JP3663958B2 - Vehicle alternator - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a vehicular AC generator, and more particularly to a vehicular AC generator suitable for use as an automobile power generator.
[0002]
[Prior art]
In general, an AC generator for a vehicle includes a rotor and a stator. The rotor includes a pair of opposed claw-shaped magnetic poles having a plurality of claw portions formed at the tip portion, and a field winding that magnetizes the claw-shaped magnetic poles. The stator is arranged at a predetermined distance from the rotor, and generates an alternating voltage by the magnetization of the claw-shaped magnetic poles of the rotor.
[0003]
In the vehicular AC generator configured as described above, the rotor rotates and a direct current flows through the field winding, thereby generating N and S poles in the pair of claw-shaped magnetic poles. The magnetic flux generated from the claw portion of the N-pole claw-shaped magnetic pole forms a magnetic circuit that passes through the stator iron core of the stator and returns to the claw portion of the S-pole claw-shaped magnetic pole.
[0004]
At this time, an alternating induced voltage is generated in the stator winding by the magnetic flux of the magnetic circuit crossing the stator winding of the stator.
[0005]
In such a vehicular AC generator, the amount of magnetic flux that crosses the stator winding affects the generated current. Therefore, in a conventional vehicle AC generator, a permanent magnet is arranged between the claws of the claw-shaped magnetic poles to increase the magnetic flux created by the field winding, thereby allowing the amount of magnetic flux to cross the stator windings. Try to increase.
[0006]
Further, in the conventional vehicle alternator, for example, as described in Japanese Patent Application Laid-Open No. 4-251553, the permanent magnets arranged between the claw portions of the claw-shaped magnetic poles are subjected to centrifugal force by the rotation of the rotor. Therefore, a non-magnetic jump-out preventing member (non-magnetic protective cover) is disposed on the outermost peripheral portion of the claw-shaped magnetic pole.
[0007]
However, in the one described in JP-A-4-251553, the permanent magnet can be prevented from jumping out by the non-magnetic protective cover, but each of the plurality of permanent magnets must be disposed directly between the claw poles. Therefore, workability is poor. On the other hand, for example, as described in JP-A-3-265450, a permanent magnet is disposed between the claw portions of the claw-shaped magnetic pole, and a nonmagnetic protective cover is provided only on the outer peripheral surface of the permanent magnet. The arrangement is known. This protective cover serves both to prevent the permanent magnet from popping out and to hold the permanent magnet.
[0008]
Japanese Patent Application Laid-Open No. 7-15929 discloses that a claw magnetic pole itself of an AC generator for a brushless vehicle is austenitic stainless steel and is subjected to a non-magnetic material treatment by heat treatment.
[0009]
[Problems to be solved by the invention]
However, in the vehicle AC generator described in Japanese Patent Laid-Open No. 3-265450, in order to use the permanent magnet jump-out preventing member also as the permanent magnet holding member, the outer peripheral portion of the permanent magnet is claw-shaped. Since it is necessary to arrange a pop-out preventing member on the inner peripheral side of the magnetic pole, the size of the permanent magnet is restricted and becomes smaller. Accordingly, there is a problem that the magnetic flux increasing action due to the arrangement of the permanent magnets is reduced, and the improvement in power generation efficiency cannot be expected so much.
[0010]
In the technique described in Japanese Patent Application Laid-Open No. 7-15929, the pawl magnetic pole itself is made of austenitic stainless steel, and the thickness of the austenitic stainless steel is required to be about 5 mm in order to reduce the leakage flux. Therefore, a large output is required for the laser to be used, and the equipment becomes large. Further, when a thin plate is used, there is a problem that the leakage magnetic flux between the claw magnetic poles increases. In addition, when the AC generator for a vehicle is left in a cold region, the nonmagnetic portion may return to the magnetic body.
[0011]
The object of the present invention is to improve the workability of arranging the permanent magnet between the claw portions of the claw-shaped magnetic pole, even in the configuration provided with the permanent magnet jump-out preventing member disposed between the claw portions of the claw-shaped magnetic pole, The object is to provide an automotive alternator with improved power generation efficiency.
[0012]
A second object of the present invention is a magnet module in which permanent magnets arranged between the claw portions of the claw-shaped magnetic pole are previously integrated by a permanent magnet holding member, and are integrated and integrated between the claw portions of the claw-shaped magnetic pole. Another object of the present invention is to provide a vehicular AC generator capable of increasing power generation current and improving power generation efficiency.
[0013]
[Means for Solving the Problems]
  The present invention is characterized by the following AC generator for vehicles. That is, it has a rotor and a stator arranged at a predetermined interval with respect to the rotor, and the rotor magnetizes the pair of claw-shaped magnetic poles arranged opposite to each other and the claw-shaped magnetic poles. Each of the claw-shaped magnetic poles includes a plurality of claw portions, and the plurality of claw portions of the claw-shaped magnetic poles are located between the claw portions adjacent to the claw-shaped magnetic poles. In order to increase the magnetic flux generated by the field winding between the claw portions adjacent to each other, the claw-shaped magnetic poles are formed so that the distance on the inner circumference side is larger than the distance on the outer circumference side. Permanent magnet pop-out preventing members for preventing the permanent magnet from popping out are disposed on the claw portion of the claw-shaped magnetic pole and the outer peripheral side of the permanent magnet. The permanent magnet is held from the inner peripheral side by a permanent magnet holding member. The stone holding member is a plate-like member bent into a cylindrical shape, and holds the width direction and the longitudinal direction of each of the plurality of permanent magnets placed on the plate-like member on the plate-like member. A claw portion for holding the permanent magnet in the width direction of the permanent magnet of the permanent magnet holding member, wherein the permanent magnet is interposed between the claw portions adjacent to the claw-shaped magnetic pole. An AC generator for a vehicle arranged in a gap formed between the claw portion of the claw-shaped magnetic pole and the permanent magnet when arranged.
