CN100440687C - Stator of alternating-current generator for vehicle and manufacturing method thereof - Google Patents
Stator of alternating-current generator for vehicle and manufacturing method thereof Download PDFInfo
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- CN100440687C CN100440687C CNB021475393A CN02147539A CN100440687C CN 100440687 C CN100440687 C CN 100440687C CN B021475393 A CNB021475393 A CN B021475393A CN 02147539 A CN02147539 A CN 02147539A CN 100440687 C CN100440687 C CN 100440687C
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Abstract
The present invention provides a stator coil of an alternating current generator for vehicles and a manufacturing method thereof, wherein the stator coil can realize the miniaturization and the high output of an alternating current generator for vehicles and can enhance insulating property. Six cutting grooves are sideways divided from the first end surface of a stator core, two conductor sections (15) are respectively inserted into each pair of the cutting grooves, and then the ends of the conductor sections (15) extend towards the side surface of the second end of the stator core are jointed to form the stator coil. Moreover, the cutting groove holding sections (16a) of the conductor sections (15) form a rectangular section so as to the connecting part (17) of a coil end and then form a circular section.
Description
Technical field
The present invention relates to the stator by oil-engine driven alternating current generator, be specifically related to passenger vehicle, truck etc. are taken advantage of the stator coil and the manufacture method thereof of the ac generator of vehicle stator of thing lift-launch.
Background technology
In recent years, vehicle-mounted dlternator requires small-sized high output day by day.And, for realizing the small-sized high output of vehicle-mounted dlternator, the duty factor of the electric conductor of taking in the stator magnetic circuit be must improve, stator coil the connecting portion permutationization and the densification of (connecting portion that stator core is outer is called coil-end) needed to realize again.
In view of this situation, for example in the WO98/54823 communique, disclosed a kind of conductor segment of short size of in the stator coil electric conductor, using and improved electric conductor duty factor and the structure of realizing coil-end permutationization and densification.
In the WO98/54823 communique, disclosed a kind of like this stator, promptly, after a plurality of conductor segment of the U word shape that will have rectangular cross sectional shape are inserted from stator core one side's end side surface, by the end of anti-inserting side is mutual in conjunction with carrying out the package of stator coil.This stator has the conductor segment of rectangular cross sectional shape because of use, so can seamlessly be accommodated in conductor segment in the grooving, can improve duty factor, and, the general traditional stator structure that the astroid coil unit made from the annulus unit formation star that continuous conductor lines is rolled into ring-type formation is wrapped in the stator core is compared, and is characterized in forming easily the stator coil of coil segment systematicness configuration.Promptly realize the permutationization and the high density of the coil-end of stator coil.
Yet the stator of putting down in writing in the WO98/54823 communique is that the conductor lines that will have the short size of rectangular cross sectional shape partly is flexed into U word shape and makes conductor segment in the central.In this warpage operation, the stress that produces at the joggling part of the conductor lines with rectangle cross section can damage the insulating coating that coats on the conductor segment, and insulating properties is worsened.
For this reason, for example the Japan Patent spy opens the cross sectional shape that conductor lines middle body that proposition such as 2000---299949 communique only will have the short size of rectangular cross sectional shape is configured as circle, the stress that joggling part produces when reducing warpage is to restrain the damage of insulating coating.
Figure 26 represents that the stator that Japan Patent spy for example opens the vehicle-mounted dlternator in the past of 2000---299949 communique record wants the sectional view of portion, and Figure 27 is the stereogram of the conductor segment of the stator coil of stator among expression formation Figure 26.
The stator coil that is wrapped among Figure 26 on the grooving 2a of stator core 21 is made of a plurality of electric conductors, has taken in 4 electric conductors in each grooving 2a, and insulator 3 sets around 4 electric conductors.In each grooving 2a, 4 electric conductors in otch from radially inboard according to the 1st position, the 2nd position, the 3rd position, the 4th sequence of positions assortment becomes row.
And the 4th locational bending part 4c5c in another grooving 2a that the 1st locational electric conductor 4a of a grooving 2a separates with 1 distance between two poles along the clockwise direction of stator core 2 becomes a pair of.Equally, the 3rd locational electric conductor 5b in another grooving 2a of separating with 1 distance between two poles of the clockwise direction of the 2nd of a grooving 2a the locational electric conductor 5a and stator core 2 becomes a pair of.These paired electric conductors are in an axial side's of stator core 2 end face side, by connecting via bending part 4c described later, 5c with connecting line.
Thus, in stator core 2 one sides' end face side, the connecting line that the 4th locational bending part 4b is connected with the 1st locational electric conductor 4a surrounds the 3rd locational electric conductor 5b with the connecting line that the 2nd locational electric conductor 5a is connected.That is, in stator core 2 one sides' end face side, bending part 5c is surrounded by bending part 4c.Like this, in stator core 2 one sides' end face side, bending part 4c, 5c become 2 layers, and constitute the coil-end group along circumferential assortment.
On the other hand, a grooving 2a No. 2 electric conductor 5a becomes a pair of with the 1st locational electric conductor 4a in another grooving 2a that separates with 1 distance between two poles along the clockwise direction of stator core 2.Equally, the 4th of a grooving 2a the locational bending part 4b becomes a pair of with the 3rd locational electric conductor 5b in another grooving 2a that separates with 1 distance between two poles along the clockwise direction of stator core 2.These paired electric conductors connect by joint in axial the opposing party's of stator core 2 end face side.
Thus, in stator core 2 the opposing party's end face side, the interior side engagement portion that the outer side engagement portion that the 4th locational bending part 4b is connected with the 3rd locational electric conductor 5b and the 4th locational electric conductor 4a are connected with the 2nd locational electric conductor 5a is with radially and the form assortment of circumferentially staggering mutually.Like this, in stator core 2 the opposing party's end face side, outer side engagement portion and interior side engagement portion radially assortment become 1 row to constitute the coil-end group.
And, as shown in figure 27, the 1st locational electric conductor 4a and the 4th locational electrical wire 4b form big section 4 of U shape by the conductor lines of short size and provide, and the 2nd locational electric conductor 5a and the 3rd locational electrical wire 5b are provided by the segment 5 that the conductor lines of lacking size forms the U shape.Each section 4,5 has axially extended part in the grooving of the taking in 2a, has the 4f of diagonal portion, 4g, 5f, 5g that extends with respect to angle that axioversion is decided and bending part 4c, the 5c that the 4f of diagonal portion, 4g, 5f, 5g are connected simultaneously.And, form from stator core 2 to the outstanding coil-end of an axial side's end face by the 4f of diagonal portion, 4g, 5f, 5g and bending part 4c, 5c.
Again, in stator core 2 the opposing party's end face side, big section 4 is extended the direction bending that distolateral edge deviates from mutually.Segment 5 extends the approaching direction bending mutually of distolateral edge.And the end 4d of big section 4 and the end 5d of segment 5 form interior side engagement portion by solder joints, and the end 5e of big section 4 end 4e and segment 51 forms outer side engagement portion by solder joints.Like this, form from stator core 2 to the outstanding coil-end of axial the opposing party's end face by the interior side engagement portion of the 4h of diagonal portion, 4i, 5h, 5i, end 4d, 5d and the outer side engagement portion of end 4e, 5e.
In addition, the conductor lines middle body plastic deformation that big section 4 and segment 5 will have the short size in rectangle cross section (flat cross section) is a circular cross-section, be flexed into roughly U word shape again, have only joggling part 4c, 5c to form circular cross-section, other parts then form the rectangle cross section.
