Alternator

• US 6,501,205 B1
• Filed: 09/12/2000
• Issued: 12/31/2002
• Est. Priority Date: 12/14/1999
• Status: Expired due to Term

• Current Assignee: Mitsubishi Denki Kabushiki Kaisha (Mitsubishi Electric Corporation)
• Original Assignee: Mitsubishi Denki Kabushiki Kaisha (Mitsubishi Electric Corporation)
• Inventors: Asao, Yoshihito, Adachi, Katsumi, Morishita, Akira
• Primary Examiner(s): LE, DANG D
• Application Number:
  US09/660,472
• Time in Patent Office: 840 Days
• Field of Search: 310/179, 310/180, 310/186, 310/195, 310/198, 310/199, 310/201, 310/202, 310/203, 310/204, 310/205, 310/206, 310/207, 310/208, 310/260, 296/05, 296/06, 320/63, 320/44, 320/45, 320/66
• US Class Current: 310/184
• CPC Class Codes: H02K 2203/09 Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02K 3/345 between conductor and core, e.g. slot insulation
• CPC Class Codes: H02K 3/50 Fastening of winding heads, equalising connectors, or connections thereto
• CPC Class Codes: H02K 9/06 with fans or impellers driven by the machine shaft

Abstract

An alternator includes a rotor for forming north-seeking (N) and south-seeking (S) poles about a rotational circumference, a stator having a stator core disposed facing the rotor and a polyphase stator winding installed in the stator core, and a bracket supporting the rotor and the stator, wherein the stator core includes a laminated iron core formed with a number of slots extending axially at a predetermined pitch in a circumferential direction, the polyphase stator winding includes a number of winding sub-portions in each which a long strand of wire is wound so as to alternately occupy an inner layer and an outer layer in a slot depth direction within the slots at intervals of a predetermined number of slots, the strand of wire folding back outside the slots at axial end surfaces of the stator core to form turn portions, and the turn portions align in a circumferential direction to constitute coil end groups.

Claims

1. An alternator comprising:

a rotor for forming north-seeking (N) and south-seeking (S) poles about a rotational circumference;

a stator comprising;

a stator core disposed facing said rotor; and

a polyphase stator winding installed in said stator core; and

a bracket supporting said rotor and said stator,

wherein said stator core comprises a laminated iron core formed with a number of slots extending axially at a predetermined pitch in a circumferential direction,

said polyphase stator winding comprises a number of winding sub-portions in each which a long strand of wire is wound so as to alternately occupy an inner layer and an outer layer in a slot depth direction within said slots at intervals of a predetermined number of slots, said strand of wire folding back outside said slots at axial end surfaces of said stator core to form turn portions, and

said turn portions align in a circumferential direction to constitute coil end groups at both axial end portions of said stator core,

wherein said number of winding sub-portions are constructed with at least one winding assembly formed by simultaneously bending and folding a plurality of said strand of wires,

wherein said winding assembly is constructed by arranging at one slot pitch offset the same number of wire-strand pairs as said predetermined number of slots, each of said wire-strand pairs constructed by arranging two strands of said strands of wire so that straight portions alternately overlap at a predetermined pitch, each of said strands of wire being formed into a pattern in which said straight portions are connected by turn portions so as to be arranged at a pitch of said predetermined number of slots and adjacent straight portions are offset by said turn portions so as to alternately occupy said inner layer and said outer layer in said slot depth direction, and by extending each end portion of said strands of wire on both sides of both ends of said winding assembly and arranging the same number of pairs of said overlapping straight portions as the number of said slots at said one slot pitch.

2. The alternator according to claim 1 wherein said turn portions constituting said coil end groups at at least one axial end portion of said stator core are formed with a generally identical shape in a circumferential direction.

3. The alternator according to claim 1 wherein spaces between adjacent turn portions in said coil end groups at at least one axial end portion of said stator core are formed so as to be generally identical in a circumferential direction.

4. The alternator according to claim 1 wherein each of said turn portions constituting said coil end groups comprises a uniform heat-radiating portion.

5. The alternator according to claim 1 wherein a pitch of said slots into which said strands of wire are wound corresponds to a pitch of said north-seeking (N) and south-seeking (S) poles of said rotor.

6. The alternator according to claim 1 wherein opening portions of said slots are formed at a uneven pitch.

7. The alternator according to claim 1 wherein opening dimensions of said opening portions of said slots are smaller than dimensions of said strands of wire in a slot-width direction.

8. The alternator according to claim 1 wherein a cross-sectional shape of said strands of wire within said slots is a rectangular shape following a shape of said slots.

9. The alternator according to claim 1 wherein a cross-sectional shape of said strands of wire is a generally flattened shape.

10. The alternator according to claim 1 wherein said turn portions of said strands of wire constituting said coil end groups are provided with resin.

11. The alternator according to claim 10 wherein said resin provided to said turn portions constituting said coil end groups contains a component having a higher coefficient of thermal conductivity than a principal component of said resin.