[0014]
With this configuration, since the permanent magnet is held by the permanent magnet holding member, the workability at the time of assembling the rotor is improved, and the permanent magnet is held by the permanent magnet holding member from the inner peripheral side. Since it is arrange | positioned between the nail | claw parts of a nail | claw-shaped magnetic pole, the magnitude | size of a permanent magnet can be enlarged and power generation efficiency can be improved.
[0015]
In the above, preferably, the pop-out prevention member is made of a non-magnetic material.
[0016]
In the above, preferably, the thickness of the pop-out prevention member is set to ½ or less of the gap length between the rotor and the rotor.
[0017]
With this configuration, an increase in the magnetic gap length can be prevented.
[0018]
In the above, preferably, the pop-out preventing member is made of a magnetic material and has a hole at a position on the outer peripheral side of the permanent magnet.
[0019]
With this configuration, the pop-out prevention member is made of a magnetic material, so that the magnetic gap length is equal to the mechanical gap length to prevent an increase in magnetic resistance. By reducing the width of the pop-out prevention member, the magnetic saturation easily occurs, and reducing the leakage magnetic flux, the amount of magnetic flux crossing the stator winding can be increased, and the power generation efficiency can be improved.
[0020]
In the above, preferably, the pop-out prevention member is disposed at a lower step portion of the step portion formed on the claw portion of the claw-shaped magnetic pole, and the thickness of the pop-out prevention member is equal to the step portion of the step portion. It is what I did.
[0021]
With this configuration, the surface of the pop-out preventing member and the surface of the claw magnetic pole are flush with each other, the mechanical strength of the rotor is increased, and the windage loss of the rotor can be reduced.
[0022]
In the above, preferably, the pop-out preventing member has an alignment claw portion.
[0023]
With such a configuration, the positioning claw portion is disposed so as to mesh with the claw-shaped magnetic pole, whereby the pop-out preventing member can be positioned with respect to the gap between the claw-shaped magnetic poles.
[0024]
DETAILED DESCRIPTION OF THE INVENTION
A configuration of an automotive alternator according to a first embodiment of the present invention will be described with reference to FIGS.
[0025]
FIG. 1 is a cross-sectional view showing the overall configuration of an automotive alternator.
[0026]
The vehicle alternator according to the present embodiment includes a bracket 1, and the bracket 1 includes a pulley-side end bracket 1F and an anti-pulley-side end bracket 1B. A shaft 41 is supported at the center of the bracket 1 via bearings 42F and 42B. A pulley 43 is attached to one end of the shaft 41, and a slip ring 10 is attached to the other end. The pulley 43 is connected to the output shaft of the engine via a belt (not shown), and rotates in proportion to the engine speed. A brush 11 is slidably attached to the slip ring 10, and power is supplied from the brush 11 to a field winding 4 described later. A rotor (rotor) 2 is attached to the center of the shaft 41. The rotor 2 includes a yoke 17 fixed to the shaft 41, a field winding 4 wound around the outer periphery of the yoke 17, and a pair of claws provided so as to sandwich the yoke 17 and the field winding 4. The magnetic poles 3N and 3S are composed of permanent magnets 5 disposed between the claw portions of the claw-shaped magnetic poles 3N and 3S. By applying a direct current from the slip ring 10 to the field winding 4, the claw-shaped magnetic poles 3N and 3S are magnetized.
[0027]
Here, the permanent magnet 5 is fixed by a permanent magnet holding member 62 as described later with reference to FIG. Further, a protrusion preventing member 61 for preventing the permanent magnet 5 from protruding is disposed on the surfaces of the claw-shaped magnetic poles 3N, 3S and the permanent magnet 5. The permanent magnet 5 is a solid magnet. By using a solid magnet, the magnetizing force and energy product of the claw-shaped magnetic pole are increased, and the magnetic flux from the claw-shaped magnetic pole claw to the stator is increased compared to a magnet in which magnetic powder is solidified with resin. The power generation efficiency is improved.
[0028]
A stator 7 is attached between the pulley-side end bracket 1F and the non-pulley-side end bracket 1B. The stator 7 is arranged at a slight distance (mechanical gap) from the rotor 2. This mechanical gap is a predetermined interval required from the relationship of mechanical characteristics, and is generally about 0.4 mm. The stator 7 has a concavo-convex stator core 8, and a stator winding 9 is wound in three phases in the recess of the stator core 8, and the claw-shaped magnetic poles 3N and 3S are driven by the engine. When rotated and magnetized, a three-phase induced voltage is generated in the stator winding 9.
[0029]
A rectifier circuit 12 and a voltage regulator 13 are disposed inside the non-pulley side end bracket 1B. The rectifier circuit 12 has a B terminal 14 connected to a positive electrode of a battery (not shown) and a ground terminal 15 connected to a negative terminal of the battery, and rectifies an AC induced voltage generated in the stator winding 9 to generate a direct current. Convert to voltage.
