JP2001231232A - Ac generator for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: Ti improve a heat-resistant life of a rectifier and reduce the cost of the rectifier when a delta-connection is employed in stator windings of an AC generator for vehicle. SOLUTION: Rectifier elements are arranged at all rectifier element arranging positions on cooling fins of a vehicle AC generator to rectify a stator output. With this constitution, the unbalance of the temperatures of a plurality of the rectifier elements, of which a rectifier is composed, is reduced and the maximum temperature of the element can be reduced, so that the heat-resistant life of the rectifier as a whole can be improved.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an alternator for a vehicle mounted on a passenger car or a truck.

[0002]

2. Description of the Related Art Rectifiers used in automotive alternators are used in harsh environments such as engine rooms, and in order to improve reliability, together with elements with excellent heat resistance, better cooling performance. There has been a continuing demand for a structure having a rectifier having an excellent cooling structure as represented by, for example, Japanese Patent No. 1851848.

In a rectifier used in a conventional automotive alternator, a rectifying element is drawn out of the package from an element directly soldered to a cooling fin or an element packaged with a resin material or the like. Solder the terminals on the cooling fins, and further solder the element on the bottom of a cup-shaped member with good electrical and thermal conductivity, and on the opposite side to the soldered surface of the rectifying element ,
After further soldering the terminal to the opening side of the cup-shaped member,
The material sealed in the cup-shaped member by sealing the opening side with a member such as rubber in order to improve environmental resistance is mechanically fixed by press-fitting into the cooling fin, and electrically connected. (In this specification, not only a pellet-shaped rectifying element cut out from a so-called semiconductor wafer, but also an element packaged with a resin material or the like as described above.) The element is soldered on the bottom surface of the opening of the member having the terminal drawn out of the packaging, and further, a cup-shaped member having good electric conductivity and heat conductivity, and the terminal is further soldered on the opening side. On the opposite side of the soldered surface of the rear rectifier,
After further soldering the terminal to the opening side of the cup-shaped member,
In order to improve the operability and stabilize the quality of the element, such as one that is sealed in the cup-shaped member by sealing the opening side with a member such as rubber to improve environmental resistance. In the following, everything including the one in the sub-assembly state will be referred to as a rectifying element.)

Here, considering the heat resistance of a rectifier used in an automotive alternator, it is necessary to take into account the rise in the ambient temperature of the rectifier and the Joule heat due to the output current from the stator winding that is supplied to the rectifier. The absolute temperature at the time of operation of the rectifier due to, for example, the operating temperature range guaranteed by the rectifier alone in all normal operation states of the vehicle alternator, and the above-mentioned increase in the ambient temperature of the rectifier. The temperature rise during operation of the rectifying element, such as by taking into account the Joule heat due to the output current from the stator winding that is energized to the rectifying element, and from the place where the above-mentioned temperature has risen, the vehicle is allowed to stand still after stopping In this case, the main factor is thermal fatigue due to expansion and contraction of the rectifying element and its peripheral members due to heat when the temperature of the element decreases repeatedly to its ambient temperature. . Therefore, when considering the heat resistance of the rectifier for rectifiers used in AC generators for vehicles, a desirable form is to reduce the difference between the amplitudes of temperature rise and fall by reducing the maximum temperature during operation. Yes. Here, since a plurality of elements are used for the rectifier,
Even if any one of the plurality of rectifying elements is broken, the performance of the automotive alternator will be degraded. Therefore, even if the average temperature of a plurality of rectifiers constituting the rectifier is the same, the lower the maximum temperature of the element and the smaller the deviation of the element temperature, the longer the heat-resistant life of the rectifier as compared with a large deviation.

Accordingly, the rectifying elements are generally arranged on the cooling fins so as to be substantially axially symmetric with respect to the center axis of the fins, so that the temperature of all the rectifying elements arranged is less biased. There are many things.

[0006] Now, the stator of the automotive alternator is
Most of them have three phases, and there are mainly star connection and triangle connection as connection methods. The star connection and the triangular connection are used differently depending on the application because of the difference in output characteristics, but in the case of the star connection, a certain number of rotations from the neutral point, which is the point connecting the three phases at the center of the connection, Then, because the generated power can be taken out, depending on the required output characteristics,
Connecting a pair of rectifying elements to the neutral point and extracting generated power is performed as necessary. Therefore, the cooling fin used for the rectifier of the automotive alternator that adopts the star connection and extracts the output from the neutral point has the rectifier of the neutral point in addition to the rectifier element for the main three phases. The cooling fins are arranged substantially axisymmetrically with respect to the central axis.