In traditional in the past stator of WO98/54823 communique record, because of conductor segment has flat cross sectional shape, the electric conductor duty factor can be improved, and coil-end permutationization and densification can be realized, can realize the small-sized high output of vehicle-mounted dlternator.But when the conductor lines with the short size of flat cross sectional shape was flexed into U word shape, the problem of existence was that joggling part can produce big stress, the insulating coating that coats on the damage conductor segment, and insulating properties worsens.And between the bight of conductor segment or bight and tabular surface mutual friction mutually produced the problem of damage insulating coating, insulating properties deterioration when the coil-end that causes when stator coil is assembled or because of the vibration that takes place in the parts running of carrying stator was touched each other.
Again, open in the stator in the past of 2000---299949 communique record the Japan Patent spy, owing to have only bending part 4c, 5c to form circular cross-section, other parts are used big section 4 and segment 5 formation stator coils that form the rectangle cross section, the stress that joggling part 4c, 5c produced when the conductor lines that therefore can reduce short size was flexed into U word shape can be restrained the damage that is coated on the insulating coating on joggling part 4c, the 5c.Yet, because of the 4f of diagonal portion, 4g, 5f, 5g form flat cross sectional shape, so when the assembling stator coil, perhaps because of the vibration that takes place in the parts running of carrying stator cause the 4f of diagonal portion, 4g, 5f, when 5g touches each other, between the bight of diagonal portion or bight and tabular surface mutual friction mutually produce the problem of damage insulating coating, insulating properties deterioration.
The present invention is for addressing the above problem, and its purpose is to provide the part in a kind of grooving that will be accommodated in conductor lines to form flat cross sectional shape, and will be formed circular cross sectional shape by the coil-end that diagonal portion and bending part constitute, can improve the stator coil and the manufacture method thereof of the ac generator of vehicle stator of insulating properties in the small-sized high output that realizes vehicle-mounted dlternator.
Summary of the invention
The stator of vehicle-mounted dlternator of the present invention has the stator core that forms a plurality of groovings and the conductor lines of coated insulation overlay film is wrapped in the stator coil that forms in the described grooving, it is characterized in that,
Described stator coil comprises: grooving incorporating section, n the 1st coil-end, n the 2nd coil-end,
In described a plurality of groovings, take in the described grooving of 2n root incorporating section respectively, wherein n is an integer, and form the rectangle cross section respectively, the tabular surface of described grooving incorporating section closely contacts with the side wall surface of this grooving, and the depth direction along grooving in each grooving is arranged into 1 row; Described n the 1st coil-end is each grooving centering of deciding the grooving number separating, axial the 1st end face side in described stator core, by the continuous conductor line of circular cross-section, will in two groovings, be accommodated in described grooving incorporating sections different on the cutting groove depth direction diverse location and be connected in series; Described n the 2nd coil-end is each grooving centering of deciding the grooving number separating, and in the 2nd axial end face side of described stator core, the described grooving incorporating section that will be accommodated in two groovings on the cutting groove depth direction diverse location is connected in series,
To in described two groovings, be accommodated in n the 1st coil-end that the described grooving incorporating section on the diverse location of cutting groove depth direction is connected in series in axial the 1st end face side of described stator core and constitute the 1st coil-end group along circumferentially arranging, will constitute the 2nd coil-end group along circumferentially arranging along in described two groovings, being accommodated in n the 2nd coil-end that the described grooving incorporating section on the cutting groove depth direction diverse location is connected in series with 1 kerf spacing in axial the 2nd end face side of described stator core with 1 kerf spacing.
Again, described the 2nd coil-end is formed by the continuous conductors with circular cross-section.
Again, it is big to have an end area of the described grooving of sectional area ratio incorporating section of coil-end of circular cross-section.
Be accommodated in the angle radius of curvature cross sectional shape bigger of the locational described grooving of the outermost radial outside incorporating section formation radial outside in the described grooving than the angle radius of curvature of radially inner side again.
Be accommodated in the angle radius of curvature cross sectional shape bigger that described grooving incorporating section on the radially inner side in the described grooving forms radially inner side than the angle radius of curvature of radial outside again.
Again, the insulating coating of the described tabular surface that closely contacts with described groove side wall of described grooving incorporating section is thinner than the insulating coating of radial outside and inside line.
Again, described grooving incorporating section is overmolding to 2 layers with insulating coating.
Again, lower floor's insulating coating of forming by the adherence fortified resin of described insulating coating and constituted by the upper strata insulating coating that heat-resistant resin is formed.
Again, the described the 1st and the 2nd coil-end group's structure be, the described the 1st and the 2nd coil-end with respect to from the rising portions of grooving incorporating section and the described stator core between the top axially, and the diagonal portion that makes inclination carries out assortment along circumferential contact.
Again, described grooving incorporating section have than the axioversion of the stator core on the coil-end that has circular cross-section relatively, from the rising portions of grooving incorporating section and the high hardness of diagonal portion between the top.
Again, the described stator coil lead-out wire that extends from the described the 1st and the 2nd coil-end group's a side has circular cross-section.
Again, a kind of manufacture method of stator of vehicle-mounted dlternator is characterized in that, comprising:
Make the operation of banded coil unit, the line part of this ribbon coil unit is by the connecting portion connection and with the assortment of decided kerf spacing, this adjacent line part forms the grooving incorporating section of internal layer of cutting groove depth direction and the state that staggers that outer field grooving incorporating section replaces owing to this connecting portion, with 2 conductor lines with circular section shape of coated insulation overlay film described kerf spacing of deciding that staggers mutually, and this line part being overlapped conductor lines that back assortment forms to staggering with 1 kerf spacing separately, with described decide the kerf spacing assortment identical several to after formation;
With the line part drawing of described coil unit is the rectangle cross sectional shape and the operation of making coil block;
The line part of described coil block is inserted from the grooving open side in the grooving of laminate core of Nogata body and this coil block is installed in operation on the laminate core;
To the described laminate core looped-shaped bending, the end face of this laminate core is involutory mutually of described coil block be installed, and this laminate core end face is welded incorporate operation.
Again, in the production process of described coil block, metal pattern comprises: the 1st stamped groove with the above groove width of described line part width; And the 2nd stamped groove that has groove width, extends to the groove depth direction continuously with the 1st stamped groove less than described line part width, use this metal pattern that the line part of described coil block is accommodated in the 1st stamped groove, press this line part from described the 1st stamped groove thruster then, this line part is pressed in described the 2nd stamped groove, makes this line part be deformed into the rectangle cross sectional shape.
Again, in the described coil block that is equipped with on described laminated core, be accommodated in the big cross sectional shape of labyrinth radius in bight of labyrinth radius ratio grooving open side that described line part that the deep-seated of cutting groove depth direction in the described grooving puts forms the bight of grooving bottom side.
Again, in the described coil block that is equipped with on described laminated core, be accommodated in the described grooving the cutting groove depth direction the most described line part of shallow position form the big cross sectional shape of labyrinth radius in bight of labyrinth radius ratio grooving bottom side in the bight of grooving open side.
Again, in described coil block production process, the overall drawing of the line part that described coil block is all.
Again, in described coil block production process, the overall drawing of line part that a plurality of described coil blocks are all.
Again, the line part that has at described coil block applies the operation that forms the 2nd insulating coating.
Again, described insulating coating is the adherence fortified resin, and described the 2nd insulating coating is a heat-resistant resin.
The present invention adopts above structure, can obtain following effect.