[0030]
The voltage regulator 13 controls the field winding current so that the DC voltage rectified by the rectifier circuit 12 for charging the battery is maintained at a constant voltage of about 14.3V. In the vehicular AC generator configured as described above, when the pulley 43 is rotated by driving the engine, the shaft 41 rotates together with the slip ring 10 and the rotor 2, and the DC current from the brush 11 is generated inside the rotor 2. The field winding 4 is energized, and the field winding 4 operates to form an N pole and an S pole on each of the claw-shaped magnetic poles 3N and 3S. The magnetic flux generated by the field winding 4 forms a magnetic circuit in which the magnetic flux emitted from the claw portion of the N-pole claw-shaped magnetic pole 3N passes through the stator core 8 and returns to the claw portion of the S-pole claw-shaped magnetic pole 3S. At this time, the magnetic flux of the permanent magnet 5 for auxiliary excitation is arranged in parallel with the magnetic flux generated by the field winding 4, and enters the S pole from the N pole to increase the magnetic flux generated by the field winding 4. As a result, the amount of magnetic flux in the magnetic circuit increases. When the magnetic flux of this magnetic circuit crosses the stator winding 9, a three-phase induced voltage is generated in the stator winding 9. The three-phase induced voltage is converted into a DC voltage by the rectifier circuit 12, and the rectified DC voltage is adjusted by the voltage regulator 13 and maintained at a constant voltage of about 14.3V. Next, the configuration of the permanent magnet holding member used for the vehicle alternator according to the present embodiment will be described with reference to FIG. 2, and the permanent magnet holding member according to the present embodiment will be used with reference to FIGS. 3 to 5. The holding state of the permanent magnet will be described.
[0031]
FIG. 2 is a plan view showing a configuration of a permanent magnet holding member used in an automotive alternator according to an embodiment of the present invention, and FIG. 3 shows a permanent magnet holding using the permanent magnet holding member according to the present embodiment. FIG. 4 is a cross-sectional view taken along the line AA ′ of FIG. 3, and FIG. 5 is a configuration of a permanent magnet holding member used in the vehicle AC generator according to the embodiment of the present invention. FIG.
[0032]
First, as shown in FIG. 2, the permanent magnet holding member 62 used in this embodiment is manufactured by pressing a non-magnetic thin plate into a shape shown in the drawing. The permanent magnet holding member 62 includes a claw portion 62m formed on the inner side in the longitudinal direction and a claw portion 62n formed on the outer side in the width direction. In the present embodiment, since the permanent magnet holding member 62 holds 12 permanent magnets, the permanent magnet holding member 62 includes 24 claw portions 62m and 24 claw portions 62n.
[0033]
The non-magnetic thin plate has a thickness of about 0.1 mm to 1.0 mm, and the material is stainless steel plate, non-magnetic spring steel, phosphor bronze or the like. Here, the reason for using spring steel is that the permanent magnet can be easily held by the claw due to the elasticity of the metal, and there is an advantage that the workability is excellent.
[0034]
Next, FIGS. 3 and 4 show a state in which the permanent magnets 5a,..., 5h are held by the permanent magnet holding member 62. FIG. For example, the permanent magnet 5e is placed on the permanent magnet holding member 62 and then held by sandwiching the permanent magnet 5e by bending the two claw portions 62m and the two claw portions 62n. . The permanent magnet 5 has a rectangular parallelepiped shape, the claw portion 62 m holds the width direction of the permanent magnet 5, and the claw portion 62 n holds the longitudinal direction of the permanent magnet 5.
[0035]
Next, as shown in FIG. 5, the permanent magnet holding member 62 holding the permanent magnets 5a,..., 5l is bent into a cylindrical shape. P point shown in the figure is a connection point, which is fixed by welding. Although detailed description is omitted, if the number of poles of the rotor claw magnetic pole is 12, the permanent magnet holding member 62 holding the permanent magnets 5a,..., 5l shown in FIG. Further, the assembly with the rotor 2 is performed in the state shown in FIG. 5 so that the convex portions of the permanent magnets arranged on the permanent magnet holding member 62 coincide between the claw magnetic poles.
[0036]
Here, the assembly process of the rotor 2 will be described with reference to FIG.
[0037]
First, the claw-shaped magnetic pole 3N is attached to the shaft 41. Furthermore, the yoke 17 and the field winding 4 are integrally assembled into the shaft 41. Further, a permanent magnet holding member 62 holding the permanent magnet 5 processed into the columnar shape shown in FIG. At this time, the permanent magnet 5 is attached so as to be disposed between the claw portions of the claw-shaped magnetic pole 3N. Further, the claw-shaped magnetic pole 3 </ b> S is attached to the shaft 41. At this time, the permanent magnet 5 is attached so as to be disposed between the claw portions of the claw-shaped magnetic pole 3S.
[0038]
As described above, since the plurality of permanent magnets 5 are held in advance by the permanent magnet holding member 62, it is easy to attach the claw-shaped magnetic poles of the rotor between the claw portions, and workability is improved. .
[0039]
Next, the state of the permanent magnet disposed between the claw portions of the claw-shaped magnetic pole will be described with reference to FIGS. 6 and 7, and disposed on the outer periphery of the claw-shaped magnetic pole with reference to FIGS. 6 and 8. The configuration of the permanent magnet pop-out preventing member will be described.
[0040]
FIG. 6 is a perspective view showing a mounting state of a permanent magnet using a permanent magnet preventing member used in the vehicle alternator according to the embodiment of the present invention, and FIG. 7 is an enlarged cross-sectional view taken along line BB ′ of FIG. FIG. 8 is a perspective view showing a configuration of a permanent magnet pop-out preventing member used in the vehicle alternator according to the embodiment of the present invention.
[0041]
As shown in FIG. 6, a plurality of claw portions 33N and 33S (both are collectively referred to as claw portions 33) are formed at the tip portions of the pair of opposed claw-shaped magnetic poles 3N and 3S. Yes. As shown in the drawing, the claw portion 33 of the claw-shaped magnetic pole 3 has a structure in which a step having one low step portion 20a and one high step portion 20b is attached to the outer peripheral side end portion in the axial direction.
[0042]
The claw portion 33N of the claw-shaped magnetic pole 3N and the claw portion 33S of the claw-shaped magnetic pole 3S are arranged so that the permanent magnet 5 for auxiliary excitation is in contact with the polarity formed by the claw-shaped magnetic poles 3N, 3S. . The permanent magnet 5 is a solid magnet such as a sintered magnet or a bonded magnet, and is fixed by a permanent magnet holding member 62.