Here, a fin used for a rectifier used in an automotive alternator for taking out an output from a neutral point of the stator winding is a star connection, and a vehicle having a stator winding of a triangular connection. Rectifier for taking out the output from the neutral point by star connection among the installation positions of the rectifier arranged in the cooling fins of the positive and negative electrodes If the stator winding has a triangular connection, the rectifying element is not arranged because it does not have a neutral point, so the rectifying element is arranged with a bias with respect to the center axis of the cooling fin. Become. In other words, when adopting triangular winding,
The temperature of the rectifying element arranged closest to the position where the rectifying element for taking out the output from the neutral point of the star connection described above is arranged because the element arrangement position next to it is vacant. Is relatively sparse, meaninglessly lower than the element temperature on the side opposite to the center axis of the cooling fin where the element is relatively close, and the temperature between the elements is apparent. There is a drawback that bias is generated.

Further, when the rectifying element is press-fitted into a fixing hole set in the cooling fin, a rectifier in which the element packaged in advance in the cooling fin is press-fitted together with the case is provided with one rectifying element. The arrangement location becomes hollow, and as a result, the area of the cooling fin is reduced, so that the cooling efficiency of the fin is reduced. In particular, since the cooling fins on the negative electrode side are in close contact with the frame of the AC generator for vehicles, the heat of the cooling fins on the negative electrode side is directly transmitted to the frame of the AC generator for vehicles, and similarly, the heat of the cooling fins on the positive electrode side is conducted. Good, insulating material is sandwiched between the negative electrode fin and the structure, the cooling of the positive rectifier element and cooling fins through the insulating material and the negative electrode fin, mainly by heat conduction In a rectifier that performs cooling, there has been a problem that the efficiency of cooling is deteriorated because the close contact portion between the components described above is reduced. The deterioration of the cooling efficiency of the rectifier due to the above-mentioned factors has caused the temperature of the rectifier to rise and the heat resistance of the rectifier to deteriorate.

[0009]

According to the present invention, when the vehicle alternator selectively uses the triangular connection and the star connection according to the required power generation characteristics, furthermore, the output from the neutral point is taken out even with the same star connection. And when not taking it out,
Using the same cooling fins, the rectifiers are evenly and evenly arranged on the rectifier to reduce the maximum temperature of the elements on the rectifier and to maximize the cooling efficiency of the rectifiers and cooling fins. Therefore, an object of the present invention is to improve the heat resistance of the rectifier by reducing the temperature of the rectifier. It is another object of the present invention to provide a highly reliable and inexpensive vehicle alternator by measuring common use of components constituting a rectifier such as cooling fins.

[0010]

In order to achieve the above object, according to the first aspect, when the output from the neutral point is not taken out by the triangular connection and the star connection, the output from the neutral point is not taken out by the star connection. In the case of employing cooling fins that are adopted when taking out the output of the rectifier, the rectifier is also arranged at the place where the rectifier for rectifying the output from the neutral point at the time of the star connection, that is, on the cooling fin By arranging rectifying elements at all the fixed points and using it for rectification, it is possible to arrange the rectifying elements on the cooling fins with a substantially uniform distribution. It is possible to arrange them evenly, and it is possible to reduce the maximum temperature of a plurality of rectifying elements arranged on the cooling fins. Further, what has been devised in order to achieve the above-described arrangement of the rectifying elements in the configuration of the terminals for connecting the rectifying elements is the subject matter of claim 1.

According to a second aspect of the present invention, a rectifying element is arranged on the cooling fins as described in the first aspect, and a bridge is formed by connecting the rectifying elements, and the output from the stator winding is converted from AC to DC. Discloses a method of manufacturing a terminal block in which a terminal made of an electric conductor for forming the bridge is fixed and insulated by an insulator.

This terminal block is configured such that the above-mentioned terminals are formed into pairs of positive and negative rectifying elements for each phase of the stator winding.
Furthermore, in the case where terminals configured to combine outputs from each pair are insulated with an insulator and integrally molded with resin to fix, one terminal is first integrally molded with the insulator,
By separating the terminals after that, it can function as a terminal for connecting the rectifying element. By reducing the number of steps to set many terminals in the mold for integral molding, cost reduction and productivity It aims to improve.

A third aspect of the present invention is to manufacture a low-cost rectifier and an automotive alternator by sharing the terminal block constituting the rectifier with the method of connecting the stator windings to each other. . One of the problems of the present invention as a whole is that, depending on the output characteristics required for an automotive alternator, the stator winding connection method is triangular connection or star connection, and furthermore, the output from the neutral point when star connection is adopted. Whether to take out
The aim is to minimize cost increases.
Therefore, it is desirable to share the terminal blocks constituting the diode bridge as well as the cooling fins. Therefore, the terminal and the part up to the terminal integrally molded with the insulator are shared, and in the work of separating the terminal after integrally molding the terminal and the insulator, the arrangement of the rectifying element as claimed in claim 1 is provided,
Not only the terminal block of the rectifier of the automotive alternator whose stator winding adopts the triangular connection, but also the rectifier of the automotive alternator that uses the stator winding adopting the conventional triangular connection and star connection This is an invention of a structure of a terminal block that can be adopted for a terminal block. According to the present invention, a mold for molding a terminal, a jig and a tool, and a mold for integrally molding a terminal with a resin can be used in common, so that equipment investment can be reduced and cost can be reduced.

