CN107636937B

CN107636937B - Rotating electrical machine

Info

Publication number: CN107636937B
Application number: CN201680031068.3A
Authority: CN
Inventors: 水谷诚一; 金光宪太郎
Original assignee: DensoTrim Corp
Current assignee: DensoTrim Corp
Priority date: 2015-05-29
Filing date: 2016-05-27
Publication date: 2020-10-13
Anticipated expiration: 2036-05-27
Also published as: WO2016194829A1; JP6373494B2; JPWO2016194829A1; CN107636937A

Abstract

A rotating electrical machine (1) is provided with: a rotor (60) rotatably supported; a stator (10) which is arranged with a gap of a predetermined distance from the rotor (60) and has an iron core (20); and a bobbin (30) mounted on the core (20); wherein the core (20) is provided with a plurality of teeth (22) extending towards the outer side of the radial direction (RA); the teeth (22) and the insulating part (32) of the coil frame (30) together form a winding part (80), and an aluminum wire (81) is wound on the winding part (80) to form a winding part (50); the width of the winding part (80) is configured to gradually expand from a winding start point (S) to a winding end point (E) of the aluminum wire (81) in the winding advancing direction.

Description

Rotating electrical machine

Technical Field

The present invention relates to a rotating electrical machine such as a magnet generator mounted on a vehicle such as a two-wheeled vehicle.

Background

In general, a vehicle such as a two-wheeled vehicle includes a generator that generates electric power by rotation of an engine mounted on the vehicle. The battery is charged with the generated power of the generator, and the electric power of the electric system of the vehicle is supplied with the charged power.

As the generator, a so-called magnet generator is often used as a rotating electric machine. The magnet generator includes a rotor (rotating body) with a magnet disposed inside a crank cover of an engine, and a stator (fixed body) disposed inside the rotor in a radial direction. The stator includes a core having a plurality of teeth, and a single-phase or three-phase winding portion (power generation coil) formed by winding a lead wire (copper wire) around an insulating portion of a bobbin attached to a portion of the plurality of teeth.

The rotor is coupled to one end of a crankshaft of the engine, and the rotor, i.e., the magnet rotates while the engine rotates, and a single-phase or three-phase alternating current is induced in the winding portion by a rotating magnetic field generated by the rotation. The induced current flows from the leading end of the winding portion to the output lead, and is supplied to the electric circuit of the vehicle.

In a rotating electrical machine such as a generator, in order to achieve reduction in size and weight, a lead wire (copper wire) is wound in order more accurately so as to be disposed at the teeth of a stator at as high a density as possible, and the outer diameter of the stator is reduced by increasing the area ratio occupied by the winding of the lead wire (copper wire).

As a method of increasing the area ratio of the windings, for example, as described in patent document 1, a relatively high tension is applied to a lead wire (copper wire) by using a winder, and the lead wire is wound around teeth of a stator so as to conform to the shape of the teeth, thereby reducing the outer diameter of the coil of the stator.

However, in the case of concentrated winding of a conductive wire (copper wire), although a plurality of winding layers are formed on the teeth of the stator, if the winding of the first layer is not wound in order, the winding of the second layer does not adhere to the first layer, and as a result, the coil is greatly uneven in processing quality. As described above, in order to wind the first layer of windings neatly, it is necessary to apply tension to the wire (copper wire) and increase friction with the insulating portion of the bobbin to fix the wire. That is, the tooth fastening force of the wire (copper wire) is increased by the tensile force of the wire generated by the winder, and the already wound coil portion is not moved in the coil advancing direction (for example, outward in the radial direction if it is the first layer).

On the other hand, the power generation coil made of a conductive wire (copper wire) is not only high in component cost but also very heavy, and therefore, the power generator itself becomes heavy. Therefore, in recent years, aluminum wires have been used instead of the conductive wires (copper wires).

Prior art documents

Patent document

Patent document 1: japanese patent laid-open publication No. 2006-94632

Disclosure of Invention

Technical problem to be solved by the invention

Fig. 11 is an enlarged cross-sectional view of a conventional winding portion.