[0043]
Here, as shown in FIG. 7, the cross-sectional shapes of the claw portions 33N and 33S of the claw-shaped magnetic pole are trapezoids that are wide on the outer peripheral side and narrow on the inner peripheral side. The distance L1 on the outer peripheral side of the claw portions 33N and 33S of adjacent claw-shaped magnetic poles is 8 mm in the present embodiment, and the distance L2 on the inner peripheral side is 10 mm in the present embodiment. The permanent magnet holding member 62 has a thickness of 0.1 mm. Since the permanent magnet holding member 62 holds the permanent magnet 5 from the inner peripheral side of the rotor, the claw portion 62m is disposed in the gap between the claw portions 33N and 33S of the claw-shaped magnetic pole and the permanent magnet 5. Will be. Accordingly, since the permanent magnet 5 can be a large magnet having a size equal to the distance L1 on the outer peripheral side of the claw portions 33N and 33S of the adjacent claw-shaped magnetic poles, the magnetic flux generated by arranging the permanent magnet 5 can be reduced. This increases the magnetizing action and improves the power generation efficiency.
[0044]
Further, as shown in FIG. 6, a pop-out preventing member 61 made of a cylindrical non-magnetic material that prevents the permanent magnet 5 from popping out on the outer surface side of the permanent magnet 5 and the outer peripheral surface of the claw portion 33 of the claw-shaped magnetic pole 3. Is arranged. In this way, the pop-out prevention member 61 is formed into an integral cylindrical shape, and can be easily attached to the claw-shaped magnetic pole 3 by means of shrink fitting, press fitting, etc., and the rotor 2 can be easily manufactured. Further, it is possible to prevent the claw-shaped magnetic pole 3 from rising up at the time of high-speed rotation.
[0045]
Further, as shown in FIG. 6, the pop-out preventing member 61 has a thickness of almost the same dimension as the step of the claw portion 33 (the step of the high step portion 20b and the low step portion 20a), and the low step portion 20a of the claw portion 33. Are attached so that the outer surface of the pop-out preventing member 61 and the outer peripheral surface of the high-step portion 20b of the claw portion 33 are substantially flush with each other, and welding between the end portion of the pop-out prevention member 6 and the high-step portion 20b of the claw portion 33 is performed. The part 21 is fixed by welding.
[0046]
Further, by providing a step on the claw portion 33 and disposing the protrusion prevention member 61 on the lower step portion 20a of the claw portion 33, the protrusion prevention member 61 and the claw-shaped magnetic pole 3 can be firmly fixed, and the rotor 2 Increases mechanical strength.
[0047]
Further, by making the outer surface of the pop-out prevention member 61 and the outer peripheral surface of the high step portion 20b of the claw portion 33 substantially flush with each other, the outer peripheral surface of the rotor 2 is free from irregularities and is generated when the rotor 2 rotates. Windage loss can be reduced.
[0048]
Further, as shown in FIG. 8, the thickness T of the non-magnetic jump-out preventing member 61 is a thin non-magnetic cover that is ½ or less of the gap length so that the magnetic gap length does not increase. Yes. In this embodiment, the gap length between the rotor and the stator is 0.35 mm, and the used non-magnetic pop-out prevention member 61 is made of stainless steel and has a thickness of 0.1 mm. Therefore, the magnetic gap length is 0.45 mm. At this thickness, the effect on the generated current is very small and there is no problem. However, if the gap length is ½ or more, deterioration of the characteristics is inevitable.
[0049]
Further, it is desirable that the axial length of the pop-out preventing member 61 is set slightly longer than the front length of the permanent magnet to be used. That is, as shown in FIG. 1, the width of the stator core 8 of the stator 7 and the length of the permanent magnet 5 arranged in the rotor 2 in the axial direction are substantially equal. Therefore, the leakage prevention magnetic flux is reduced by setting the length in the axial direction of the pop-out preventing member 61 to be slightly longer than the length in the front direction of the permanent magnet to be used.
[0050]
As described above, in the present embodiment, the permanent magnet is held from the inside using the permanent magnet holding member, and the protrusion preventing member 61 is formed on the claw portion of the claw-shaped magnetic pole and the outer peripheral side of the permanent magnet. Is trying to arrange. Therefore, since the permanent magnet is held by the permanent magnet holding member and then attached to the rotor, the workability of attaching the permanent magnet is improved.
[0051]
Further, since the permanent magnet holding member holds the permanent magnet from the inner peripheral side and the pop-out prevention member is arranged on the outer peripheral side, the permanent magnet arranged between the claw portions of the claw-shaped magnetic pole can be enlarged. Therefore, power generation efficiency can be improved.
[0052]
Further, since the claw portion of the claw-shaped magnetic pole is provided with a step, and a protrusion prevention member having the same thickness as this step is arranged at this step portion, it is possible to reduce the windage loss when the rotor rotates. it can.
[0053]
Next, a vehicle alternator according to a second embodiment of the present invention will be described with reference to FIG.
[0054]
FIG. 9 is a perspective view of a main part of an automotive alternator according to the second embodiment of the present invention. The overall configuration of the vehicle alternator according to the present embodiment is the same as that shown in FIG. 1, and the permanent magnet holding structure by the permanent magnet holding member is the same as that shown in FIGS. It is.
[0055]
In the present embodiment, the claw portions 33N ′ and 33S ′ of the claw-shaped magnetic poles 3N ′ and 3S ′ are different from the embodiment shown in FIG. The step of the low step portion is not provided. Therefore, the pop-out preventing member 61 made of a non-magnetic thin plate is directly disposed on the outer periphery of the claw portions 33N ′ and 33S ′ of the claw-shaped magnetic poles 3N ′ and 3S ′. The pop-out preventing member 61 is fixed to the claw portions 33N ′ and 33S ′ in the welded portion 21.