A fourth aspect of the present invention relates to the invention relating to the electric capacity of the rectifying element of the first aspect. If the number of rectifying elements is increased as in claim 1 simply by considering the cooling efficiency of the elements, an increase in cost cannot be avoided. However, since the output current from each stator winding is substantially the same, the number of rectifiers connected to a terminal on the terminal block connected to a certain stator-side output terminal differs from the electric capacity of the element. The larger the number of rectifying elements connected to the terminals of the terminal block connected to the stator-side output terminals, the smaller the current flowing through one element,
Since the electric capacity of the element capacity can be reduced, the price of a rectifier element having a small electric capacity is generally inexpensive compared to that of a large rectifier element. It is possible to keep it to a minimum.

[0015]

FIG. 2 shows an outline of an automotive alternator. In the vehicle alternator, since the rotor 1 is disposed in the stator 2 and the rotor 1 is disposed together with the stator on the frames 5 and 6 via the bearings 3 and 4, the end of the rotor 1 is provided. The rotor 1 is rotated by a power transmission mechanism such as a belt or a chain (not shown) so that the rotor 1 obtains power from the internal combustion engine of the vehicle on which the vehicle AC generator is mounted. The rotor is rotated inside the stator, and a current is applied to the rotor-side field coil to generate a voltage on the stator side. The output terminal 8 of the stator is connected to the terminal 9 of the rectifier, thereby fixing the stator. The AC output from the child is rectified by the rectifier 10.

FIG. 3 shows an example of a conventional rectifier used in an automotive alternator, which employs a star connection for the stator winding and uses the output from the neutral point. .

Here, the rectifier includes a positive-side cooling fin 11, a negative-side cooling fin (not shown in the figure), a terminal block 12 (an output terminal of the stator winding and a positive-side cooling fin used in the rectifier shown in FIG. 3 and thereafter). In order to connect the rectifier on the negative electrode side and form a bridge for the commutator, and to form a rectifier, a terminal made of electrically conductive material and a member for insulating and fixing the terminal are integrated. The molded terminal block is shown in a perspective view to clarify the arrangement of the terminals in the insulating material, and the members for insulating and fixing are indicated by dotted lines.) , 14, 15, 16, rectifying elements 13, 14, 1 fixed to negative-side rectifying elements 17, 18, 19, 20 and positive-side cooling fins 11, 11
5, 16 and the negative-side cooling fins, the insulator 21 for insulating the negative-side rectifiers 17, 18, 19, and 20, the positive-side cooling fins 11, and the negative-side cooling fins while sandwiching the insulator 21 between the terminal blocks. Screws 22, 23,
24. Here, the rectifiers 14 and 18 are rectifiers for extracting the output from the neutral point of the star connection, and when it is not necessary to extract the output from the neutral point, the rectifiers 14 and 18 are unnecessary. Becomes

Terminal 25 integrally formed with terminal block 12
Of the output ends of the four stator windings at the end 26 of the
One of the three output terminals, not the output terminal from the neutral point, is connected.
The terminals 30 of the negative side rectifier 17 are connected to the terminals 28 and 29 by one or more of electrical and mechanical connection methods such as brazing, welding, soldering, and mechanical crimping of the terminals. They are connected by using them together.

Similarly, the terminal 32 of the terminal block 12 has an end 32 at the output end from the neutral point of the star-connected stator, and an end 33 at the terminal 34 of the positive side rectifying element 14. The terminal 35 of the negative side rectifying element 18 is provided at the portion 35, and one of the output ends of the stator winding other than the two ends described above is provided at the end 38 of the terminal 37 of the terminal block 12, The terminal 40 of the positive side rectifying element 15 is provided at the terminal end 39, the terminal 42 of the negative side rectifying element 19 is provided at the terminal end 41, and the remaining stator winding is provided at the terminal end 44 of the terminal 43 of the terminal block 12. One output end, end 45
The terminal 46 of the positive side rectifying element 16 and the terminal 48 of the negative side rectifying element 20 are connected to the terminal 47 in the same manner as the respective ends of the terminal 25 described above. Here, the central axis of the rectifier is shown as 49, and the positive side rectifiers 13, 14, 15, 16 which serve as heat sources when the rectifier operates.
Are arranged substantially symmetrically with respect to 49. Similarly, the negative-side rectifiers 17, 18 and 19, 20 are similarly arranged at positions substantially symmetrical with respect to 49, and have a structure that minimizes the temperature deviation of the rectifying element.

FIG. 4 shows the positive-electrode-side cooling fins 11 used alone in the case of FIG. 3 as mechanically fixed and electrically conductive by press-fitting the aforementioned rectifying element. A hole penetrating through the fins in the thickness direction of the fin with the same inner diameter as the outer diameter of the rectifying element for arranging the rectifying element for transmitting heat due to self-heating of the rectifying element to the cooling fin when energized is provided. When a star connection is used for the winding, 50, 51, 52, 53 so that the output from the neutral point can be taken out.
And four places in total, approximately equally spaced, and the center line 5 of the cooling fins
4 are arranged substantially symmetrically. That is, since the fin of FIG. 4 is applied to FIG. 3, 50, 51, and 5 of FIG.
In FIG. 3, 13, 14, 15, 16 rectifying elements are press-fitted into the holes 2, 53.