The aluminum wire a has a lower tensile strength than the wire (copper wire), and when a tension is applied and wound around the teeth T, the aluminum wire a may be elongated or broken by the tension. Therefore, the aluminum wire a needs to be wound with a lower tension than the lead wire (copper wire), and as a result, friction between the aluminum wire a and the insulating portion B of the bobbin is insufficient compared with the lead wire (copper wire), and as shown in fig. 11, the tensile force F of the aluminum wire a generated by the winding machine becomes smaller than the tooth fastening force D of the aluminum wire a, and disorder (slackening, displacement) Z is likely to occur in the winding of the first layer. Further, the occurrence of disorder in the windings of the first layer causes disorder in the windings of the second and subsequent layers, and further causes significant variation in the processing quality of the coil.

Further, since aluminum wire has a higher resistivity than that of a lead wire (copper wire), it is necessary to use aluminum wire having a larger wire diameter than that of the lead wire (copper wire) in order to obtain the same output as that of the lead wire (copper wire), but when the larger aluminum wire is used and the winding is misaligned, the outer diameter of the stator may not be restricted to the same size as that of the lead wire (copper wire).

The present invention has been made in view of the above problems, and an object of the present invention is to provide a rotary electric machine in which a first layer of windings can be neatly wound with a low tension in windings of a stator using aluminum wires.

Means for solving the technical problem

In order to achieve the above object, a rotating electric machine according to the present invention includes: a rotor rotatably supported; a stator having an iron core, the stator being disposed with a gap of a predetermined distance from the rotor; and a bobbin mounted on the core; wherein the core includes a plurality of teeth extending outward in a radial direction RA; the teeth and the insulating part of the coil rack form a winding part, and an aluminum wire is wound on the winding part to form a winding part; the width of the winding portion is configured to gradually increase from a winding start point to a winding end point of the aluminum wire in a winding advancing direction.

Effects of the invention

Thus, even if the aluminum wire is wound with a lower tension than the lead wire (copper wire), the winding can be performed neatly without causing a disorder in the winding of the first layer, and the outer diameter of the stator can be narrowed to the same size as when the lead wire (copper wire) is used.

Drawings

Fig. 1 is a side view of a magnet generator according to a first embodiment of the present invention, as viewed in the axial direction of arrow I shown in fig. 2.

Fig. 2 is a schematic sectional view taken along the line of arrows II-II of fig. 1.

Fig. 3 is a side view showing laminated plates constituting a stator of the magnet generator according to the present embodiment.

Fig. 4 is a perspective view showing a bobbin divided body constituting one side of the bobbin having the divided structure according to the present embodiment.

Fig. 5 is an enlarged cross-sectional view of the winding portion according to the present embodiment.

Fig. 6 is a side view showing a connection line between winding portions according to the present embodiment.

Fig. 7 is an enlarged cross-sectional view of a winding portion according to a second embodiment of the present invention.

Fig. 8 is an enlarged cross-sectional view of a winding portion according to a third embodiment of the present invention.

Fig. 9 is an enlarged cross-sectional view of a winding portion according to a fourth embodiment of the present invention.

Fig. 10 is an enlarged cross-sectional view of a winding portion according to a modification of the fourth embodiment of the present invention.

Fig. 11 is an enlarged cross-sectional view of a conventional winding portion.

Detailed Description

Preferred embodiments of a magnet generator and a connection mechanism (structure) thereof according to the present invention will be described below with reference to the accompanying drawings.

(first embodiment)

Fig. 1 to 3 show an outline of the structure of a single-phase magnet generator as a rotating electric machine according to the first embodiment.

The magnet generator 1 (hereinafter, also simply referred to as "generator") is mounted in the vicinity of an engine of, for example, a motorcycle (not shown), and generates electric power by rotating with the rotational force of the engine. The electric power generated by the generator 1 is supplied to a vehicle-side electric circuit, not shown.

The generator 1 includes a stator (fixed body) 10 and a rotor (rotating body) 60. The stator 10 includes a core 20, a bobbin 30, and a winding portion 50. The core 20 is formed by laminating thin metal plates such as iron or electromagnetic steel plates. The core 20 has a substantially annular core body 21 (see fig. 2 and 3).