[0056]
As described above, in the present embodiment, the permanent magnet is held from the inside using the permanent magnet holding member, and the protrusion preventing member 61 is formed on the claw portion of the claw-shaped magnetic pole and the outer peripheral side of the permanent magnet. Is trying to arrange. Accordingly, since the permanent magnet is attached to the rotor after being held by the permanent magnet holding member, the workability of attaching the permanent magnet is improved.
[0057]
Further, since the permanent magnet holding member holds the permanent magnet from the inner peripheral side and the pop-out prevention member is arranged on the outer peripheral side, the permanent magnet arranged between the claw portions of the claw-shaped magnetic pole can be enlarged. Therefore, power generation efficiency can be improved.
[0058]
Next, an automotive alternator according to a third embodiment of the present invention will be described with reference to FIGS.
[0059]
FIG. 10 is a perspective view of a main part of a vehicle AC generator according to the third embodiment of the present invention, and FIG. 11 is a perspective view of the pop-out preventing member shown in FIG. The overall configuration of the vehicle alternator according to the present embodiment is the same as that shown in FIG. 1, and the permanent magnet holding structure by the permanent magnet holding member is the same as that shown in FIGS. It is.
[0060]
In the present embodiment, a magnetic material is used as the material of the pop-out preventing member 61 ′. In the pop-out preventing member 61 ', the width L3 of the portion 61Z overlapping the claw-shaped magnetic pole is slightly longer than the length of the permanent magnet used, and has substantially the same shape as the claw-shaped magnetic pole. Further, in a portion that does not overlap with the claw-shaped magnetic pole, that is, a portion that is disposed between the claw magnetic poles, a hole 61Y is provided in the central portion, and the overlapping portion 61Z is connected by the connecting portion 61X. The leakage magnetic flux is reduced by narrowing the width L4 of the magnetic body of the connecting portion 61X. By using a magnetic material as the material for the pop-out prevention member, the magnetic gap length between the rotor and the stator matches the mechanical gap length, and the magnetic resistance between the rotor and the stator is increased. Can be prevented. Also, when viewed from the stator side, the outer surface of the rotor is almost magnetic, so the magnetic flux pulsation between the gaps that occurs when the magnetic flux goes from the stator side to the rotor side is reduced, and magnetic vibration Is reduced and noise is reduced.
[0061]
Further, as described in FIG. 6, the claw-shaped magnetic poles 3N, 3S are provided with the high step portion 20b and the low step portion 20a on the surface of the claw portions 33N, 33S, and the claw-shaped magnetic poles 3N, 3S and the pop-out preventing member 61 ' The adhesion is improved. When the pop-out preventing member 61 'is made of a magnetic material in this way, the portion located between the claw-shaped magnetic poles (the outer surface portion of the permanent magnet) narrows the magnetic material width L4 so as to reduce the leakage magnetic flux. I have to. Further, the pop-out preventing member 61 ′ and the claw-shaped magnetic poles 3 </ b> N and 3 </ b> S are welded and fixed at the welded portion 21.
[0062]
In the example shown in FIG. 11, the case where there is one hole 61 </ b> Y disposed between the claw magnetic poles has been described. However, as shown in FIG. 12, a plurality of holes 61 </ b> Y ′ may be provided. Is.
[0063]
The pop-out preventing members 61 and 61 'described so far are preliminarily shrink-fitted into the claw magnetic pole surface of the rotor, and then the claw-shaped magnetic pole 3 and the pop-out preventing member 61 are fixed by welding. Since the permanent magnet 5 disposed between the claw magnetic poles is temporarily fixed to the permanent magnet holding member 62, the permanent magnet 5, the permanent magnet holding member 62, and the claw-shaped magnetic pole 3 are bonded and integrated by a varnish. .
[0064]
That is, also in this embodiment, the pop-out preventing member 61 ′ is placed on the lower step portion 20 a of the claw portion 33 so that the outer surface of the pop-out prevention member 61 ′ and the outer peripheral surface of the high step portion 20 b of the claw portion 33 are substantially flush. As a result, the magnetic gap between the rotor 2 and the stator 7 coincides with the mechanical gap, and the magnetic resistance between the rotor 2 and the stator 7 does not increase. At this time, since the pop-out preventing member 61 'is composed of a thin magnetic plate, a part of the magnetic flux of the permanent magnet 5 is short-circuited through the pop-out preventing member 61' as shown by a dotted line in FIG. The narrow portion of the pop-out prevention member 61 'is immediately magnetically saturated. The amount of magnetic flux leaking from the pop-out prevention member 61 is only a small amount of the total magnetic flux of the permanent magnet 5, and the effect of providing the permanent magnet 5 to increase the magnetic flux produced by the field winding 4 is provided. There is no loss. Incidentally, compared with the conventional one in which the magnetic material holding member is arranged on the outer surface of the permanent magnet between the claws of the claw-shaped magnetic pole as in the conventional case, the generated current is improved by about 5 A compared to the conventional one. it can.
[0065]
Further, since the outer peripheral surface of the rotor 2 is almost magnetic when viewed from the stator 7 side, the magnetic resistance between the rotor 2 and the stator 7 is substantially constant, and the magnetic flux of the magnetic circuit rotates from the stator 7. Magnetic flux pulsation between the rotor 2 and the stator 7 generated when moving toward the child 2 is reduced, thereby reducing magnetic vibration and reducing noise.
[0066]
According to the present embodiment configured as described above, since the material of the pop-out prevention member is made of a magnetic material and the gap between the electrodes is narrowed, the generated current can be increased and the power generation efficiency can be improved.
