in the first cooling plate
32
. Furthermore, screw holes
37
a
,
37
b
,
37
c
, and
37
n
for electrically connecting the lead wires
26
a
,
26
b
, and
26
c
and the neutral leads
28
of the stator winding
17
to the rectifier
12
are provided therein. Additionally, each of mounting seats
39
a
,
39
b
,
39
c
, and
39
n
is provided on the outer peripheral portion around a corresponding one of the screw holes
37
a
,
37
b
,
37
c
, and
37
n.
This rectifier
12
is assembled as follows. First, the first cooling plate
32
is placed so that the through hole dug in each of the flange portions
32
c
is aligned with a corresponding one of through holes dug in the second cooling plate
33
. Moreover, the circuit board
35
is stacked on the cooling plate
32
so that each of the through holes
35
a
is aligned with a corresponding one of the through holes dug in the flange portions
32
c
. At that time, an insulator
34
is interposed between each of the flange portions
32
c
and
Asao Yoshihito
Tanaka Kazunori
Aguirrechea J.
Mullins Burton S.
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