In the following description, for convenience of description, the longitudinal direction of the virtual central axis O (see fig. 3) of the core body 21 is referred to as an axial direction AX. The direction radially extending around the central axis O along a cross section perpendicular to the central axis O is referred to as a radial direction RA, and the direction surrounding the periphery of the core 21 is referred to as a circumferential direction CR. In a state where the core 20 is mounted on the generator 1, the axial direction AX, the radial direction RA, and the circumferential direction CR coincide with the axial direction, the radial direction, and the circumferential direction of the generator 1, respectively. Next, the description will be made on the premise that the core 20 is mounted on the generator 1.

The core 20 includes, in addition to the annular core body 21, a plurality of teeth 22 (see fig. 3) extending outward in the radial direction RA from the core body 21. In the present embodiment, 12 teeth 22 are provided at equal intervals in the circumferential direction of the core body 21.

The bobbin 30 is an annular insulator formed of, for example, an insulating resin, and has a split structure in which the bobbin is split into front and rear halves in the axial direction AX. Fig. 4 shows the bobbin split body 30A on one side in this split structure. The bobbin 30 is integrally provided with an insulating portion 32 in a state where the two bobbin divided

bodies

30A, 30B (see fig. 2) are assembled with each other, and a plurality of insulating portions 32 are provided outside the annular bobbin body 31 and the bobbin body 31 in the radial direction RA. In the present embodiment, 12 insulating portions 32 are provided at equal intervals in the circumferential direction CR of the bobbin main body 31.

Next, a description will be given of a state in which two bobbin divided

bodies

30A and 30B are assembled to form one bobbin 30.

The bobbin body 31 of the bobbin 30 faces the core body 21, and the plurality of insulating portions 32 face the plurality of teeth 22, respectively, and are provided on one surface 23 side (crank cover side) and the other surface 24 side (crank shaft side) of the core 20 in the axial direction AX so as to sandwich the core 20.

As shown in fig. 4, a plate-like stopper 33 extending in a plane direction parallel to the axis of the bobbin body 31 is formed near the insulating portion 32 of the bobbin body 31. Further, a plate-like stopper 44 extending in a plane direction parallel to the axis of the bobbin body 31 is formed at an end portion of the insulating portion 32 on the opposite side to the bobbin body 31.

The teeth 22 and the insulating portions 32 of the two bobbins 30 sandwiching the teeth 22 from both sides in the axial direction AX of the core 20 form a winding portion 80, and the winding portion 80 is wound with, for example, an aluminum wire 81 in a concentrated winding manner, thereby forming a winding portion (power generation coil) 50. Here, the concentrated winding is a structure in which a plurality of one coils (single coils) each including a winding wound around one tooth are formed, and a structure in which a single coil is formed so as to extend over a plurality of teeth is called a distributed winding or the like. In the present embodiment, a plurality of winding portions 50 are formed by winding a single insulated aluminum wire 81 on each of the insulating portions 32 of the plurality of winding portions 80 a predetermined number of times. When the winding is not housed in the winding portion 80 a predetermined number of times, the winding is configured such that a plurality of layers are formed on the same winding portion 80. Further, the insulation between the winding portion 50 and the teeth 22 of the core 20 is ensured by the insulating portion 32.

In the present embodiment, for example, the winding portion 50 is formed by winding the aluminum wire 81 around the winding portion 80 while drawing the aluminum wire 81 by applying a predetermined tension using a winding machine, not shown. This allows the winding portion 50 to be tightly wound around the inclined surface 82 of the insulating portion 32 of the winding portion 80. Here, the winding portion 50 is positioned in the radial direction RA by the stopper body 44 and the stopper body 33 of the bobbin 30. Further, the aluminum wire 81 is wound at a lower tension than that in usual winding of a conductive wire made of a copper wire.

As shown in fig. 5, the circumferential direction CR width of the teeth 22 constituting the winding portion 80 gradually increases from the core body 21 side to the side opposite to the core body 21 (stopper 44 side). Similarly, the insulating portion 32 sandwiching the teeth 22 also gradually expands in width in the circumferential direction CR from the bobbin main body 31 side to the side opposite to the bobbin main body 31 side (stopper 44 side).