[0067]
Further, noise can be reduced by reducing magnetic vibration between the rotor and the stator.
[0068]
Furthermore, the welded portion between the pop-out preventing member and the claw-shaped magnetic pole is not corroded, and the durability of the rotor can be improved.
[0069]
In addition, since the pop-out preventing member has a ring shape, it is easy to manufacture the rotor, and it is possible to prevent the claw-shaped magnetic pole from being raised during high-speed rotation.
[0070]
In addition, the pop-out prevention member is arranged in the lower step part of the claw part so that the outer surface of the pop-out prevention member and the outer peripheral surface of the high step part of the claw part are almost flush with each other, so that the pop-out prevention member and the claw-shaped magnetic pole are firmly And the windage loss of the rotor can be reduced.
[0071]
Next, a pop-out preventing member according to a fourth embodiment of the present invention will be described. FIGS. 13 and 14 illustrate the claw-shaped magnetic pole 3 of the rotor 2, and shows a case where a metal cover having properties of a magnetic body and a non-magnetic body is used as the material of the pop-out prevention member 61.
[0072]
A composite magnetic material is used as the material of the metal cover. For example, martensitic stainless steel (SUS420J2, SUS403, etc.), preferably 13Cr stainless steel (composition is, for example, C ... 0.5-0.6% by weight, Si ... 0.35% by weight, Mn ... 0.6-0 0.8 wt%, P ... 0.03 wt% or less, S ... 0.02 wt% or less, Cr ... 12.5 to 13.5 wt%, and remaining Fe). Further, ferritic stainless steel may be used. Specifically, 13Cr-Fe (C ... 0.69% by weight, Si ... 0.3% by weight, Mn ... 0.7% by weight, P ... 0.021% by weight, S ... 0.0% by Hitachi Metals, Ltd. 002 wt%, Cr ... 13.1 wt%) alloys can be used.
[0073]
As shown in FIG. 13, the claw-shaped magnetic pole 3 is composed of a pair of opposed claw-shaped magnetic poles 3N and 3S, and a plurality of claw portions 33N and 33S (both of the claw-shaped magnetic poles 3N and 3S) Collectively referred to as a claw portion 33). As shown in the drawing, the claw portion 33 of the claw-shaped magnetic pole 3 has a structure in which a step having one low step portion 20a and one high step portion 20b is attached to the outer peripheral side end portion in the axial direction.
[0074]
As shown in FIG. 13, the claw portion 33N of the claw-shaped magnetic pole 3N and the claw portion 33S of the claw-shaped magnetic pole 3S have the same polarity with respect to the polarity formed by the claw-shaped magnetic poles 3N and 3S by the permanent magnet 5 for auxiliary excitation. It is arranged to touch. The permanent magnet 5 is a solid magnet such as a sintered magnet or a bonded magnet, and is integrated by the permanent magnet holding member 62 described above.
[0075]
On the outer surface side of the permanent magnet 5 and the outer peripheral surface of the claw portion 33 of the claw-shaped magnetic pole 3, a cylindrical pop-out preventing member 61 for preventing the permanent magnet 5 from popping is disposed as shown in FIG. In this way, the pop-out prevention member 61 is formed into an integral cylindrical shape, and can be easily attached to the claw-shaped magnetic pole 3 by means of shrink fitting, press fitting, etc., and the rotor 2 can be easily manufactured. In addition, the claw-shaped magnetic pole 3 can be prevented from rising during high-speed rotation.
[0076]
Further, as shown in FIGS. 13 and 14, the pop-out preventing member 61 has substantially the same thickness as the step of the claw portion 33, and the outer surface of the pop-out preventing member 61 and the claw portion 33 are formed on the lower step portion 20 a of the claw portion 33. The outer peripheral surface of the high step portion 20b is attached so as to be substantially flush with each other, and is fixed by welding at the welded portion 21 between the end portion of the pop-out prevention member 6 and the high step portion 20b of the claw portion 33. Further, by providing a step on the claw portion 33 and arranging the pop-out preventing member 61 on the lower step portion 20a of the claw portion 33, the pop-out preventing member 61 and the claw-shaped magnetic pole 3 can be firmly fixed. Increases your strength. Further, by making the outer surface of the pop-out prevention member 61 and the outer peripheral surface of the high step portion 20b of the claw portion 33 substantially flush with each other, the outer peripheral surface of the rotor 2 is free from irregularities and is generated when the rotor 2 rotates. Windage loss can be reduced.
[0077]
In the present invention, in order not to increase the magnetic gap length, the protrusion preventing member is provided so that the portion disposed on the surface of the claw-shaped magnetic pole is a magnetic material and the portion disposed between the claw-shaped magnetic poles is a non-magnetic material. By disposing, the leakage magnetic flux between the claw magnetic poles can be reduced. In this embodiment, the gap length between the rotor and the stator is 0.35 mm, and the thickness of the 13Cr—Fe alloy used is 0.5 mm. Therefore, in the examples of FIGS. 13 and 14, the low step portion 20a is 0.5 mm lower than the high step portion 20b. Further, it is desirable that the axial length of the pop-out preventing member 61 is set to be slightly longer than the axial length of the permanent magnet to be used.
[0078]
Next, a method for creating a magnetic part and a nonmagnetic part will be described. The 13Cr-Fe alloy manufactured by Hitachi Metals, Ltd. described above is a metal whose properties of a magnetic material show properties of a non-magnetic material by applying heat. As the heat applied at this time, the magnetic portion can be changed to a non-magnetic material in a short time by applying the metal at a temperature of 1200 to 1300 ° C. for 1 minute or by melting the metal surface at 1500 ° C.