FIG. 5 also shows the cooling fins on the negative electrode side. Holes for disposing rectifying elements having the same functions and dimensions as those of the positive electrode fins also employ star-shaped stator windings. In this case, a total of four holes 55, 56, 57 and 58 are arranged substantially symmetrically with respect to the center axis 59 of the cooling fin so that the output from the neutral point can be taken out. Therefore, although not shown in FIG. 3, since the cooling fins of FIG. 5 are employed, 55, 56, 57, and 58 shown in FIG.
3 are press-fitted with the rectifiers shown in FIG. 3, 17, 18, 19.20 in FIG. 3. FIG. 6 is a wiring diagram of the stator and the rectifiers when the rectifier shown in FIG. 3 is used. And 60 is called the neutral point of the star connection.

FIG. 7 shows an example of a conventional rectifier used in an automotive alternator employing a triangular winding as a stator winding connection method. Here, the rectifier includes the positive-side cooling fins 61 and the negative-side cooling fins (not shown in FIG. 3) as in FIG.
A terminal block 62, a rectifying element 63 fixed to the positive electrode fin,
Rectifier elements 66, 6 fixed to negative fins 64, 65
7, 68, the positive electrode side cooling fins and the insulator 69 for insulating the rectifying element, the negative electrode side cooling fins and the rectifying element, and the positive electrode side cooling fins 60 and the insulator 69 are fixed to the negative electrode side cooling fins while being sandwiched between terminal blocks. The screws 70, 71, and 72 are provided.

Since the cooling fins 61 on the positive electrode side are the same as the cooling fins 11 shown in FIG. 3, that is, those shown in FIG.
A total of four holes for rectifying elements are provided. In the case of a rectifier used in a conventional triangular connection, the rectifying elements are holes 50 and 5 for installing rectifying elements on cooling fins, respectively.
1, 52, and 53 are fixed to the cooling fins 61 by being press-fitted to portions other than 51, maintain electrical connection between the fins and the rectifying element, and dissipate heat due to self-heating of the element when energized. To tell. Similarly, although not shown, the negative-side cooling fins employed in FIG. 7 employ the negative-side cooling fins having the shape shown in FIG.
A rectifier is formed by press-fitting a rectifying element into holes other than 56 among holes 5, 56, 57, and 58. Here, one of the three output ends of the triangularly connected stator winding is crimped to the end 74 of the terminal 73 included in the terminal block 62, and a connection method such as soldering, brazing, or welding is used. Are used alone or in combination to provide both mechanical connection and electrical connection. Terminal 73
The other end 75 has a terminal 76 of the positive-side rectifying element 63,
The terminal 78 of the negative side rectifying element 66 is electrically and mechanically connected to the terminal end 77 by welding, brazing, soldering, or the like. Similarly, at the end 80 of the terminal 79 and the end 85 of the terminal 84 included in the terminal block 62, the remaining two output ends of the three output ends of the stator windings connected in a triangular manner are the same as 61, respectively. And the end portion 8 of the terminal 79.
1, 83 and the ends 87, 89 of the terminal 85, the terminals 82, 88 of the positive side rectifying element, the terminal 84 of the negative side rectifying element,
90 rectifies the AC output from the stator winding into a DC output by a bridge of rectifying elements constituted by connecting in the same manner as the connection between 75 and 76 and the connection between 77 and 78, respectively.

In this conventional example, the same cooling fins are used when the triangular connection is used on both the positive and negative electrode sides and when the star connection is used, so the four fixed points shown in FIG. One of 51, 51, 52, 52 is vacant, and the arrangement of the rectifying elements on the cooling fins is asymmetric with respect to the central axis 54. That is, with reference to FIG. 4, among the fixing positions of the positive electrode side fins, the rectifying element placement locations 52 and 53 on the right side with respect to the central axis 54 are shown in FIG.
As shown in FIG. 7, two rectifying elements 64 and 65 are provided, one for each, and a total of two rectifying elements are arranged on the left side of the central axis 54 in FIG.
Are arranged, and the arrangement position 51 shown in FIG. 4 is vacant. Therefore, the center axis 91 of the cooling fin in FIG.
On the basis of, the rectifying element serving as a heat source during operation is relatively densely arranged on the right side, while the rectifying element serving as a heat source during operation is sparsely arranged on the left side when operating,
The rectifying element 6 on the right side which is arranged at the positions 52 and 53 in FIG.
4 and 65 are higher than the temperature of the rectifying element 63 on the left side arranged at the fixed position 50 of the rectifying element shown in FIG. This non-uniform temperature distribution is similarly selected from among the four rectifying element installation locations that are substantially axially symmetric with respect to the center axis of the fin, also for the negative cooling fin (not shown).
Since the location of the three rectifying elements has the same relationship as that of the positive electrode fin, the temperature distribution is similarly non-uniform on the left and right of the central axis.