That is, the winding portion 80 has the same shape as the teeth 22, and is provided such that the width W2 on the stopper 44 side is larger than the width W1 on the bobbin body 31 side. The circumferential thickness of the insulating portion 32 of the bobbin 30 constituting the winding portion 80 is constant from the inner diameter side toward the outer diameter side. The thickness of the insulating portion 32 in the circumferential direction depends on the required insulation resistance, and the inclination angle of the insulating portion 32 is the same as that of the teeth 22. Then, the first layer of the aluminum wire 81 is wound around the winding portion 80 from the winding start point S on the bobbin body 31 side to the winding end point E (the winding direction is shown by an arrow in fig. 5) on the stopper 44 side outside in the radial direction RA. With these configurations, the winding portion (power generation coil) 50 formed of the aluminum wire 81 wound around the winding portion 80 is increased in width from the inner diameter side to the outer diameter side thereof, and is parallel to the inclination of the bobbin 30. That is, the width of the winding portion (power generation coil) 50 wound around the teeth 22 in the circumferential direction is small on the inner diameter side and large on the outer diameter side.

On the other hand, as shown in fig. 2, the core body 21 of the core 20 is fixed to the inside of the engine cover 2 by, for example, bolts or the like. A hub 4 is attached to an end portion of a crankshaft 3 of an engine not shown. Therefore, the hub 4 rotates together with the crankshaft 3 when the engine is running.

The rotor 60 is disposed outside the stator 10 in the radial direction RA with a predetermined gap therebetween. The rotor 60 includes: a cylindrical portion 61 formed in an annular shape in the circumferential direction CR; and a wall portion 64 closing an opening on one side in the axial direction AX of the cylinder portion 61. The tube portion 61 and the wall portion 64 are integrally formed with each other. The hub 4 is fixed to the wall portion 64.

A plurality of magnets (permanent magnets) 62 are provided on the inner wall of the cylindrical portion 61 at equal angular intervals along the circumferential direction CR. In the present embodiment, the plurality of magnets 62 are provided so that the directions of their magnetic poles (N-pole and S-pole) are alternately opposite in the radial direction RA, and a total of 12 magnets 62 are provided. As shown in fig. 1, a projection 63 is formed on a part of the outer peripheral surface of the cylindrical portion 61.

The wall portion 64 is fixed to the hub 4 so that the cylindrical portion 61 of the stator 60 is positioned outside the core 20 in the radial direction RA. Thereby, the tip end portions of the teeth 22 of the core 20 are positioned to face the magnet 62. The rotor 60 rotates together with the crankshaft 3 and the hub 4 when the engine is running. When the rotor 60 rotates, induced electromotive force is generated in the winding portion 50 formed on the insulating portion 32 (winding portion 80) covering the teeth 22, which faces the magnet 62. As a result, a current is generated in the winding portion 50. The current generated in the winding portion 50 is supplied to an electrical load such as a battery and a headlamp of the motorcycle via an output cable (harness) 5 (see fig. 2) connecting the winding portion 50 and the vehicle-side electrical circuit. As described above, the generator 1 of the present embodiment is an outer rotor type generator.

A rotation sensor 70 is provided outside the rotor 60 in the radial direction RA with a predetermined gap therebetween. The rotation sensor 70 outputs a signal corresponding to the rotational position of the projection 63 when the rotor 60 rotates. This signal is transmitted to an electronic control unit (hereinafter referred to as "ECU") not shown via a harness 71. This enables the ECU to detect the rotational position of the rotor 60, that is, the rotational position of the crankshaft 3.

As described above, according to the rotating electric machine of the present embodiment, various operational effects can be obtained as follows.

First, since the aluminum wire 81 is used for the wire material forming the plurality of winding portions 50 of the stator (fixed body) 10, the weight of the generator itself can be reduced, and the component cost can be significantly reduced as compared with the case of using a lead wire made of a copper wire.

As shown in fig. 5, the width in the circumferential direction CR of the winding portion 80 around which the aluminum wire 81 is wound is configured to gradually increase in the winding direction from the winding start point S of the first layer of the aluminum wire 81 to the winding end point E of the first layer, and gradually increase in the radial direction outward from the bobbin body 31 if the number of layers is odd, such as the first layer.