[0079]
Specifically, an alloy made of 13Cr—Fe having magnetic properties is raised only to a place where it is placed between the claw magnetic poles by using a welding machine using plasma, laser, and electron beam to locally raise the temperature to about 1500 ° C. It is dissolved so as to have a non-magnetic property. Further, the plasma, laser, and electron beam used at this time are preferably matched to the width between the claw magnetic poles, but may be divided into several when the beam diameter is thin. Needless to say, it is performed in an inert gas such as argon gas in order to prevent oxidation of the weld.
[0080]
In the above description, the pop-out preventing member having a magnetic part and a non-magnetic part using a 13Cr—Fe alloy has been described. However, the pop-out preventing member 61 is composed of a magnetic part 61a made of a magnetic material and a non-magnetic material. Even if the nonmagnetic portions 61b are regularly arranged and the joints are integrally manufactured by welding, the same effect can be obtained. Further, at this time, the nonmagnetic portion 61b is disposed between the claw magnetic poles where leakage magnetic flux is likely to be generated to reduce the leakage magnetic flux, and the magnetic portion 61a is disposed in a place where it is not desired to increase the gap length. Therefore, good power generation performance can be obtained without increasing the gap length.
[0081]
Next, a seventh embodiment will be described with reference to FIGS.
[0082]
15 and 16 show that the 13Cr-Fe alloy ring having a thickness of about 0.1 mm to 1 mm is laminated in the axial direction of the outer peripheral surface of the rotor 2, and the portion corresponding to the gap between the claw poles is argon, laser, electron beam. The metal is melted locally by using, for example, a non-magnetic part. At this time, the alloy is arranged on the outermost peripheral portion of the claw-shaped magnetic pole by shrink fitting, press fitting or the like. Needless to say, the effect of the lamination is to reduce loss due to eddy currents. For example, a 13Cr—Fe alloy may be formed into a long and wire shape and wound around the outer peripheral surface of the claw-shaped magnetic pole. Also in this case, the same effect can be obtained by heat-treating the portion disposed between the claw magnetic poles using the above-described welding machine.
[0083]
Next, a sixth embodiment will be described with reference to FIGS. 17 and 18, the same reference numerals as those in FIGS. 13 and 14 denote the same components. The difference between FIGS. 17 and 18 and FIGS. 13 and 14 is that a hole 61 y is provided in a portion corresponding to between the claw-shaped magnetic poles of the pop-out prevention member 61.
[0084]
In addition, when using a configuration in which holes are provided between the claw-shaped magnetic poles as shown in FIGS. 17 and 18, only the connecting portion 61X, which is not the hole 61Y, is made nonmagnetic by heat treatment. do it. Moreover, the same effect can be acquired also in these Examples.
[0085]
Next, a seventh embodiment will be described with reference to FIGS. 19 and 20, the same reference numerals as those in FIGS. 13 and 14 denote the same components. The difference between FIGS. 19 and 20 and FIGS. 13 and 14 is that a claw portion 70 for alignment is provided as a part of the pop-out prevention member 61. The positioning claw portion 70 is disposed so as to mesh with the claw-shaped magnetic poles 3N, 3S, thereby enabling the protrusion preventing member 61 to be positioned with respect to the gap between the claw-shaped magnetic poles 3N, 3S. Furthermore, the pop-out prevention member 61 is prevented from shifting in the circumferential direction of the rotor 2.
[0086]
The alignment member 70 does not have to be provided between all the claw-shaped magnetic poles 3N and 3S as shown in the figure, and the same function can be achieved if at least one exists.
[0087]
In the fourth, fifth, sixth, and seventh embodiments, the claw portion of the claw-shaped magnetic pole is stepped and the pop-out prevention member 61 is attached to the outer peripheral surface of the claw-shaped magnetic pole, but no step is provided. However, the obtained effect is almost the same.
[0088]
When no step is provided, the seventh embodiment has an effect that the protrusion preventing member 61 is not displaced in the axial direction by bending the alignment claw portion 70 to the inside of the rotor 2.
[0089]
【The invention's effect】
Since the permanent magnet arranged between the claw portions of the claw-shaped magnetic pole is previously held by the permanent magnet holding member from the inner peripheral side and integrally molded, the magnet module is incorporated between the claw-shaped magnetic pole claw portions. Workability at the time of assembling is improved.
[0090]
Further, a permanent magnet arranged between the claws of the claw-shaped magnetic pole is built in between the claws of the claw-shaped magnetic pole by incorporating a magnet module in which permanent magnets arranged between the claws of the claw-shaped magnetic pole are previously molded integrally with a permanent magnet holding member. By making the magnet a solid magnet, the generated current is increased and the power generation efficiency is improved.
[0091]
In addition, in the thing provided with a pop-out preventing member for preventing the pop-out of the permanent magnet disposed between the claw portions of the claw-shaped magnetic pole, the pop-out preventive member is disposed between the outer surface side of the permanent magnet and the claw-shaped magnetic pole claw portion, In addition, since the material of the pop-out prevention member is a non-magnetic material or a magnetic material, or a composite material in which a non-magnetic material and a magnetic material are mixed, the permanent magnet can be increased in size, generating current is increased and generating efficiency is improved. To do.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of the overall configuration of an automotive alternator according to a first embodiment of the present invention.
2 is a plan view of the permanent magnet holding member of FIG. 1. FIG.
FIG. 3 is a plan view for explaining a permanent magnet holding state using the permanent magnet holding member of FIG. 2;
4 is a cross-sectional view taken along the line AA ′ of FIG.
FIG. 5 shows a side view of the permanent magnet holding member of FIG. 2;
6 is a perspective view of a permanent magnet attached state using the permanent magnet preventing member of FIG. 2; FIG.
7 is an enlarged cross-sectional view taken along the line BB ′ of FIG.