Adopt the present invention, because the stator of vehicle-mounted dlternator has the stator core that forms a plurality of groovings and the conductor lines of coated insulation overlay film is wrapped in the stator coil that forms in the described grooving,
Described stator coil comprises: (n: the side wall surface that forms flat cross section, tabular surface and this grooving integer), respectively connects airtight, is arranged into along the cutting groove depth direction grooving incorporating section of 1 row in each grooving to take in 2n in described a plurality of groovings separately; Decide the right position separately of the grooving of grooving number separating and to be accommodated in n the 1st coil-end that the described grooving incorporating section in the different numberings is connected in series by continuous conductor line with non-flat cross section along the cutting groove depth direction in two groovings of the 1st axial end face side of described stator core; And the right position separately of the grooving of deciding the grooving number separating will be accommodated in n the 2nd coil-end that the described grooving incorporating section in the different numberings is connected in series along the cutting groove depth direction in two groovings of the 2nd axial end face side of described stator core,
To be accommodated in n the 1st coil-end that the described grooving incorporating section in the different numberings is connected in series along circumferentially with 1 kerf spacing assortment and constitute the 1st coil-end group along the cutting groove depth direction in described two groovings of the 1st axial end face side of described stator core, to be accommodated in n the 2nd coil-end that the described grooving incorporating section in the different numberings is connected in series along circumferentially with 1 kerf spacing assortment and constitute the 2nd coil-end group along the cutting groove depth direction in described two groovings of the 2nd axial end face side of described stator core, therefore, the small-sized high output of vehicle-mounted dlternator can be realized, the stator of the vehicle-mounted dlternator of exhausted level property can be obtained to improve simultaneously.
Because described the 2nd coil-end is formed by the continuous conductor line with non-flat cross section, therefore, can restrain contacting the insulating coating that causes with the 2nd coil-end and damage, further improve insulating properties.
Again,, therefore, the caloric value of coil block can be restrained in the time of on being equipped on vehicle-mounted dlternator, cooling fan can be reduced because it is big to have an end area of the described grooving of sectional area ratio incorporating section of coil-end in non-flat cross section.
Again, because it is bigger than the angle radius of curvature of radially inner side to be accommodated in the cross sectional shape of the described grooving incorporating section in the outermost numbering in the described grooving and to be the angle radius of curvature of radial outside, therefore, the conductor lines package can restrained on grooving the time and the touching of grooving, can restrain the damage of insulating coating, improve insulating properties.
Again, because it is bigger than the angle radius of curvature of radial outside to be accommodated in the cross sectional shape of the described grooving incorporating section in the interior numbering in the described grooving and to be the angle radius of curvature of radially inner side, therefore can restrain the damage of touching the insulating coating that causes, improve insulating properties because of the flange part and the grooving incorporating section of T font front end.
Again, because the insulating coating of the described tabular surface that connects airtight with described groove side wall of described grooving incorporating section is thinner than the insulating coating of radial outside and inside line, therefore, can be with the heating of grooving incorporating section apace to stator core transmission and from the surface radiating of stator core, the temperature that can restrain stator coil rises with heat release area.
Again,, therefore, the insulating coating damage of grooving incorporating section can be restrained, insulating properties can be improved because described grooving incorporating section is overmolding to 2 layers with insulating coating.
Again, since lower floor's insulating coating that described insulating coating is made up of the adherence fortified resin and the upper strata insulating coating formed by heat-resistant resin constitute, therefore, can restrain the insulating coating damage that causes because of bending, and it is softening to restrain the insulating coating that the heating because of stator coil causes, obtains good insulation performance.
Again, because the described the 1st and the 2nd coil-end group's structure to be the above-mentioned the 1st and the 2nd coil-end carry out assortment with respect to the diagonal portion that axially makes inclination from the described stator core between the rising portions of grooving incorporating section and the top along circumferentially contacting, therefore, can reduce from the elongation of the end face of the 1st and the 2nd coil-end group's stator core, can reduce the draft loss on the 1st and the 2nd coil-end group when on vehicle-mounted dlternator, carrying.
Again, because described grooving incorporating section has the hardness higher than diagonal portion, this diagonal portion be positioned at the stator core on the coil-end that has non-flat cross section relatively axioversion, between the rising portions and top of grooving incorporating section, therefore make the diagonal portion distortion of coil easily, also be not easy to damage insulating coating even coil touches each other, can improve insulating properties.
Again, have circular cross-section, so carry out the operation that is connected of lead-out wire and rectifier easily owing to form the described stator coil lead-out wire that extends from the described the 1st and the 2nd coil-end group's a side.
Again, since the manufacture method of the stator of vehicle-mounted dlternator of the present invention comprise:
Make the operation of banded coil unit, this ribbon coil unit connects line part with the assortment of decided kerf spacing by connecting portion, and form this adjacent line part and along the cutting groove depth direction internal layer and outer formation are intersected the form of shape of staggering by this connecting portion, with 2 conductor lines of the non-flat cross sectional shape of having of coated insulation overlay film described kerf spacing of deciding that staggers mutually, this line part is overlapped conductor lines that assortment forms to staggering with 1 kerf spacing separately, decide with described that kerf spacing is identical severally to be constituted assortment;
With the line part drawing of described coil unit is the flat cross sectional shape and the operation of making coil block;
The line part of described coil block is inserted from the grooving open side in the grooving of laminate core of Nogata body and this coil block is installed in operation on the laminate core;
To the described laminate core looped-shaped bending, the end face of this laminate core is involutory mutually of described coil block be installed, this laminate core end face is welded incorporate operation, therefore, the binding site on the end face can be obviously reduced, the manufacture method of the vehicle-mounted dlternator stator of highly productive can be obtained.
Again, because in the production process of described coil block, metal pattern comprises: the 1st stamped groove with the above groove width of described line part width; And the 2nd stamped groove that has groove width, extends to the groove depth direction continuously with the 1st stamped groove less than described line part width, use this metal pattern that the line part of described coil block is accommodated in the 1st stamped groove, press this line part from described the 1st stamped groove thruster then, this line part is pressed in described the 2nd stamped groove, this line part is deformed into flat cross sectional shape, therefore, location to the metal ink film of coil unit is simple and easy, stamping press can be improved, and flat cross sectional shape can be simply line part be deformed into.
Again, because in the described coil block that is equipped with on described laminated core, the radius of curvature in bight that is accommodated in cross sectional shape that described line part that the deep-seated of cutting groove depth direction in the described grooving puts forms and is the grooving bottom side is bigger than the radius of curvature in the bight of grooving open side, therefore, can smoothly coil block be installed on the laminate core, and the insulating coating that the interference that can restrain flange part and line part causes damages the raising insulating properties.
Again, because in the described coil block that is equipped with on described laminated core, be accommodated in the described grooving the cutting groove depth direction the cross sectional shape that forms of the most described line part of shallow position be that the radius of curvature in bight of grooving open side is bigger than the radius of curvature in the bight of grooving bottom side, therefore, protruding picture portion and the line part that can restrain the T font portion front end of laminate core with the laminate core looped-shaped bending time touch, can restrain the insulating coating damage that the interference of flange part and line part causes, improve insulating properties.
Again,, therefore, manufacturing process is simplified, shorten manufacturing time owing to the overall drawings of line part in described coil block production process that described coil block is all.
Again, because in described coil block production process, therefore the line part drawing together that a plurality of described coil blocks are all, can make manufacturing process simplify, and shortens manufacturing time.
Again, apply the operation that forms the 2nd insulating coating, therefore, when the line part drawing,, also can improve insulating properties by the obstruction of will breaking of the 2nd insulating coating even break at insulating resin owing to have at the line part of described coil block
Again, because described insulating coating is the adherence fortified resin, described the 2nd insulating coating is a heat-resistant resin, and the insulating coating that causes in the time of can restraining the drawing because of line part breaks, and it is softening to restrain the 2nd insulating coating that the heating because of stator coil causes, improves insulating properties.
The simple declaration of accompanying drawing
Fig. 1 wants the stereogram of portion for see the stator of the vehicle-mounted dlternator of the invention process form 1 from the 1st axial end face side.