Therefore, the surface of the winding portion 80 on which the aluminum wire 81 is wound is inclined with respect to the winding direction to form an inclined surface 82, and the tightening force of the winding machine to tighten the aluminum wire 81 to the winding portion 80 is divided into a direction D1 parallel to the inclined surface 82 and a direction D2 perpendicular to the inclined surface 82. Therefore, the tightening force in the direction D1 parallel to the inclined surface 82 can oppose the tensile force F of the aluminum wire 81 generated by the wire winder.

Although the tensile force F of the winding machine is always applied in the winding advancing direction at any position of the first layer of the winding portion 50 where the predetermined number of windings is present, the circumferential direction CR width of the winding portion 80 (the teeth 22 and the insulating portion 32) is larger than that of the portion wound immediately before, and therefore, the movement of the winding portion 50 in the winding advancing direction is suppressed, and as a result, even if the aluminum wire 81 is wound with a lower tension than the lead wire (copper wire), the winding portion 50 can be wound neatly without causing a disorder in the windings of the first layer. Further, since the first layer of the winding is wound in order, the second and subsequent layers are also bonded to the previous layer, and therefore all the layers form the ordered winding, the outer diameter of the stator 10 can be narrowed to the same size as when the lead wire (copper wire) is used. That is, the winding start point of the winding portion 50 is preferably on the inner diameter side, which is the portion of the winding portion 80 having the narrowest circumferential width. The winding direction of the winding portion 50 is preferably a direction in which the width in the circumferential direction of the winding portion 80 increases.

Further, since the aluminum wire 81 can be wound with a low tension, elongation and breakage due to the tension can be prevented. In particular, the tensile strength of the aluminum wire is only a fraction of that of copper, and therefore, from the viewpoint of preventing breakage, it is also necessary to reduce the tensile tension at the time of winding the aluminum wire 81 to a fraction of that of the copper wire.

The winding portion 50 wound around the winding portion 80 is fixed to each other by an adhesive or the like after the winding and mounting, and is bonded to the bobbin 30.

As shown in fig. 6, when a plurality of winding portions 50 (coils) are connected by one aluminum wire 81, a connection wire 83 is present in a portion spanning between the winding

portions

50 and 50. That is, the aluminum wire 81 existing between the winding end portion Z of one of the winding portions 50 and the winding start portion X of the adjacent winding portion 50 is the connection wire 83.

The first winding start point and the last winding end point of one aluminum wire 81 wound around the winding portion 50 in the connection wire 83 are so-called lead wires, and the lead wires are directly or indirectly connected to, for example, a harness (for example, an output cable 5) connected to an external circuit. Alternatively, when the winding unit 50 is a three-phase coil having the same number, the connection line 83 is connected to the neutral point in a star connection, although not shown in detail.

As described above, the magnet generator 1 according to the present invention is mounted on an engine of a two-wheeled vehicle or the like or in the vicinity thereof, and therefore vibration is easily transmitted. If the connection line 83 is not fixed, the connection line 83 may be broken by the vibration or the insulating film of the connection line 83 may be scratched to cause an electrical short circuit.

For this reason, it is preferable that the connection wire 83 having a small tensile force applied during winding be firmly bonded and fixed to, for example, the bobbin body 31 of the bobbin 30 in a stable state.

The condition for bonding and fixing the connection wire 83 in a stable state is that both ends of the connection wire 83 are stably fixed to the winding portion 50, where one of both ends of the connection wire 83 is a winding start point portion X and the other is a winding end point portion Z. That is, if the regular winding of the first layer of the winding portion 50 is unstable, the adhesive does not equally penetrate, and the fixation is unstable. If the fixation of the first layer is unstable, the fixation of the winding start point portion X connected to the connection wire 83 becomes unstable, and the fixation of the connection wire 83 also becomes unstable, and if the fixation of the first layer is unstable, the fixation of the outermost layer of the winding portion 50 wound on the first layer also becomes unstable. Since the winding end portion Z of the outermost layer is also connected to the connecting line 83, if the fixation of the outermost layer is unstable, the fixation of the connecting line 83 still becomes unstable. From this, it is important to stabilize the regular winding of the first layer of the winding portion 50.