FIG. 8 is a connection diagram of a triangularly connected stator and a rectifying element when the rectifier shown in FIG. 7 is used.

FIG. 1 shows an embodiment which eliminates the non-uniformity of the temperature distribution as described above. The cooling fins 92 on the positive electrode side adopt the fins having the shape shown in FIG. 4, and the same cooling fins as those used in the rectifier shown in FIGS. Similarly, although not shown, the cooling fins on the negative electrode side shown in FIG. 5 are employed similarly to the conventional example shown in FIGS. Positive-side rectifying elements 93, 94, 95, 96
Are arranged and press-fitted at all the installation locations 50, 51, 52, and 53 of the rectifying elements arranged substantially axially symmetrically with respect to the center line 54 of the cooling fin shown in FIG.
To maintain the electrical connection between the fin and the element, and transmit the heat generated by self-heating of the element when energized to the cooling fin. Similarly, the negative side rectifying elements 97, 98, 99, 10
Numeral 0 denotes a cooling fin 92 shown in FIG. 1 which is arranged and pressed into all of the rectifying element arrangement locations 55, 56, 57 and 58 which are arranged substantially axially symmetrically with respect to the center line 59 of the cooling fin shown in FIG.
To maintain the electrical connection between the fin and the element, and transmit the heat generated by self-heating of the element when energized to the cooling fin. The terminal block 101 has terminals 101, 102, 1
Those having the shapes 03 respectively are arranged as shown in FIG. The positive-side fin 92 and the positive-side rectifying elements 93, 94, 9 press-fitted into the positive-side fin.
5, 96, a negative electrode side fin (not shown in FIG. 1), an insulating material 105 for insulating the negative electrode side rectifying elements 97, 98, 99, 100, and a positive electrode side cooling fin 92 and an insulator 105 together with a terminal block. It is composed of screws 105, 106, and 107 to be fixed to the cooling fin on the negative electrode side while being sandwiched by the terminal block.

Here, the terminal 10 included in the terminal block 101
At the second end 109, one of the three output ends of the triangularly connected stator winding is swaged, and a connection method such as soldering, brazing, or welding is used alone or in combination. They are connected while having both mechanical and electrical connections. The other end 110 of the terminal 102 has a terminal 111 of the positive-side rectifying element 93 and a terminal end 112.
The terminal 113 of the negative side rectifying element 97 is electrically and mechanically connected by welding, brazing, soldering or the like. Similarly, the end 114 of the terminal 103 included in the terminal block 101
The other two output terminals of the three output terminals of the triangularly connected stator winding are each connected to one end 115 of the terminal 104 by one.
09 is connected in the same manner as that of the terminal
The terminals 118 and 117 of the positive side rectifying element 96 and the terminal 119 of the negative side rectifying element 100 are connected to the ends 116 and 117 by the same connection method as 110, 111 and 112 and 113, respectively. What is characteristic here is that the terminal 103 is connected to four terminal rectifying elements as shown in FIG.
0, 121, 122, and 123. End 1
Reference numeral 20 denotes a terminal 124 of the positive-side rectifying element 94, 121 denotes a terminal 125 of the negative-side rectifying element 98, 122 denotes a terminal of the positive-side rectifying element 95, and 123 denotes a negative-side rectifying element 9.
9 are electrically and mechanically connected by welding, brazing, soldering, or the like, respectively, and the rectifying element fixing points 50, 5 shown on the positive-electrode-side cooling fins shown in FIG.
1, rectifying elements 93, 94, 95, and 96 shown in FIG. 1 and rectifying element fixing points 55 and 5 shown on the negative cooling fins shown in FIG.
All of the rectifying elements 97, 98, 99, 100 shown in FIG.
By connecting to a terminal included in the terminal block 101, a rectifier for rectifying an output from the stator winding into an AC output to a DC output is configured.

Therefore, in the conventional triangular winding, as shown in FIG. 7, a total of three rectifying elements are connected to the positive electrode side and a total of three rectifying elements are connected to the negative electrode side. Cooling fins used in a rectifier that has four fixed points for rectifying elements that are substantially axially symmetric with respect to 54 and that can rectify the output from the neutral point of the star winding and take out the output as an output,
When applied to a triangular winding, there is a problem that the arrangement of the rectifying elements always becomes uneven and the temperature distribution becomes uneven. However, in the present invention, only the output terminal of one stator winding is provided. By connecting two positive and negative rectifying elements,
Since the rectifying element can be arranged axially symmetrically with respect to the center axis 127 of the cooling fin as shown in (1), it is possible to eliminate the bias of the temperature distribution. The bias of the temperature of the rectifying element to be performed is reduced, and the temperatures of the positive side rectifying elements 93, 94, 95, and 96 shown in FIG. 1 are made lower than those of the positive side rectifying elements shown by 64 and 65 in FIG. 9, and at the same time, 97, 98, 99, 100 in FIG. 9 as compared with 67, 68 in FIG.
Temperature of the rectifying element can be lowered.