8 shows a perspective view of the permanent magnet pop-out preventing member of FIG. 6. FIG.
FIG. 9 is a perspective view of a main part of an automotive alternator according to a second embodiment of the present invention.
FIG. 10 is a perspective view of a main part of an automotive alternator according to a third embodiment of the present invention.
11 is a perspective view of the pop-out preventing member of FIG.
12 is a perspective view of another example of the pop-out preventing member of FIG.
FIG. 13 is a perspective view of a claw portion of a claw-shaped magnetic pole according to a fourth embodiment of the present invention.
14 shows a partial cross-sectional view of FIG.
FIG. 15 is a perspective view of a claw portion of a claw-shaped magnetic pole according to a fifth embodiment of the present invention.
16 shows a partial cross-sectional view of FIG.
FIG. 17 is a perspective view of a claw portion of a claw-shaped magnetic pole according to a sixth embodiment of the present invention.
FIG. 18 shows a partial cross-sectional view of FIG.
FIG. 19 is a perspective view of a claw portion of a claw-shaped magnetic pole according to a seventh embodiment of the present invention.
20 shows a partial cross-sectional view of FIG.
[Explanation of symbols]
2 ... rotor, 3, 3N, 3S ... claw-shaped magnetic pole, 4 ... field winding, 5 ... permanent magnet, 7 ... stator, 8 ... stator core, 9 ... stator winding, 17 ... yoke, 20a ... Low stage part, 20b ... High stage part, 21 ... Welded part, 61 ... Jump-out prevention member, 61X ... Connection part, 61Y ... Hole part, 62 ... Permanent magnet holding member, 62m, 62n ... Claw part.

Claims (12)

A rotor,
A stator disposed at a predetermined interval with respect to the rotor,
The rotor is
A pair of claw-shaped magnetic poles arranged opposite to each other;
A field winding for magnetizing the claw-shaped magnetic pole;
Each of the claw-shaped magnetic poles includes a plurality of claw portions,
The plurality of claw portions of the claw-shaped magnetic pole are formed such that the distance on the inner peripheral side between the claw portions adjacent to the claw-shaped magnetic pole also increases the distance on the outer peripheral side,
A permanent magnet for increasing the magnetic flux formed by the field winding is disposed between the claw portions adjacent to the claw-shaped magnetic pole,
A permanent magnet pop-out prevention member for preventing the permanent magnet from popping out is disposed on the outer peripheral side of the claw portion and the permanent magnet of the claw-shaped magnetic pole,
The plurality of permanent magnets are held from the inner peripheral side by a permanent magnet holding member,
The permanent magnet holding member is
The plate-like member is bent into a cylindrical shape,
On the plate member, the claw portion for holding the width direction and the longitudinal direction of each of the plurality of permanent magnets placed on the plate member,
The claw portion for holding the permanent magnet in the width direction of the permanent magnet holding member is configured such that when the permanent magnet is disposed between the plurality of claw portions adjacent to the claw-shaped magnetic pole, An AC generator for a vehicle, which is disposed in a gap formed between the claw portion and the permanent magnet. In the vehicle alternator according to claim 1,
The pop-out preventing member is made of a nonmagnetic material.
A vehicle alternator characterized by the above . In the vehicle alternator according to claim 2,
The thickness of the pop-out prevention member is ½ or less of the gap length between the rotor and the stator.
A vehicle alternator characterized by the above . In the vehicle alternator according to claim 1,
The pop-out preventing member is constituted by a magnetic material element,
A hole is formed in the pop-out prevention member portion located on the outer peripheral side of the permanent magnet .
A vehicle alternator characterized by the above . In the vehicle alternator according to claim 1,
A step portion is formed on the outer peripheral surface of the claw portion of the claw-shaped magnetic pole,
The pop-out prevention member is arranged at the lower step portion of the step portion,
The AC generator for vehicles, wherein the thickness of the pop-out prevention member is equal to the step of the step portion. In the vehicle alternator according to claim 1,
The pop-out prevention member is welded to the claw portion of the claw-shaped magnetic pole,
The AC generator for a vehicle, wherein the permanent magnet holding member, the permanent magnet, and the claw-shaped magnetic pole are integrally fixed by a varnish. In the vehicle alternator according to claim 1,
A portion located on the outer peripheral side of the claw part of the claw-shaped magnetic pole is formed of a magnetic part,
An AC generator for vehicles, wherein a portion located on the outer peripheral side of the permanent magnet is formed of a non-magnetic portion. In the vehicle alternator according to claim 7 ,
The pop-out prevention member is a ring integrally manufactured by connecting a magnetic metal and a non-magnetic metal by welding.
A vehicle alternator characterized by the above . In the vehicle alternator according to claim 7 ,
The pop-out prevention member is formed by locally heat-treating a magnetic body made of a composite magnetic material to form the non-magnetic portion.
A vehicle alternator characterized by the above . In the vehicle alternator according to claim 7 ,
The pop-out preventing member,
It is constructed by stacking multiple rings of composite magnetic material in the axial direction,
It is obtained by processing a non-magnetic material I by the heat treatment of the portion located on the outer peripheral side of the permanent magnet
A vehicle alternator characterized by the above . In the vehicle alternator according to claim 7 ,
The pop-out preventing member,
The wire composite of magnetic material to said claw poles outermost surface be those constructed by winding in a ring shape,
It is obtained by processing a non-magnetic material I by the heat treatment of the portion located on the outer peripheral side of the permanent magnet
A vehicle alternator characterized by the above . In the vehicle alternator according to claim 7,
The vehicle alternator according to claim 1, wherein the pop-out preventing member has a positioning claw portion that can be positioned with respect to a gap between the claw-shaped magnetic poles.

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