Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
2000-05-17
2001-12-04
Mullins, Burton S. (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S184000, C310S206000, C310S071000
Reexamination Certificate
active
06326715
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an alternator driven by an internal combustion engine, and in particular, relates to a stator for an automotive alternator mounted to a vehicle such as a passenger car or a truck.
2. Description of the Related Art
Conventionally, a stator winding in a stator for an automotive alternator is manufactured by preparing an annular coil by winding continuous wire into an annular shape, preparing a star shape coil by deforming this annular coil into a star shape, and then installing straight portions of this star shape coil into slots in a stator core. However, excessive stress is applied to the wire when installing the star shape coil in the slots of the stator core, increasing the likelihood of wire breakage or insulation defects, and productivity has been markedly inferior.
Thus, in order to solve such deficiencies, a method for manufacturing stator windings by first bending an electric conductor into U-shaped segments and inserting a number of these segments into the slots in the stator core, and then joining end portions of these segments extending outwards from the slots, has been proposed in Japanese Patent Laid-Open No. HEI 11-164506, for example.
FIG. 13
is a plan showing connection of one phase of a stator winding in the stator for an automotive alternator disclosed in Japanese Patent Laid-Open No. HEI 11-164506, for example,
FIG. 14
is a schematic perspective of segments constituting the stator winding, and
FIGS. 15
to
17
are developed projections each showing a portion of the connections of one phase of the stator winding.
The stator
8
in
FIG. 13
includes: a stator core
15
; and a stator winding
16
composed of a number of segments
30
arranged in slots
15
a
formed in the stator core
15
. In this case, thirty-six slots
15
a
are formed in the stator core
15
at even pitch so as to house three phases of windings therein corresponding with the number (12) of magnetic poles in a rotor (not shown).
The segments
30
are inserted two at a time from a first axial end of the stator core
15
into pairs of slots
15
a
which are three slots apart (a pitch of one magnetic pole). Then, the stator winding
16
is constructed by joining end portions of the segments
30
extending outwards from a second axial end of the stator
15
in a predetermined pattern. Moreover, the segments
30
are accommodated so as to line up in a row of four in a radial direction within each slot
15
a.
Hereinafter, the four segment accommodating positions lined up in the radial direction within each slot
15
a
will be numbered from an outer circumferential side as first, second, third, and fourth positions, respectively.
As shown in
FIG. 14
, large segments
31
and small segments
32
, each composed of an electric conductor such as insulated copper having a rectangular cross section formed into a general U shape, are used for the segments
30
.
The small segments
32
are inserted from the first axial end into the second positions within first slots
15
a
and into the third positions within second slots
15
a
three slots away from the first slots
15
a
in a clockwise direction in FIG.
13
. The large segments
31
are similarly inserted from the first axial end into the first positions within the first slots
15
a
and into the fourth positions within the second slots
15
a
three slots away from the first slots
15
a
in the clockwise direction in FIG.
13
. Thus, straight portions
31
a
and
32
a
of the large and small segments
31
and
32
are arranged so as to line up in a row in a radial direction within each of the slots
15
a.
At the first axial end of the stator core
15
, turn portions
31
c
of the large segments
31
surround outer circumferential sides of turn portions
32
c
of the small segments
32
inserted into the same pairs of slots
15
a.
The turn portions
31
c
and
32
c
are arranged to line up in rows in a circumferential direction and constitute a second coil-end portion
16
b.
At the second axial end of the stator core
15
, end portions
32
b
of the small segments
32
extending outwards from the second axial end from the second positions within the first slots
15
a
are joined to end portions
31
b
of the large segments
31
extending outwards from the second axial end from the first positions within the second slots
15
a
three slots away from the first slots
15
a
in the clockwise direction in
FIG. 13
, and end portions
31
b
of the large segments
31
extending outwards from the second axial end from the fourth positions within the first slots
15
a
are joined to end portions
32
b
of the small segments
32
extending outwards from the second axial end from the third positions within the second slots
15
a
three slots away from the first slots
15
a
in the clockwise direction in FIG.
13
. The joint portions formed by joining the end portions
32
b
of the small segments
32
extending outwards from the second axial end from the second positions within the slots
15
a
to the end portions
31
b
of the large segments
31
extending outwards from the second axial end from the first positions within the slots
15
a
and the joint portions formed by joining the end portions
31
b
of the large segments
31
extending outwards from the second axial end from the fourth positions within the slots
15
a
to the end portions
32
b
of the small segments
32
extending outwards from the second axial end from the third positions within the slots
15
a
line up radially, are arranged to line up in rows in a circumferential direction and constitute a first coil-end portion
16
a.
The method of winding one phase (the X phase) of the stator winding
16
will now be explained with reference to
FIGS. 15
to
17
. Moreover, in each of the figures, electric conductors disposed on the outermost circumference in a radial direction are represented by doubledotted chain lines, electric conductors disposed in the second position from the outer circumference in the radial direction are represented by solid lines, electric conductors disposed in the third position from the outer circumference in the radial direction are represented by broken lines, and electric conductors disposed in the fourth position from the outer circumference in the radial direction are represented by, a single-dotted chain lines. Furthermore, the upper level represents the second coil-end portion
16
b
composed of arranged turn portions, and the lower level represents the first coil-end portion
16
a composed of arranged joint portions. The horizontal row of numbers in the center of each diagram are slot numbers.
First, as shown in
FIG. 15
, large and small segments
31
and
32
are inserted into every third slot from slot number
1
. In the first coil-end portion
16
a,
the end portions
32
b
of the small segments
32
extending outwards from the second positions within the first slots
15
a
are joined to the end portions
31
b
of the large segments
31
extending outwards from the first positions of the second slots
15
a
three slots away in the clockwise direction in
FIG. 13
, and end portions
31
b
of the large segments
31
extending outwards from the fourth positions of the first slots
15
a
are joined to end portions
32
b
of the small segments
32
extending outwards from the third positions of the second slots
15
a
three slots away in the clockwise direction in FIG.
13
. Then, the turn portions
31
c
and
32
c
of the large and small segments
31
and
32
inserted into slot numbers
1
and
34
are cut.
In this manner, a lap-wound first winding sub-portion
161
is formed having two turns per slot. At the same time, a lap-wound second winding sub-portion
162
is formed having two turns per slot as shown in FIG.
16
. As shown in
FIG. 17
, the first and second winding sub-portions
161
and
162
are joined (by a bridging connection) between a second end portion
161
b
of the first winding sub-portion
161
and a first end portion
162
a
of the second winding sub-por
Asao Yoshihito
Higashino Kyoko
Mitsubishi Denki & Kabushiki Kaisha
Mullins Burton S.
Sughrue Mion Zinn Macpeak & Seas, PLLC
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