As described above, in the present invention, the winding portion 50 can be wound neatly without causing a disorder in the winding of the first layer. Further, since the winding of the first layer is wound in order, the second layer and the subsequent layers are also bonded to the previous layer, and therefore, all the layers form the ordered winding, and the movement of the connection wire 83 due to the overhead wire and the vibration can be suppressed. As a result, the connection wire 83 can be firmly bonded and fixed to, for example, the bobbin body 31 of the bobbin 30 in a stable state.

Further, the aluminum wire 81 has a property of being relatively easily stretched. If the fixation of the winding portion 50 is unstable, the aluminum wire 81 may be elongated, which is not preferable. Specifically, if the aluminum wire 81 is elongated, the wire diameter is reduced, and the resistance is increased, which may cause a performance degradation or a temperature rise in the winding portion 50.

As described above, in the present application, since the winding portion 50 can be stably fixed, the aluminum wire 81 can be prevented from being elongated, and performance degradation and temperature increase of the winding portion 50 can be suppressed.

As described above, the bobbin 30 has a split structure (bobbin split

bodies

30A and 30B) divided into two halves in the axial direction AX. In consideration of the variation of the bobbin 30 in the axial direction thereof and the variation of the bobbin 20 in the axial direction thereof, the dimension of the bobbin 30 in the axial direction AX is set so that a gap is always formed between the joint surfaces of the divided portions in a state where the core 20 is sandwiched, and the divided edge portions are not laminated with each other in any case in a state where the core 20 including the teeth 22 is sandwiched on both sides in the axial direction AX. In addition, since the bobbin 30 is formed by resin molding, it has a draft angle caused by a mold, and since there is also deformation (bending) after molding, it has a shape slightly opened outward.

In the above-described configuration of the bobbin 30, for example, in the case where a high tension is applied to the wire and the wire is wound into the winding portion, the wire may directly contact the teeth 22 in the gap of the divided portion. Further, when the insulating cover of the lead is broken, a short circuit may occur. In addition, due to high tension of the wound wire, breakage may occur at the divided edge portion or the corner portion of the bobbin 30.

Further, the gap is not formed only in the insulating portion 32 of the bobbin 30, but a gap is also formed in the plate-like stopper 44 formed in the end portion of the insulating portion 32 opposite to the bobbin main body 31, and for example, when the winding end point E of the winding portion 50 is located on the stopper 44 side, for example, when the wire is wound by applying a high tension, the wire at the winding end point E may enter between the wire wound before and the stopper 44, and there is a possibility that a short circuit or a wire elongation may still occur.

However, according to the rotating electric machine of the present embodiment, since the aluminum wire 81 can be wound with a low tension, the aluminum wire 81 is unlikely to directly contact the teeth 22 in the gaps of the divided portions of the bobbin 30, and in addition, the possibility of cracking at the divided edge portions and corner portions of the bobbin 30 becomes low. Further, the aluminum wire 81 is less likely to be elongated.

In addition, according to the rotating electric machine of the present embodiment, since the tension at the time of winding is low, the resistance of the aluminum wire 81 against the cold and hot pressure applied in the use environment is improved. Aluminum wire 81 has a larger coefficient of linear expansion than conventional copper wires. That is, the difference in linear expansion coefficient is large with respect to the tooth portion containing iron as a main component. Therefore, at low temperatures, the winding portion 50 formed of the aluminum wire 81 shrinks greatly, and may enter the tooth portion. However, the pressure is not too high at this time because of the low tension at the time of winding. Further, although the rotating electric machine according to the present embodiment is mounted on an engine and applied with large vibration, the pressure ratio as a whole is small for the above reasons, and damage to the aluminum wire 81 and the like can be suppressed.

(second embodiment)

Next, a second embodiment of the present invention will be described with reference to fig. 7. In addition, the same structures as those of the first embodiment are given the same reference numerals and the description is omitted, and only the differences from the first embodiment will be described below.

In the first embodiment, the example is shown in which the circumferential direction CR width of both the teeth 22 and the insulating portion 32 in the winding portion 80 is gradually enlarged toward the stopper body 44 side outside in the radial direction RA, but in the second embodiment, as shown in fig. 7, the circumferential direction CR width of the teeth 22 constituting the winding portion 80 is constant in the radial direction RA as in the conventional case.