Therefore, according to the present invention, it is possible to reduce the temperature deviation of the rectifying element used in the automotive alternator and to reduce the temperature of the element that exhibits the highest temperature during operation among a plurality of elements, as compared with the conventional example. Accordingly, the heat resistance of the rectifier as a whole can be improved, so that the heat resistance of the vehicle alternator can also be improved.

The specific example of the rectifier shown in FIG. 1 employs a star winding for the stator winding, but can also be applied to a case where the output from the neutral point of the star connection is not taken out.

Now, the application of claim 4 will be considered. The electric capacity of the positive side rectifying elements 94 and 95 can be made smaller than the electric capacity of 93 and 96. This is because the outputs from the ends of the three stator windings are substantially equal, and the rectifiers 94 and 95 divide the output from one stator winding to two rectifiers. Therefore, 94,95
Of the rectifier can be reduced to about half as compared with 93 and 96. Considering the balance of heat generation, 9
The use of the same electric capacity of 4 and 95 is consistent with the object of the present invention that the heat of the element is balanced with respect to the central axis 128 of the fin to reduce the temperature of the entire rectifier. Therefore, the electric capacity of the elements 94 and 95 should be the same. The same can be applied to the negative side rectifying elements 97, 98, 99, 100. The electric capacity of the rectifying elements 98, 99 can be made smaller than that of 97, 100. is there. Of course, the electric capacity of the rectifier element may be unified to a portion where the output from the end of the stator winding is not divided into a plurality of rectifier elements, that is, a relatively large capacity, and all may have the same capacity. In this case, the number of rectifying elements used in one rectifier is increased as compared with the conventional example, so that the object of improving the heat resistance as compared with the conventional example can be achieved, but at the same time, the cost is reduced. Compared with the conventional example, the increase of the rectifying element increases. However, since the capacity of the rectifying element is generally proportional to the price of the rectifying element itself, an element having a small electric capacity is replaced by the element 9 in FIG.
Adopting 4, 95, 98, 99 or the like can reduce the cost of the rectifier and the vehicle alternator, and can suppress the increase in cost as compared with the conventional example.

FIG. 9 is a connection diagram of a triangularly connected stator and a rectifying element when the rectifier shown in FIG. 1 is used. Each of the two ends of each of the three phases 129, 130, and 131 has a vertex 131, 13 of a triangle as shown in FIG.
At 2133, a triangularly connected stator is formed by appropriately connecting each other. Here, in the connection diagram shown in FIG. 9, the tip of the triangular vertex 132 is
35 and a negative-side rectifying element 1365 are connected. Similarly, a positive-side rectifying element 137 and a negative-side rectifying element 138 are connected to the tip of the vertex 134. On the other hand, the positive-side rectifying elements 139 and 141 and the negative-side rectifying elements 140 and 142 are connected to the tip of the vertex 133, and two positive and negative rectifying elements are connected. That is, the terminal end 109 of the terminal block to which the output end of the stator winding of FIG. 1 is connected.
9 is connected to 115 or 115, and the positive side rectifying element 93 or 96 in FIG.
This corresponds to 35 or 137, and the negative side rectifying element 97 or 100 in FIG. 1 corresponds to 136 or 138 in FIG. Similarly, the output end of the stator winding connected to 114 in FIG. 1 corresponds to the output end from vertex 134 in FIG.
The positive side rectifying element 94 or 95 of FIG.
39 corresponds to the negative side rectifying element 98 or 99 in FIG. 1 corresponds to 140 or 142 in FIG.

FIG. 10 shows another specific example. Considering that the rectifier shown in FIG. 10 is used for rectifying the output from the triangularly connected stator windings, ends 147, 148, and 14 of terminals 144, 145, and 146 are integrally formed with the terminal block 143.
Out of 9, 150, 147 and 150 are the output terminals after the terminals on one side of the two stator windings are connected to each other as usual, for example, the connection diagram of the triangularly connected stator of FIG. The vertexes 132 or 134 are connected, and one rectifying element on the positive electrode side and one rectifying element on the negative electrode side are connected to the output terminal from the stator winding via the terminals of the terminal block used for the rectifier, respectively. Is rectifying. On the other hand, before connecting the ends of the two phases to the terminals of the terminal block, one is connected to 148, the other is connected to 149, and the remaining one is connected to the stator winding terminals. Connect the phase ends of the windings via terminals,
At the same time, it is connected to two pairs of rectifying elements. Even in such a case, the output of the portion where the terminals of the stator winding are connected to each other via one terminal among the three output terminals is the positive side 2
Since two pairs of rectifying elements, two on the negative electrode side, can be connected, the rectifying elements can be arranged symmetrically with respect to the center axis 151 of the cooling fin, thereby eliminating the bias of the temperature distribution of the cooling fin. As a result, it is possible to reduce the temperature of the rectifying element and improve the heat resistance.

