Alternator

Details Alternator Alternator

2000-09-19

2002-09-10

Ramirez, Nestor (Department: 2834)

Electrical generator or motor structure

Dynamoelectric

Rotary

C310S260000

Reexamination Certificate

active

06448681

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an automotive alternator mounted on a vehicle, such as a passenger car or a truck, and more particularly, to a stator winding of stator of the automotive alternator.
2. Description of the Related Art
FIG. 15
is a sectional view of a conventional automotive alternator.
The automotive alternator is constituted by a Lundell-type rotor
7
rotatably installed via a shaft
6
in a case
3
composed of an aluminum front bracket
1
and an aluminum rear bracket
2
, and a stator
8
secured to an inner wall of the case
3
so as to cover an outer peripheral of the rotor
7
.
The shaft
6
is rotatably supported by the front bracket
1
and the rear bracket
2
. A pulley
4
is secured to one end of the shaft
6
to allow rotating torque of an engine to be transmitted to the shaft
6
via a belt (not shown).
Slip rings
9
are secured to the other end of the shaft
6
to supply electric current to the rotor
7
, and a pair of brushes
10
are accommodated in a brush holder
11
disposed in the case
3
so that the brushes
10
slide in contact with the slip rings
9
. A regulator
18
for adjusting a magnitude of ac voltage generated at the stator
8
is adhesively attached to a heat sink
17
fitted in the brush holder
11
. A rectifier
12
which is electrically connected to the stator
8
and rectifies alternating current produced in the stator
8
into direct current is installed in the case
3
.
The rotor
7
is constructed by a rotor coil
13
for generating magnetic flux on passage of electric current, and a pair of pole cores
20
and
21
which are provided to cover the rotor coil
13
and in which magnetic poles are formed by the magnetic flux generated by the rotor coil
13
. The pair of pole cores
20
and
21
is made of iron and has a plurality of claw-shaped magnetic poles
22
and
23
arranged at equiangular pitches in a circumferential direction on outer peripheries thereof, and is secured to the shaft
6
such that the pole cores
20
and
21
oppose each other with the claw-shaped magnetic poles
22
and
23
intermeshed. Furthermore, centrifugal fans
5
are secured to both axial end surfaces of the rotor
7
.
The stator
8
is constructed by a stator core
15
and a stator winding assembly
16
formed by a conductor wound around the stator core
15
and in which alternating current is produced by changes in magnetic flux from the rotor
7
as the rotor
7
rotates.
A structure of the stator winding assembly
16
will now be described in conjunction with
FIG. 16
illustrating the winding.
The stator winding assembly
16
is formed by an a-phase stator winding member
16
a
, a b-phase stator winding member, and a c-phase stator winding member. The a-phase stator winding member
16
a
, the b-phase stator winding member, and the c-phase stator winding member are disposed such that they are shifted by one slot
15
a
from one another and are in a star connection.
FIG. 16
illustrates a winding structure of the a-phase stator winding assembly
16
a
; it does not illustrate winding structures of the b-phase stator winding member and the c-phase stator winding member. In
FIG. 16
, solid lines denote conductors connected to the rear bracket
2
(coupling portions of conductor segments, which will be discussed hereinafter), and dotted lines denote conductors connected to the front bracket
1
(coupling portions of the conductor segments which will be discussed hereinafter).
The a-phase stator winding assembly
16
a
is equipped with a first winding
54
and a second winding
55
. The first winding
54
connected to an a-phase lead wire
100
begins at a second layer (hereinafter, a first layer from an outer peripheral side will be indicated by “address
1
”, a second layer by “address
2
”, a third layer by “address
3
”, and a fourth layer by “address
4
”) from an outer peripheral side in the slot
15
a
of slot number
1
, and extends counterclockwise into a slot
15
a
at address
1
of slot number
4
from the front bracket
1
side. The first winding
54
further extends clockwise from the rear bracket
2
side into a slot
15
a
at address
4
of slot number
4
, and exits to the front bracket
1
side. Then, the first winding
54
extends counterclockwise into a slot
15
a
at address
3
of slot number
4
from the front bracket
1
side, and exits to the rear bracket
2
side. Thereafter, the first winding
54
extends counterclockwise into a slot
15
a
at address
2
of slot number
7
, and exits to the front bracket
1
side.
Thus, the conductor led out to the rear bracket
2
side at address
1
, where a first layer is located in each slot
15
a
, enters toward the front bracket
1
at address
4
, where a fourth layer is located, in a slot
15
a
away clockwise by three slots. Furthermore, the conductor led out to the rear bracket
2
side at address
3
, where a third layer is located in each slot
15
a
, enters toward the front bracket
1
at address
2
, where a second layer is located in a slot
15
a
, away by three slots counterclockwise.
Lastly, the conductor led out to the rear bracket
2
side at address
3
, where a third layer is located, of slot number
34
extends counterclockwise and reaches address
1
, where the first layer is located, of slot number
1
, which is an end point of the first winding
54
.
The end point of the first winding
54
provides a start point of the second winding
55
. The second winding
55
extends clockwise and enters a slot
15
a
at address
2
, where the second layer is located, of slot number
34
from the front bracket
1
side. Subsequently, the conductor led out from the rear bracket
2
side extends clockwise from the rear bracket
2
side, enters a slot
15
a
at address
3
, where the third layer is located, of slot number
31
, and exits to the front bracket
1
side. Then, the second winding
55
extends clockwise, enters a slot
15
a
at address
4
of slot number
28
from the front bracket
1
side, and exits to the rear bracket
2
side. Thereafter, the second winding
55
extends counterclockwise, enters a slot
15
a
at address
1
of slot number
31
, and exits to the front bracket
1
side. The conductor extends clockwise and enters a slot
15
a
at address
2
of slot number
28
.
Thus, the conductor led out to the rear bracket
2
side at address
4
in each slot
15
a
enters toward the front bracket
1
side at address
1
in the slot
15
a
located three slots away counterclockwise. Furthermore, the conductor led out to the rear bracket
2
side at address
2
in each slot
15
a
enters toward the front bracket
1
side at address
3
in the slot
15
a
located three slots away clockwise.
Lastly, the conductor led out to the front bracket
1
side at address
3
of slot number
1
extends clockwise and reaches address
4
of slot number
34
, which is an end point of the second winding
55
. A neutral point leader line
101
is connected to the end point.
As described above, in the a-phase stator winding member
16
a
, the first winding
54
connected to the a-phase lead wire
100
is wound around once counterclockwise as a whole, switching to the clockwise direction at a plurality of locations at every three slots. Then, the second winding
55
is wound around once clockwise as a whole, switching to the counterclockwise direction at a plurality of locations at every three slots. Thus, the a-phase stator winding member
16
a
having four turns is fabricated.
The same description of the a-phase stator winding member applies to the b-phase stator winding member and the c-phase stator winding member, so that the description will not be repeated.
The three-phase stator winding assembly
16
having the configuration set forth above is formed by joining numerous short conductor segments
50
shown in FIG.
17
.
The conductor segments
50
constituting the conductor are made by forming a copper wire, which is provided with insulating coating and has a round section, into a substantially U shape. Each of the co

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