On the other hand, only the width in the circumferential direction CR of the insulating portion 32 sandwiching the teeth 22 is gradually enlarged from the bobbin body 31 side to the side opposite to the bobbin body 31 side (stopper 44 side). Therefore, the winding portion 80 has the same shape as the insulating portion 32 of the bobbin 30, and the final shape thereof is configured such that the width W2 on the stopper 44 side is larger than the width W1 on the bobbin main body 31 side, as in the first embodiment.

In the case of the second embodiment, the conventional core 20 can be used as it is. Further, the same action and effect as those of the first embodiment are obtained.

(third embodiment)

Next, a third embodiment of the present invention will be described with reference to fig. 8. In addition, the same structures as those of the first embodiment are given the same reference numerals and the description is omitted, and only the differences from the first embodiment will be described below.

In the first and second embodiments, the width in the circumferential direction CR of the winding portion 80 is gradually widened toward the stopper body 44 side outside in the radial direction RA, but in the third embodiment, as shown in fig. 8, the width in the axial direction AX of the winding portion 80 is gradually widened toward the stopper body 44 side outside in the radial direction RA.

In this case, since the width (thickness) in the axial direction AX of the teeth 22 is constant, only the insulating portion 32 sandwiching the teeth 22 has its width in the axial direction AX gradually enlarged from the bobbin body 31 side to the side opposite to the bobbin body 31 side (stopper 44 side) as in the second embodiment.

This third embodiment is suitable for use in a case where the interval between adjacent teeth 22 is small, for example. Further, the same action and effect as those of the first embodiment are obtained.

(fourth embodiment)

Next, a fourth embodiment of the present invention will be described with reference to fig. 9 and 10. In addition, the same structures as those of the first embodiment are given the same reference numerals and the description is omitted, and only the differences from the first embodiment will be described below.

In the fourth embodiment, a groove 84 is formed in the surface 82 of the insulating portion 32 around which the aluminum wire 81 is wound, so that the aluminum wire 81 is spirally formed along the groove 84.

As shown in fig. 9, the groove 84 may be present in the entire winding direction of the surface 82, or may be present only at the root of the tooth on the winding start point side as shown in fig. 10. The width of the root in the circumferential direction (the width W1 on the bobbin body 31 side) is narrower than the width on the outer diameter side (the width W2 on the stopper body 44 side), and although not shown in detail, the root has an axially long cross section. Since a fly wheel (winding portion) of a winding machine (not shown) rotates on a fixed circumferential track, it is difficult to match the cross section of the root portion with the winding portion 80 due to the longitudinal length, and it is difficult to perform the winding process.

However, if the groove 84 is formed in the root portion as in the present embodiment, it is possible to provide a solution to the above-described technical problem.

The depth of the groove 84 formed on the surface 82 of the insulating portion 32 is determined by the fixing force (D1) at the time of winding, but is preferably approximately 1/4 to 1/8 of the wire diameter. When the groove 84 is deep, the height of the projections on both sides of the groove 84 is relatively high, and if the thickness of the insulating portion 32 required for insulation from the core 20 is calculated, the thickness becomes extremely thick. If this thickness is increased, it will have a result of preventing heat dissipation from the core 20 and the winding portion 50, which is not desirable.

However, in the present embodiment, the depth of the groove 84 can be set to be shallower than the case where the groove is formed in the surface of the conventional flat insulating portion. As a result, the heat dissipation property is excellent, and the mold cost can be suppressed and the mold life can be improved, and the manufacturing cost can be suppressed to a low level.

On the other hand, by providing a curved surface or a chamfer at the corner of the bobbin 30, the ease of the winding operation at the root of the tooth 22 can be improved. Further, if the curved surface or chamfer of the corner of the bobbin 30 is set to be larger in size closer to the root of the tooth 22, the convenience of the winding work can be further improved. Further, the dimensional change is more preferably gradual.