FIG. 11 is another specific example, which is basically configured in the same way as FIG. 10, but depending on the position of the terminal of the stator winding, the terminal of the terminal block may be configured as shown in FIG. It is possible to improve the productivity of the stator by arranging them. In this example, a portion where one rectifying element is connected to each of the positive and negative rectifying elements is connected to two ends of the end connections of the three ends of the stator winding triangularly connected in the same manner as in FIG. For example, in the connection diagram of the triangular winding in FIG. 9, the two end tips of the vertices 132 and 134 of the triangle are:
As in the specific example shown in FIG. 10, the wires are connected before being connected to the terminal block, and connected to the ends 156, 157 of 153, 154 of the three terminals 152, 153, 154 of the terminal block. As for the vertices 133 of the triangle shown in the connection diagram of the triangular winding shown in FIG. 9, the ends from the remaining two output phases are directly connected to the terminal ends 155, 1 of the terminal block.
By being connected to the terminal 58, the ends of the two phases are connected by the terminal 152 and are connected to two pairs of rectifying elements, each of which includes two positive and negative rectifying elements. Even in such an arrangement, the rectifying element can be arranged substantially axially symmetrically with respect to the center axis 159 of the cooling fin, which is the object of the present invention.
As in the case of the tenth embodiment, this is an example of the specific embodiment of the first aspect, and the temperature of the rectifying element can be reduced and the heat resistance can be improved.

The terminal block 143 shown in FIG. 10 has terminals 144 and 144 in a terminal block formed integrally with an insulator.
145 and 146 are included. In order to integrally mold the three terminals with the insulator, 144, 145, 146
Must be set one by one in the molding die, and the number of working steps increases. Also, for example, when molding a terminal by pressing,
Since a large number of press dies are required according to the shape of each terminal, the cost of manufacturing the dies increases. Therefore, a specific example of claim 2 is shown in FIG. The terminal molded integrally with the terminal block is shown in FIG.
After being integrally formed and molded as shown in FIG. 12, two portions of the hatched portions 160 and 161 which are not included in the resin shown in FIG. 12 are cut off to separate the terminal into three pieces, thereby functioning as a terminal block of the rectifier shown in FIG. It is possible to fulfill.

Similarly, in the terminal block having the terminal arrangement as shown in FIG. 14, the two terminals of the hatched portions 162 and 163 are cut off to separate the terminal into three, and the terminal block of the rectifier shown in FIG. It is possible to fulfill the function as.
Further, by removing a part of the insulator of the terminal block in advance and cutting off the hatched portion 164 at the portion where the terminal is exposed, the terminal is separated into four pieces to form a star-shaped connection as shown in FIG. It can also be used as a terminal block of a rectifier when the output of the adopted stator from its neutral point is also taken out.

As described above, by adopting the structure of the terminal block which can be used for both star connection and triangular connection with one terminal molding die and one resin integral molding die, it is possible to suppress initial investment in manufacturing. Can reduce the cost of the product.

Similarly, FIG. 15 is a concrete example of the third embodiment.
By cutting the cutting portions 165 and 166 indicated by oblique lines, FIG.
It is possible to configure a terminal block of a rectifier in the case where a triangular winding as shown in FIG. 0 or a star winding is used for the stator winding but an output from the neutral point of the star connection is not taken out. .
Further, a part of the insulator constituting the terminal block is exposed when the terminal and the insulator are integrally formed, and the hatched portion 167 of the exposed terminal is exposed.
By cutting the stator winding, it is possible to adopt a star winding for the stator winding and to use it as a terminal block of a rectifier when extracting output from a neutral point.

[0039]

According to the invention described above, a star-shaped connection is used for the stator winding, and cooling fins used for the rectifier when the output from the neutral point is taken out are connected to the stator winding by a triangular connection and a star. In the case where the cooling wire is used for a rectifier in which the output from the neutral point is not taken out when adopting the type connection, the heat resistance of the rectifying element can be improved.

Next, when the terminal block constituting the rectifier is integrally molded with a conductive terminal and an insulator, the terminals are integrated into one piece at the time of resin molding, and a portion not covered with the resin is cut off after molding. In order to improve the work efficiency, it is no longer necessary to set several terminals, which are finely divided into a molding die for integrally molding the terminal block, in the integrally molded mold. Can be supplied.

Further, after the terminal and the insulator are integrally formed as a terminal block, a portion not included in the insulator is cut in accordance with the winding method of the stator, so that the terminal block can be supplied. Depending on the output characteristics required for the automotive alternator, the method of connecting the stator windings such as triangular connection or star connection, and whether or not to extract the output from the neutral point in the case of star connection Regardless of the type, one terminal manufacturing die, one terminal integrated molding terminal block, only by cutting the part of the terminal exposed from the insulator in the final process, only Since the terminal block corresponding to the change of the child winding can be manufactured, it is possible to easily and inexpensively cope with the connection method of all the stator windings.