Fig. 2 wants the stereogram of portion for see the stator of the vehicle-mounted dlternator of the invention process form 1 from the 2nd axial end face side.
Fig. 3 is the stereogram of conductor segment of stator coil of stator that is applicable to the vehicle-mounted dlternator of the invention process form 1.
The stereogram that Fig. 4 uses for explanation conductor segment formation method shown in Figure 3.
The stereogram that Fig. 5 uses for the method for explanation installation conductor segment in the stator core of the stator of the vehicle-mounted dlternator of the invention process form 1
Fig. 6 is the process chart of the manufacture method of the stator of the vehicle-mounted dlternator of explanation the invention process form 1.
Fig. 7 is the figure of the conductor segment configuration usefulness in the grooving of the stator core in the stator of the vehicle-mounted dlternator of explanation the invention process form 1.
Fig. 8 is the end view drawing of the wiring state of 1 phase coil on the stator coil of the stator of the vehicle-mounted dlternator of explanation the invention process form 1.
Fig. 9 is applicable to the stereogram of special-shaped conductor section of stator coil of stator of the vehicle-mounted dlternator of the invention process form 2 for expression.
Figure 10 is applicable to the stereogram of conductor segment of stator coil of stator of the vehicle-mounted dlternator of the invention process form 3 for expression.
Figure 11 is applicable to the stereogram that the formation method of conductor segment of stator coil of stator of the vehicle-mounted dlternator of the invention process form 4 is used for expression.
Figure 12 is applicable to the stereogram that the formation method of conductor segment of stator coil of stator of the vehicle-mounted dlternator of the invention process form 5 is used for expression.
Figure 13 for the invention process form 6, see that from internal side diameter the stator of vehicle-mounted dlternator wants the plane graph of portion.
Figure 14 wants the stereogram of portion for the stator of the vehicle-mounted dlternator of expression the invention process form 7.
Figure 15 is the end view drawing of the wiring state of 1 phase coil on the stator coil of the stator of the vehicle-mounted dlternator of explanation the invention process form 7.
Figure 16 is applicable to the figure of manufacture method of coil block of stator coil of stator of the vehicle-mounted dlternator of the invention process shape 7 for explanation.
Figure 17 is applicable to the figure of manufacture method of coil block of stator coil of stator of the vehicle-mounted dlternator of the invention process shape 7 for explanation.
Figure 18 is applicable to the figure of manufacture method of coil block of stator coil of stator of the vehicle-mounted dlternator of the invention process shape 7 for explanation.
Figure 19 is applicable to the end view of conductor assembly of stator coil of stator of the vehicle-mounted dlternator of the invention process form 7 for expression.
Figure 20 is applicable to the stereogram of loop construction of coil block of stator coil of stator of the vehicle-mounted dlternator of the invention process shape 7 for explanation.
Figure 21 is the operation cutaway view of the manufacturing method for stators of the stator of the vehicle-mounted dlternator of explanation the invention process shape 7.
Figure 22 is applicable to the figure of stamping procedure of coil block of stator coil of stator of the vehicle-mounted dlternator of the invention process shape 8 for explanation.
Figure 23 is applicable to the operation cutaway view of manufacture method of coil block of stator coil of stator of the vehicle-mounted dlternator of the invention process shape 9 for explanation.
Figure 24 on the stator of the vehicle-mounted dlternator of explanation the invention process shape 10 grooving in the cutaway view of conductor lines assortment state.
Figure 25 is applicable to the figure of stamping procedure of coil block of stator coil of stator of the vehicle-mounted dlternator of the invention process shape 10 for explanation.
Figure 26 wants the sectional view of portion for the stator of the traditional vehicle-mounted dlternator of expression.
Figure 27 constitutes the stereogram of conventional truck with the conductor segment of the stator coil of the stator of alternating current generator for expression.
Concrete example
Example of the present invention is described with reference to the accompanying drawings.
Example 1
Fig. 1 wants the stereogram of portion for see the stator of the vehicle-mounted dlternator of the invention process form 1 from the 1st axial end face side, Fig. 2 wants the stereogram of portion for see the stator of the vehicle-mounted dlternator of the invention process form 1 from the 2nd axial end face side, Fig. 3 is applicable to the stereogram of conductor segment of stator coil of stator of the vehicle-mounted dlternator of the invention process form 1 for expression, the stereogram that Fig. 4 uses for explanation conductor segment formation method shown in Figure 3, the stereogram that Fig. 5 uses for the method for explanation installation conductor segment in the stator core of the stator of the vehicle-mounted dlternator of the invention process form 1, Fig. 6 is a invention process form 1, explanation is at the process chart of the manufacture method of the stator of vehicle-mounted dlternator, Fig. 7 is the figure of the configuration of the conductor segment in the grooving of the stator core of explanation in the stator of the vehicle-mounted dlternator of the invention process form 1 usefulness, and Fig. 8 is the 1 mutually end view drawing of the wiring state of the coil of part of explanation on the stator coil of the stator of the vehicle-mounted dlternator of the invention process form 1.In addition, among Fig. 8, solid line is represented the wiring state of stator core the 1st end face side, and dotted line is represented the wiring state of stator core the 2nd end face side, and stain is represented the junction surface, 1,7,13.......91 represents grooving numbering.
Among each figure, stator 10 by stator core 11, be wrapped in the stator coil 12 in the stator core 11 and the insulator 13 that is installed in each grooving 11a of stator core 11 constitutes.
In addition, in each grooving 11a, begin the grooving incorporating section of 4 conductor segment 15 to be made into row according to the order of the 1st position, the 2nd position, the 3rd position and the 4th position from radially inner side.
Below, the manufacture method of stator 10 is described
At first, as shown in Figure 4, be deformed into circular cross-section after using punching press anchor clamps 20 will have the central portion punching press of copper wires 21 of short size in rectangle cross section of coated insulation overlay film 14.Secondly, with the central portion warpage of copper wires 21, make conductor segment 15 shown in Figure 3.
Then, as shown in Figure 5 and Figure 6, from each of the grooving 11a of laterally spaced 6 groovings of axial the 1st end face of stator core 11 (1 distance between two poles) to inserting 2 conductor segment 15 respectively.Thus, as shown in Figure 7, the grooving incorporating section 16a of the line part 16 of conductor segment 15 makes the length direction in rectangle cross section with radially consistent, is accommodated in each grooving 11a. with being arranged into 1 row.In addition, though the insulator 13 among Fig. 7 is not shown, each grooving incorporating section 16a connects airtight by the side wall surface of insulator 13 with grooving 11a.
The front of the line part 16 of conductor segment 15 shown in Fig. 6 (b), the front of the line part 16 of each conductor segment 15 of extending to the 2nd end side surface of stator core 11 from each grooving 11a to circumferential skewing for deviating from mutually.
As shown in Figure 8, be numbered No. 1, No. 7 at grooving ... among .91 number the grooving group, the end 16c of the end 16c of the conductor segment 15 of extending from the 2nd position of m grooving 11a and the conductor segment 15 of extending from the 1st position of (m+6) number grooving 11a radially overlaps, and makes the ripple web-like coil of 2 bendings 1 time by the TIG solder joints.Equally, the end 16c of the end 16c of the conductor segment 15 of extending from the 4th position of m grooving 11a and the conductor segment 15 of extending from the 3rd position of (m+6) number grooving 11a radially overlaps, and makes the ripple web-like coil of 2 bendings 1 time by the TIG solder joints.