12. The alternator according to claim 11 wherein said resin is placed in contact with said bracket.

13. The alternator according to claim 1, further comprising a rectifier disposed at one axial end of said stator, said rectifier being electrically connected to winding ends of said polyphase stator winding and converting alternating-current output from said polyphase stator winding into direct current,

wherein said rotor comprises:

a Lundell-type rotor core having a number of claw-shaped magnetic poles providing said north-seeking (N) and south-seeking (S) poles; and

a cooling means for supplying cooling air inside said bracket by rotation of said rotor,

whereby said coil end groups and said rectifier are cooled by passage of said cooling air inside said bracket.

14. The alternator according to claim 13 wherein said cooling means is a fan disposed on at least one axial end portion of said rotor core.

15. The alternator according to claim 14 wherein said fans are disposed on both axial end portions of said rotor core.

16. The alternator according to claim 13 wherein an axial length of said stator including said coil end groups is shorter than an axial length of said rotor core.

17. The alternator according to claim 13 wherein directions of inclination of said strands of wire constituting inner circumferential sides of said coil end groups are parallel at both axial ends of said stator.

18. The alternator according to claim 13 wherein:

a number of slots housing said polyphase stator winding is two per pole per phase; and

said polyphase stator winding comprises a first polyphase winding portion and a second polyphase winding portion each corresponding to one slot per pole per phase.

19. The alternator according to claim 18 wherein said first polyphase winding portion and said second polyphase winding portion are connected in series and winding ends thereof are connected to said rectifier.

20. The alternator according to claim 18 wherein said rectifier comprises:

a first rectifier for converting alternating-current output from said first polyphase winding portion; and

a second rectifier for converting alternating-current output from said second polyphase winding portion,

output from said first polyphase winding portion and said second polyphase winding portion being combined after being converted separately by said first and second rectifiers.

21. The alternator according to claim 18 wherein each of said first and second polyphase winding portions is a three-phase connection,

opening portions of slots constituting a slot group into which said first polyphase winding portion is inserted and opening portions of slots constituting a slot group into which said second polyphase winding portion is inserted being arranged at an even pitch corresponding to an electrical angle of 30°

.

22. The alternator according to claim 18 wherein each of said first and second polyphase winding portions is a three-phase connection,

opening portions of slots constituting a slot group into which said first polyphase winding portion is inserted and opening portions of slots constituting a slot group into which said second polyphase winding portion is inserted being arranged so as to alternate between an electrical angle of (α

°

) and an electrical angle of (60°

−

α

°

).

23. The alternator according to claim 18 wherein at least one of said first and second polyphase winding portions is a star-connection and a neutral point of said star connected polyphase winding portion is connected to said rectifier.

24. The alternator according to claim 13 wherein a field current flowing to a field coil for supplying a magnetic field to said claw-shaped magnetic poles is limited when rotational frequency of said alternator is greater than or equal to a predetermined value.

25. The alternator according to claim 13 wherein magnets are interposed between said claw-shaped magnetic poles.

26. An alternator comprising:

a rotor for forming north-seeking (N) and south-seeking (S) poles about a rotational circumference;

a stator comprising;

a stator core disposed facing said rotor; and

a polyphase stator winding installed in said stator core; and

a bracket supporting said rotor and said stator,

wherein said stator core comprises a laminated iron core formed with a number of slots extending axially at a predetermined pitch in a circumferential direction,

said polyphase stator winding comprises a number of winding sub-portions in each which a long strand of wire is wound so as to alternately occupy an inner layer and an outer layer in a slot depth direction within said slots at intervals of a predetermined number of slots, said strand of wire folding back outside said slots at axial end surfaces of said stator core to form turn portions, and

said turn portions align in a circumferential direction to constitute coil end groups at both axial end portions of said stator core,

wherein 2n strands of said strands of wire are disposed in a row in said depth direction in each of said slots; and

said turn portions of said strands of wire are arranged so as to align into n rows in a circumferential direction.

27. An alternator comprising:

a rotor for forming north-seeking (N) and south-seeking (S) poles about a rotational circumference;

a stator comprising;

a stator core disposed facing said rotor; and

a polyphase stator winding installed in said stator core; and

a bracket supporting said rotor and said stator,

wherein said stator core comprises a laminated iron core formed with a number of slots extending axially at a predetermined pitch in a circumferential direction,

said polyphase stator winding comprises a number of winding sub-portions in each which a long strand of wire is wound so as to alternately occupy an inner layer and an outer layer in a slot depth direction within said slots at intervals of a predetermined number of slots, said strand of wire folding back outside said slots at axial end surfaces of said stator core to form turn portions, and

said turn portions align in a circumferential direction to constitute coil end groups at both axial end portions of said stator core,

wherein 2n strands of said strands of wire are disposed in a row in said depth direction in each of said slots; and

said turn portions of said strands of wire are arranged so as to stack up into n layers, where n is an integer which is equal to or more than 2.