Further, in the present invention, the number of rectifying terminals is increased more than usual, which may raise the cost. However, in the present invention, the number of rectifying elements connected to the output terminal of the stator winding is different from that of another stator. For the part larger than the number of rectifiers connected to the output terminal of the winding, it is possible to use a rectifier with a smaller electric capacity, while minimizing cost increase, It is possible to improve the heat resistance, which is an essential component of automotive alternator components.

[Brief description of the drawings]

FIG. 1 is a view showing a rectifier used in a case where an output from a neutral point is not taken out by a triangular connection or a star connection to a stator winding of an automotive alternator, showing an embodiment of the present invention. .

FIG. 2 is a diagram showing an example of a vehicular AC generator equipped with a rectifier.

FIG. 3 is a diagram showing an example of a rectifier used when a stator winding used in an automotive alternator is star-connected and an output from the neutral is taken out and rectified.

FIG. 4 is a diagram showing an example of a positive-electrode-side cooling fin used in a rectifier of an automotive alternator.

FIG. 5 is a diagram showing an example of a negative-electrode-side cooling fin used in a rectifier of an automotive alternator.

FIG. 6 is a diagram showing an example of a connection diagram of a star-connected stator winding used in a vehicle alternator and a rectifier for rectifying the output thereof.

FIG. 7 is a diagram showing a conventional example of a rectifier used when a stator winding used in a vehicle AC generator is triangularly connected.

FIG. 8 is a diagram illustrating an example of a connection diagram of a triangularly-connected stator winding used in an automotive alternator and a rectifier for rectifying the output of the stator winding.

FIG. 9 is a diagram showing an embodiment of a triangularly-connected stator winding and a rectifier for rectifying the output of the stator winding used in the automotive alternator to which the present invention is applied.

FIG. 10 is a view showing an example of the present invention, showing a rectifier used when a triangular connection is used for a stator winding of an automotive alternator.

FIG. 11 is a view showing another example of the rectifier used in the case where the stator winding of the automotive alternator is used for triangular connection, showing another example of the present invention.

FIG. 12 is a diagram showing a configuration of a terminal block constituting a rectifier representing an example of an embodiment of the present invention.

FIG. 13 is a view showing an example of a shape of an insulator and a terminal before molding used in the terminal block shown in FIG. 12;

FIG. 14 is a diagram showing a configuration of a terminal block constituting a rectifier according to another example of the present invention.

FIG. 15 is a diagram showing a configuration of a terminal block constituting a rectifier according to another example of the present invention.

[Explanation of symbols]

8: stator output end, 9: rectifier, 92: cooling fin,
Reference numeral 101 denotes a terminal block, 103 denotes a terminal to which two positive and negative rectifying elements are connected, and 134 denotes a triangular winding connection part to which two positive and negative two rectifying elements are connected at the tip.

 ──────────────────────────────────────────────────の Continued on the front page (72) Inventor Makoto Hirama 2477 Takaba, Hitachinaka, Ibaraki Prefecture Inside Hitachi Car Engineering Co., Ltd. Within the Automotive Equipment Group (72) Inventor Toshio Ishikawa 2520 Oita Takaba, Hitachinaka City, Ibaraki Prefecture Hitachi, Ltd. F term in the automotive equipment group (reference) 5H619 AA05 AA11 BB02 BB06 BB17 PP00

Claims (4)

[Claims] 1. A rectifier for full-wave rectifying an output from a stator winding of an automotive alternator, wherein a rectifying element to be used is provided on cooling fins for fixing, cooling, and electrically connecting. When the fixed point of a certain rectifying element is substantially axially symmetric with respect to the center axis of the cooling fin, and the stator winding has a star connection, a rectifying element for rectifying the output from the neutral point is arranged. When the cooling fins that can be used for the rectifier when the output from the neutral point of the stator winding in the triangular connection or the star connection is not taken out, all the fixed points on the cooling fins are used. A rectifier that uses the arranged rectifier element for rectification, and a terminal block that is formed by integral molding of a member for fixing the terminal that controls the connection between the rectifier elements to insulation that constitutes the rectifier, and the rectifier. To adopt Features and the AC generator for a vehicle. 2. The terminal of the rectifier according to claim 1, wherein after the terminal is formed of an insulating material, a part of the terminal is separated to separate the terminal. A terminal block characterized by being a base, a rectifier using the terminal block, and a vehicle alternator. 3. The terminal block according to claim 1, wherein a part of a member constituting the terminal is cut off, so that the stator winding has a star connection and an output from a neutral point is rectified. By arranging the rectifying element only on a part of the rectifying element fixing point of the cooling fin according to claim 1, the triangularly-connected stator winding and A terminal block that can be used as a terminal block of a rectifier used for full-wave rectification of the output from the stator winding when the output from the neutral point of the star-connected stator winding is not taken out. Rectifier using terminal block and AC generator for vehicle. 4. The rectifier according to claim 1, wherein the electric capacity of some rectifier elements is not the same as the other electric capacity, and a vehicular alternator using the rectifier.