Secondly, the linking part 17 of 2 conductor segment 15 that inserts the centering of the grooving 11a between No. 55 and No. 61 is cut off, will insert No. 61 linking part 17 cut-outs with 2 conductor segment 15 of the centering of No. 67 grooving 11a.And, the cut-out end of the conductor segment 15 that will extend from the 1st position of No. 55 grooving 11a by TIG welding and the cut-out termination of extending conductor segment 15 from the 4th position of No. 61 grooving 11a are closed, the cut-out end of the cut-out end of the conductor segment 15 of extending from the 3rd position of No. 55 grooving 11a and the conductor segment 15 of extending from the 4th position of No. 67 grooving 11a is by the TIG solder joints, and the cut-out end of the conductor segment 15 of extending from the 1st position of No. 61 grooving 11a and the cut-out end of the conductor segment 15 of extending from the 2nd position of No. 61 grooving 11a are by the TIG solder joints.Thus, can obtain 1 phase coil sections that 4 bendings ripple web-like coil series connection shape is once connected.And the cut-out end of the conductor segment 15 of extending from the 2nd position of No. 67 grooving 11a and the conductor segment 15 of extending from the 3rd position of No. 61 grooving 11a are cut off end becomes 1 lead-out wire of coil sections (O) and neutral point (N) mutually respectively.
And, being installed in grooving respectively is numbered No. 2, No. 8 ... .92 number grooving group, grooving is numbered No. 3, No. 9 ... .93 number grooving group, grooving is numbered No. 4, No. 10 ... grooving group/grooving of .94 number is numbered No. 5, No. 11 ... .95 number grooving group and grooving are numbered No. 6, No. 12 ... the conductor segment 15 on .96 number the grooving group is carried out wiring equally, makes 6 phase coil sections (not shown).
Again, being wrapped in grooving is numbered No. 1, No. 7 ... the coil on No. 91 the grooving group, being wrapped in grooving is numbered No. 3, No. 9 ... the coil on No. 93 grooving groups, being wrapped in grooving is numbered No. 5, No. 11 ... the coil on No. 95 grooving groups is by engaging neutral point N each other, become Y connection (interchange wiring), being wrapped in grooving is numbered No. 2, No. 8 ... the coil on No. 92 grooving groups, being wrapped in grooving is numbered No. 4, No. 10 ... the coil on No. 94 grooving groups, being wrapped in grooving is numbered No. 6, No. 12 ... the coil on No. 96 grooving groups similarly is wired as Y shape, make 2 groups 3 cross streams coils, as Fig. 1, shown in Fig. 2 and Fig. 6 (c), can obtain stator 10.Again these 3 cross streams coils of 2 groups are constituted stator coil 12.
The stator coil 12 of this structure has the grooving incorporating section 16a in rectangle cross section, connect airtight by the side wall surface of insulator 13 its tabular surface and each grooving 11a, and in each grooving 11a along grooving 11a depth direction side by side assortment become a row.
And, each centering at the grooving 11a that separates 6 grooving numbers, in the 1st axial end face side of stator core 11, connecting the 1st position and the 2nd locational grooving incorporating section 16a that is accommodated in two grooving 11a by linking part 17 series connection shapes with circular cross-section, connecting the 3rd position and the 4th locational grooving incorporating section 16a that is accommodated in grooving 11a by linking part 17 series connection shapes with circular cross-section, wherein, linking part 17 constitutes by bending part 17a and with a pair of diagonal 17b of portion that each grooving incorporating section 16a is connected with bending part 17a, becomes the 1st coil-end.And 2 the 1st coil-end along circumferentially assortment, constitute the 1st coil-end group 12a with 1 kerf spacing, and thus, the 1st coil-end is radially with circumferentially away from one another along circumferentially neat assortment.
Equally, each centering of the grooving 11a that separates 6 grooving numbers, in the 2nd axial end face side of stator core 11, the extension side of line part 16 is engaged each other for the 1st position that is accommodated in two grooving 11a and the 2nd locational grooving incorporating section 16a and the series connection shape is connected.Wherein, the mutual portion of the extension side of line part 16 being engaged the 2nd coil-end of forming comprises: with the junction surface 18 of the mutual portion of the end 16c of line part 16 joint; And a pair of diagonal 16b of portion that each grooving incorporating section 16a is connected with junction surface 18.And these 2 the 2nd coil-end along circumferentially assortment, constitute the 2nd coil-end group 12b with 1 kerf spacing, and thus, the 2nd coil-end is radially with circumferentially away from one another along circumferentially neat assortment.
Like this, adopt this example 1, because of the grooving incorporating section 16a formation rectangle cross section of conductor segment 15, so can increase the conductor duty factor of grooving 11a.Again, the grooving incorporating section 16a that will be accommodated in the difference numbering of the grooving 11a that separates 6 groovings in the both end sides of stator core 11 is connected in series on 2 the 1st and the 2nd coil-end respectively, with 2 the 1st and the 2nd coil-end with 1 kerf spacing along circumferentially assortment, constitute the 1st and the 2nd coil-end group 12a, therefore, can realize permutationization and the densification of the 1st and the 2nd coil-end group 12a, 12b.The result is the stator that obtains realizing high output.
Again, form circular cross-section owing to be equivalent to the linking part 17 of the 1st coil-end, therefore when copper wires 21 is flexed into the U font, can reduce the stress of bending part 17a (joggling part) generation of linking part 17, can restrain the damage that coats the insulating coating 14 on the bending part 17a, improve insulating properties.
Again, because linking part 17 forms circular cross-section, therefore, even the vibration that takes place in turning round when stator coil 12 assemblings or because of the parts that are equipped with stator 10 is touched linking part 17 (the 1st coil-end) each other, also can restrain the damage of insulating coating 14, improve insulating properties.
Because stator coil 12 lead-out wire O and neutral point N form circular cross-section, therefore can simply insulating coating 14 be removed again.Thus, when being assembled in stator 10 on the alternating current generator, can be reliably and simply the lead-out wire O of stator 10 is connected with rectifier.
Though in described example 1,, when being used for the stator coil that constitutes by coincidence rolled coil, also can obtain same effect to using the stator coil 12 that constitutes by ripple web-like coil to be described.
Again, though the structure that subtend is inserted 2 conductor segment 15 respectively with the centering of the grooving 11a that separates 6 groovings in described example 1 is described, but the number of the conductor segment 15 that the centering of the grooving 11a that separates 6 groovings is inserted does not limit, and can be 1, can be more than 3 yet.But the number of the grooving incorporating section 16a that takes in grooving 11a is an even number.
Though the structure that subtend is inserted conductor segment 15 with the centering of the grooving 11a that separates 6 groovings in described example 1 is described, do not limit again.But when the grooving number of every grade of every phase was 1, conductor segment 15 should be inserted the centering of the grooving 11a that separates 3 groovings.
Again, be deformed into circular cross-section by punching press anchor clamps 20, also the central portion of a plurality of copper wires 21 can be deformed into circular cross-section by punching press anchor clamps 20 together though described example 1 is each and every one ground of central portion 1 with copper wires 21.Can simplify manufacturing process in this case, shorten manufacturing time.
Example 2
Be that conductor segment 15 and special-shaped conductor section 22 are constituted stator coil in this example 2.And, on the position that 4 ripple web-like coil series connection shapes that constitute each phase coil connect, use conductor segment 22.This conductor segment 22 as shown in Figure 9, use 20 pairs of coated insulation overlay films 14 of punching press anchor clamps the short size with rectangle cross section copper wires one distolaterally carry out punching press, be deformed into circular cross-section.