(other embodiments)

In the above embodiment, the example in which the width in the circumferential direction CR or the width in the axial direction AX of the winding portion 80 around which the aluminum wire 81 is wound is configured to be gradually increased in the winding direction from the winding start point to the winding end point of the aluminum wire 81 is shown, but the widths in both directions may be configured to be increased in the winding direction, although not shown.

In the above-described embodiment, the example is shown in which the generator 1 is sealed in the engine case (not shown) by fixing the core 20 (core body 21) of the stator (fixed body) 10 to the inside of the engine cover 2 by, for example, bolts or the like and covering the same with the engine cover 2, but the present invention is not limited to this, and for example, it is also conceivable that the stator 10 is fixed to, for example, the root side of the crankshaft 3 on the engine case side and the generator 1 is not sealed in the engine case.

Further, a switching circuit such as an inverter may be provided in an external electric circuit, and the generator 1 may be used as a starter generator.

Further, the invention of the present application can be applied not only to the aluminum wire 81 but also to a case where a copper wire is used as in the related art. For example, it is also useful when the tensile force applied to the insulating film formed on the surface of the copper wire is to be suppressed without increasing the tension at the time of winding the wire, when the flaw resistance of the copper wire is insufficient, or when a thin insulating film is used for the copper wire. Further, it is also useful when a wire made of a composite material using both aluminum and copper is used.

Further, in the above-described embodiment, the insulating resin is formed in the shape of a bobbin in order to ensure the insulation between the aluminum wire 81 and the tooth 22, but an integrally molded product or a powder resin may be used.

Further, an insulating resin may be provided on the surface of the teeth 22 independently of the teeth 22.

In the above embodiment, the aluminum wire 81 is used for the winding portion 50, but the present embodiment can be applied to a copper wire with low tensile strength called a thin wire.

Further, in the above-described embodiments, the outer rotor type generator in which the rotor is provided outside the stator has been described, but the rotor may be provided inside the stator. In this case, the rotating electric machine can be used as an inner rotor type generator or motor. Further, the rotating electric machine may be configured such that the rotor is fixed and the stator is relatively rotated with respect to the rotor. As described above, the present invention is not limited to the above embodiments, and can be applied to various forms without departing from the spirit thereof.

Description of the reference numerals

1: magnet type generator (rotating electrical machine)

10: stator (fixed body)

20: iron core

22: tooth

32: insulator

30: coil rack

50: winding part

60: rotor (rotator)

80: winding part

81: aluminum wire

Claims

1. A rotating electrical machine (1) is provided with:

a rotor (60) rotatably supported;

a stator (10) which is disposed with a gap of a predetermined distance from the rotor (60) and has a core (20); and

a bobbin (30) mounted on the core (20); it is characterized in that the preparation method is characterized in that,

the core (20) is provided with a plurality of teeth (22) extending towards the outer side of the radial direction (RA);

the teeth (22) and an insulating part (32) of the coil frame (30) together form a winding part (80), and an aluminum wire (81) with lower strength than a copper wire is wound on the winding part (80) to form a winding part (50);

the width of the winding portion (80) is configured such that the circumferential direction (CR) width of the winding portion (80) is gradually increased from a winding start point (S) to a winding end point (E) of the aluminum wire (81) in the winding advancing direction of the first layer as compared with a previously wound portion at any position of the first layer of the winding portion (50) where the predetermined number of windings are present.

2. The rotating electric machine according to claim 1,

the width of the winding portion (80) is the width of the core (20) in the circumferential direction (CR).

3. The rotating electric machine according to claim 1,

the width of the winding portion (80) is the width of the core (20) in the axial direction (AX).

4. The rotating electric machine according to any one of claims 1 to 3,

the shape of the winding portion (80) is the shape of the teeth (22).

5. The rotating electric machine according to any one of claims 1 to 3,

the shape of the winding part (80) is the shape of the insulating part (32) of the coil frame (30).

6. The rotating electric machine according to any one of claims 1 to 3,

the winding portion (50) is formed by concentrated winding.

7. The rotating electric machine according to any one of claims 1 to 3,

the bobbin (30) has a split structure that is split in the axial direction (AX) of the core (20), and a gap is formed in the joint surface of the split portion of the bobbin (30) in a state in which the core (20) is sandwiched.