Describe below with reference to Fig. 8, special-shaped conductor section 22 be installed in respectively the 1st position of No. 55 grooving 11a and the 3rd position, No. 61 grooving 11a on the 2nd position and the 4th position of 4 positions, the 1st position to the and No. 67 grooving 11a.After special-shaped conductor segment 22 is inserted grooving 11a with each, the bending shown in Fig. 9 arrow of formation.Other the centering of grooving 11a, similarly insert conductor segment 15 with above-mentioned example 1 again.The front bending of the square-section portion 23 of conductor segment 22, and have 16b of diagonal portion and equal 23b of diagonal portion and the end 23c of end 16c with conductor segment 15, the remnants of defeated troops of square-section m23 become grooving incorporating section 23a.And the linking part 17 that circular cross-section portion 24 bends to not with conductor segment 15 touches.
Again, in the 2nd end face side, the end 23c of the special-shaped conductor section 22 of extending from the 1st position of No. 55 grooving 11a and the 3rd position engages with end 16c from the extended conductor segment 15 in the 2nd position and the 4th position of No. 49 grooving 11a.Again, the end 23c of the special-shaped conductor section 22 of extending from the 1st position of No. 61 grooving 11a and the 3rd position engages with end 16c from the extended conductor segment 15 in the 2nd position and the 4th position of No. 55 grooving 11a.Again, the end 23c of the special-shaped conductor section 22 of extending from the 2nd position of No. 61 grooving 11a and the 4th position engages with end 16c from the extended conductor segment 15 in the 1st position and the 3rd position of No. 67 grooving 11a.Again, the end 23c of the special-shaped conductor section 22 of extending from the 2nd position of No. 67 grooving 11a and the 4th position engages with end 16c from the extended conductor segment 15 in the 1st position and the 3rd position of No. 73 grooving 11a.
Then, in the 1st end face side, the end 24a of the special-shaped conductor section 22 of extending from the 1st position of No. 55 grooving 11a engages with the end 24a that the 4th position from No. 61 grooving 11a extends to the special-shaped conductor section 22 of the 1st end face side, the end 24a of the special-shaped conductor section 22 of extending from the 3rd position of No. 55 grooving 11a engages with end 24a from the extended special-shaped conductor section 22 in the 4th position of No. 67 grooving 11a, engages with end 24a from the extended special-shaped conductor section 22 in the 1st position of No. 61 grooving 11a from the end 24a of the special-shaped conductor section 22 of the 1st position extension of No. 61 grooving 11a.
Thus, the same with described example 1, can obtain the 1 phase coil sections that 4 bendings ripple web-like coil series connection shape is once connected.And extending to end 24a that 4a under the end of special-shaped conductor section 22 of the 1st end face side and the 3rd position from No. 61 grooving 11a extend to the special-shaped conductor section 22 of the 1st end face side from the 2nd position of No. 67 grooving 11a becomes 1 lead-out wire of coil sections (O) and neutral point (N) mutually respectively.
In addition, other 5 phase coil sections also are same formations.
Thus, adopt this example 2,,, can improve the wiring operation so when 4 ripple web-like coils that will constitute each phase coil formation are connected in series, will conductor segment 15 not cut off because of using special-shaped conductor section 22.
Example 3
Adopt this example 3, because of the conductor of the 2nd coil-end by circular cross-section constitutes, so even when stator coil is assembled or because of the vibration that takes place in the parts running that is equipped with stator is touched the 2nd coil-end each other, also can restrain the damage of insulating coating 14.Thus, can restrain the damage of the insulating coating 14 on the 1st coil-end group and the 2nd coil-end group, improve insulating properties.
Example 4
As shown in figure 11, be shaped on conductor segment in this example 4, this conductor segment is that to be stamped to form shape be the rectangle cross section to the both ends by the copper wires 26 of the short size with circular cross-section of 20 pairs of coated insulation overlay films 14 of punching press anchor clamps.Central portion with copper wires is flexed into the U font then.
In addition, except the copper wires 26 of making conductor segment has the circular cross-section, structure is the same with described example 1.
Thus, adopt described example 4, make because of conductor segment adopts the copper wires with circular cross-section, thus compare with copper wires 21 with rectangle cross section cheap, but low-cost production's stator.
Owing to the drawing of grooving incorporating section, therefore the hardness ratio connecting portion height of grooving incorporating section as the 1st coil-end group's connecting portion easy deformation, even connecting portion touches each other, does not allow meaning to cause insulating coating 14 damages yet, can improve insulating properties again.
In addition, though described example 4 is by being formed the grooving incorporating section by punching press to improve hardness, the high method of hardness of grooving incorporating section hardness ratio connecting portion is not limited thereto.
Example 5
As shown in figure 12, this example 5 is at first made insulating coating 14 coatings and is had the copper wires 27 of central portion for the short size of the circular cross-section in big footpath, will be deformed into the rectangle cross section by punch process except the position the central portion of copper wires 27 again.Then, with the central portion warpage of copper wires 27, be made into the U word shape conductor segment 28 that a pair of line part 29 is connected by line part 30.The sectional area of the sectional area ratio line part 29 of the connecting portion 30 of this conductor segment 28 is big.
In addition, replace the conductor segment 15 except using conductor segment 28, structure is the same with described example 1.
Adopt described example 5, the 1st coil-end group's who is made of connecting portion 30 sectional area ratio is big by the sectional area of the grooving incorporating section that line part 29 constitutes, thus, when carrying stator on alternating current generator, the caloric value that can restrain the 1st coil-end group, the volume of the cooling fan that can be reduced into cooling coil end group and equip can be realized the miniaturization of alternating current generator.
Example 6
As shown in figure 13, this example 6 is in the 1st coil-end group 12a, and the circumferentially adjacent 17b of diagonal portion is along circumferentially contact shape assortment, and in the 2nd coil-end group 12b, the circumferentially adjacent 16b of diagonal portion is along circumferentially contact shape assortment.
In addition, other structures are identical with example 1.
Adopt example 6,,, reduce the 1st and the 2nd coil-end group 12a so can increase the gradient axial with respect to the stator core 11 of the 16b of diagonal portion, 17b because of the circumferential adjacent 16b of diagonal portion, 17b assortment seamlessly,, the axial height of 12b.The result when carrying on alternating current generator, can reduce the 1st and the 2nd coil-end group 12a,, the draft loss on the 12b.The result can strengthen the cooling air quantity of cooling fan, can make the 1st and the 2nd coil- end group 12a,, 12b high efficiency cooling, the temperature that can restrain stator rises, so that alternating current generator is realized high output.
Example 7
Figure 14 wants the stereogram of portion for the stator of the vehicle-mounted dlternator of expression the invention process form 7, Figure 15 is the end view drawing of the wiring state of the coil of the 1 phase part of explanation on the stator coil of the stator of the vehicle-mounted dlternator of the invention process form 7, Figure 16 is applicable to the figure of manufacture method of coil block of stator coil of stator of the vehicle-mounted dlternator of the invention process shape 7 for explanation, Figure 17 is applicable to the figure of manufacture method of coil block of stator coil of stator of the vehicle-mounted dlternator of the invention process shape 7 for explanation, Figure 18 is applicable to the figure of manufacture method of coil block of stator coil of stator of the vehicle-mounted dlternator of the invention process shape 7 for explanation.Figure 19 is applicable to the end view of conductor assembly of stator coil of stator of the vehicle-mounted dlternator of the invention process form 7 for expression, Figure 20 is applicable to the stereogram of loop construction of coil block of stator coil of stator of the vehicle-mounted dlternator of the invention process shape 7 for explanation, Figure 21 is the operation cutaway view of the manufacturing method for stators of the stator of the vehicle-mounted dlternator of explanation the invention process shape 7.In addition, among Figure 15, solid line is represented the wiring state of stator core the 1st end face side, and dotted line is represented the wiring state of stator core the 2nd end face side, and stain is represented the junction surface, 1,7,13.......91 represents grooving numbering.
Among Figure 14, stator 35 comprises: the laminated core by cylindric shaping is made, the inside all side openings of axially extended grooving 11a, along circumferentially being formed with a plurality of stator core 11 with institute's determining deviation; A plurality of continuous conductor lines are wrapped in grooving 11a go up the stator coil 36 that forms; And be installed in insulator 13 on the grooving 11a.
Wherein, conductor lines 40 adopts the copper wires that is coated with insulating coating.And, the position (grooving incorporating section) that is accommodated in the conductor lines 40 in the grooving 11a has the rectangle cross section, in the 1st and the 2nd end face side of stator core 11, the linking part 41 that separates the conductor lines 40 that the outer field grooving incorporating section in internal layer grooving incorporating section in a side the grooving 11a of 6 groovings and the opposing party's the grooving 11a is connected in series has circular cross-section.This linking part 41 is made of a pair of diagonal 41b of portion that bending part 41a, each grooving incorporating section are connected with bending part 41a, becomes the 1st and the 2nd coil respectively..
Below, specify 1 coil structure of the coil 37 of part mutually that constitutes stator coil 36 with reference to Figure 15.
51 ~ 54 formations of the 1st to the 4th coil that the coil 37 of 1 phase part is made up of 1 conductor lines 40 respectively.The structure of the 1st coil 51 be with 1 conductor lines 40 from No. 1 to No. 91 every 6 groovings, the 1st position in the grooving 11a and the 2nd position intersected constitute the ripple web-like.The structure of the 2nd coil 52 be with conductor lines 40 from No. 1 to No. 91 every 6 groovings, the 2nd position and the 1st position of grooving 11a intersected constitute the ripple web-like.The structure of the 3rd coil 53 be with conductor lines 40 from No. 1 to No. 91 every 6 groovings, the 3rd position and the 4th position of grooving 11a intersected constitute the ripple web-like.The structure of the 4th coil 54 be with conductor lines 40 from No. 1 to No. 91 every 6 groovings, the 4th position and the 3rd position of grooving 11a intersected constitute the ripple web-like.And in each grooving 11a, radially align the length direction in rectangle cross section in the grooving incorporating section 42 of conductor lines 40, and radially assortment becomes 4 to become row side by side.
The 1st end face side in stator core 11, to carrying out the TIG welding from the volume top 52a of portion of extended the 2nd coil 52 in the 2nd position of No. 1 grooving 11a and the 4th coil 54 end of volume (EOV) end 54b that extend from the 3rd position of No. 91 grooving 11a, to carrying out the TIG welding, form the coil of 2 bendings again from the volume top 54a of portion of extended the 4th coil 54 in the 4th position of No. 1 grooving 11a with from the 2nd coil 52 end of volume (EOV) end 52b that No. 1 of No. 91 grooving 11a is extended.
Again, the 2nd end face side in stator core 11, to carrying out the TIG welding from the volume top 51a of portion of extended the 1st coil 51 in the 1st position of No. 1 grooving 11a and the 3rd coil 53 end of volume (EOV) end 53b that extend from the 4th position of No. 91 grooving 11a, to carrying out the TIG welding, form the coil of 2 bendings again from the volume top 53a of portion of extended the 3rd coil 53 in the 3rd position of No. 1 grooving 11a and the 1st coil 51 end of volume (EOV) end 51b that extend from the 2nd position of No. 91 grooving 11a.
And, to cut off to the linking part 41 of the conductor lines 40 of the 3rd coil 53 of the 1st end face side extension of stator core 11 from the 3rd position of No. 61 grooving 11a and the 4th position of No. 67 grooving 11a, will cut off to the linking part 41 of the conductor lines 40 of the 4th coil 54 of the 1st end face side extension of stator core 11 from the 3rd position of No. 67 grooving 11a and the 4th position of No. 73 grooving 11a.Then, the cut-out end 53c of the 3rd coil 53 is cut off end 54c with the 4th coil 54 engages, form by the be connected in series 1 phase coil 37 partly of the bending formed of the 1st to the 4th coil 51 ~ 54.
In addition, the cut-out end 54d of the cut-out end 53d of the 3rd coil 53 and the 4th coil 54 becomes lead-out wire (O) and neutral point (N) respectively.
Equally, package there is the grooving 11a of conductor lines 40 1 grooving that respectively staggers, forms 6 coils 37 of part mutually.
And, being wrapped in grooving is numbered No. 1, No. 7 ... the coil 37 on No. 91 grooving groups, being wrapped in grooving is numbered No. 3, No. 9 ... the coil 37 on No. 93 grooving groups, being wrapped in grooving is numbered No. 5, No. 11 ... the coil 37 on No. 95 grooving groups is by engaging neutral point (N) each other and carrying out Y connection, equally, being wrapped in grooving is numbered No. 2, No. 8 ... the coil 37 on No. 92 grooving groups, being wrapped in grooving is numbered No. 4, No. 10 ... the coil 37 on No. 94 grooving groups, being wrapped in grooving is numbered No. 6, No. 12 ... the coil 37 on No. 96 grooving groups engages centerline (N) and carries out Y connection, make 2 groups 3 cross streams coils, can obtain stator 35.In addition, these 3 cross streams coils of 2 groups constitute stator coil 36.
Connect airtight by the side wall surface of insulator 13 with its tabular surface and each grooving 11a the grooving incorporating section 42 with rectangle cross section of the stator 35 of this structure, in each grooving 11a along grooving 11a depth direction side by side assortment become a row.
And, the centering separately that separates the grooving 11a of 6 grooving numbers, in the 1st axial end face side of stator core 11, connecting the 1st position and the 2nd locational grooving incorporating section 42 that is accommodated in two grooving 11a by linking part 41 series connection shapes, connecting the 3rd position and the 4th locational grooving incorporating section 42 that is accommodated in grooving 11a by linking part 41 series connection shapes with circular cross-section with circular cross-section.These two linking parts (the 1st coil-end) radially deviate from configuration, and thus, the 1st coil-end radially and circumferentially deviates from mutually, and the edge is circumferentially to separate 1 neat assortment of kerf spacing.Constitute the 1st coil-end group 36a.
Equally, the centering separately that separates the grooving 11a of 6 grooving numbers, in the 2nd axial end face side of stator core 11, the 1st position that is accommodated in two grooving 11a is connected by the linking part 41 series connection shapes with circular cross-section with the 2nd locational grooving incorporating section 42, and the 3rd position that is accommodated in two grooving 11a is connected by the linking part 41 series connection shapes with circular cross-section with the 4th locational grooving incorporating section 42.These two linking parts (the 2nd coil-end) radially deviate from configuration, and thus, the 2nd coil-end radially and circumferentially deviates from mutually, separating 1 neat assortment of kerf spacing, and constitute the 2nd coil-end group 36a along circumferentially.
Therefore, in this example 7, also can increase the conductor duty factor of grooving 11a, and, can realize permutationization and the densification of the 1st and the 2nd coil-end group 36a, 36b.Consequently obtain to realize the stator of high output.
Again, form circular cross-section owing to constitute the linking part 41 of the 1st and the 2nd coil-end, therefore when conductor lines 40 warpages are formed the bending part 41a of linking part 41, can reduce bending part 41a and go up the stress that produces, reduce the damage of the insulating coating that coats bending part 41a, improve insulating properties.
Again, because of linking part 41 forms circular cross-section, so, improve insulating properties even when stator coil is assembled or because of the vibration that takes place in the parts running that is equipped with stator is touched linking part 41 (the 1st and the 2nd coil-end) each other, also can restrain the damage of insulating coating.
Because stator coil 36 lead-out wire O and neutral point N form circular cross-section, therefore can simply the insulating coating that is coated on the end of lead-out wire O and neutral point N be removed again.Thus, when being assembled in stator 35 on the alternating current generator, can be reliably and simply the lead-out wire O of stator 35 is connected with rectifier.
In addition, this example 7 be with the 1st and the 2nd coil-end along the circumferentially spaced assortment, but also can at this moment, can reduce the 1st and the 2nd coil-end group's draft loss with the diagonal portion of the 1st and the 2nd coil-end along circumferentially connecting airtight the shape assortment.Can obtain the effect same with described example 6.
Below, specify stator 35 with reference to Figure 16 to Figure 21.
At first, with 1 kerf spacing side by side in the plane with 12 continuous conductor lines 39.Secondly, as shown in figure 16,12 conductor lines 39 are turned back with institute's determining deviation (positions of the two line of two point) together, as shown in figure 17,12 conductor lines 39 are with respect to centre line L tilt angle alpha degree, form helical coil around the coil unit 43 of band shape.This conductor lines 39 is made of the copper wires with circular cross-section that is coated with insulating coating.
And, have on the position of distance D at coil unit 43 Width branches, pair of pin group 44 is inserted between each conductor lines 39 from the face side of coil unit 43.Equally, have on the position of distance D, pair of pin group 44 is inserted between each conductor lines 39 from the inside side of coil unit 43 at coil unit 43 Width branches.In the Width end of coil unit 43 location rule pin group 45 is inserted between each conductor lines 39 then.Like this, pin group 44,45 positions as shown in figure 17.Wherein, the groove direction length (axial length of stator core 11) of the grooving 58a of distance D and laminate core described later 58 is unanimous on the whole.
Thus, the pair of pin group 44 who inserts 39 of each conductor lines from the face side of coil unit 43 moves in that the length direction of coil unit 43 is reverse mutually shown in solid arrow Figure 17.Equally, the pair of pin group 44 who inserts 39 of each conductor lines from the inside side of coil unit 43 moves in that the length direction of coil unit 43 is reverse mutually shown in dotted arrow Figure 17.At this moment, insert between each conductor lines 39, because of location rule pin group 45 so can stop conductor lines 39 to be rocked.
The position of each conductor lines 39 that is positioned at 44 of pair of pin groups is with respect to the distortion of the length direction quadrature shape of coil unit 43.Thus, the line part 56a that is out of shape with respect to coil unit 43 length direction quadrature shapes overlaps on direction in the table of coil unit 43 in pairs, becomes 96 pairs with 1 kerf spacing assortment on the length direction of coil unit 43.And the position of each conductor lines 39 that is positioned at pair of pin group 44 foreign side position becomes the connecting portion that links between the line part 56a of 6 groovings separating.Like this, the coil unit 56 of the band shape of making constitutes the coil structure equal with coil segment described later shown in Figure 19 57 except line part 56a has the circular cross-section this point.Promptly, coil unit 56 by connecting portion with line part 56a with 6 kerf spacing assortments, and, adjacent line part 56a forms conductor lines 39 by connecting portion in the both sides of thickness direction width (W) part is intersected 2 conductor lines 39 of shape, 6 kerf spacings that stagger mutually that stagger, with line part 56a overlap conductor lines 39 that assortment forms to 1 kerf spacing that staggers separately, assortment becomes 6 pairs of formations.
Then, this is banded coil unit 56 is arranged on the punching press anchor clamps 46.As shown in figure 18, these punching press anchor clamps 46 constitute by the metal pattern 47 that stamped groove 48 is arranged with 1 kerf spacing assortment and with the press tool 49 of a kerf spacing assortment.And, the groove of the grooving 58a of the length of the groove of each stamped groove 48 and laminate core described later 58 is unanimous on the whole to length (axial length of stator core 11), and, by having with the 1st stamped groove 48a of the equal groove width in the line of conductor lines 39 footpath and in the 1st stamped groove 48a, forming continuously and the 2nd stamped groove 48b that compares the ditch width of the 1st stamped groove 48a constitutes.Again, the high length of groove of the length of depression bar 49a and stamped groove 48 is unanimous on the whole, and width is then unanimous on the whole with the groove width of stamped groove 48b.
Thus, push each right line part 56a plastic deformation on one side and push in the 2nd stamped groove 48b from the 1st stamped groove 48a on one side, until with the bottom butt of the 2nd stamped groove 48b.And each right line part 56a continues pushing by press tool 49, becomes the grooving incorporating section 42 with rectangle cross section shown in Figure 18 (b).Then, press tool 49 is extracted, the coil unit 56 of band shape is taken out from metal pattern 47, obtain coil block shown in Figure 19 57.
The structure of the coil block 57 of Zhi Zuoing is with 1 kerf spacing assortment a pair of grooving incorporating section 42 that overlaps on 96 pairs of directions (suitable with the width of coil block 57) with the drawing quadrature of Figure 19 to be arranged like this, and the grooving incorporating section 42 of Width one side of the grooving incorporating section 42 that each is right is connected by the grooving incorporating section 42 of linking part 41 with each the right grooving incorporating section 42 Width opposite side that separates 6 groovings.Promptly, as shown in figure 20, grooving incorporating section 42 is connected by linking part 41 carries out assortment in 6 kerf spacing modes, and, adjacent grooving incorporating section 42 intersects 2 piece conductor lines 40 that the shape that stagger forms mutually stagger 6 kerf spacings in the both sides of Width with width (W) part of conductor lines 40 by linking part 41, and the 42 coincidence assortments of grooving incorporating section are paired.And, the conductor lines 40 of this structure to becoming 6 pairs with 1 the kerf spacing assortment of staggering, constitute coil block 57.
Then, shown in Figure 21 (a), insulator 58 is installed on each grooving 58a of laminate core 58.This laminate core 58 is folded a plurality of magnetic steel flaggies and is formed the Nogata body, and forms 96 grooving 58a.And, shown in Figure 21 (b), 2 coil blocks 57 are overlapped and are installed on the laminate core 58 from grooving 58a.Thus, coil block 57 makes the length direction of square-section of 4 grooving receipts portions 42 consistent with the cutting groove depth direction, and is arranged into row and is accommodated in the grooving 58a on the cutting groove depth direction, is installed on the laminate core 58.
Then, shown in Figure 21 (c), laminate core 58 looped-shaped bendings of 2 coil blocks 57 are installed, the two ends of the laminate core 58 of looped-shaped bending are involutory, and involutory portion is carried out laser welding.The laminate core 58 that two ends are welded as a whole promptly becomes stator core.
Like this, adopt this example, because being connected by linking part 41, grooving incorporating section 42 carries out assortment in 6 kerf spacing modes, and, adjacent grooving incorporating section 42 intersects 2 piece conductor lines 40 that the shape that stagger form mutually stagger 6 kerf spacings in the both sides of Width with width (W) part of conductor lines 40 by linking part 41, with grooving incorporating section 42 overlap conductor lines 40 that assortments form to becoming 6 pairs with 1 the kerf spacing assortment of staggering, constitute coil block 57.Therefore, compare the joint operation that can obviously reduce by the 2nd end face side, improve the assembleability of stator with the above-mentioned example 1 of the conductor segment 15 of using U word shape.
Owing to use punching press anchor clamps 46,96 couple's of coil unit 56 line part 56a is carried out punching press together again,, make coil block 57, therefore all disposable plastic deformations of line part 56a are the rectangle cross section, and manufacturing time shortens in the manufacturing process that can simplify coil block 57.
Again because punching press is carried out by the line part 56a to circular cross-section in grooving incorporating section 42, form the rectangle cross section, therefore, the 41b of the diagonal portion height of the hardness ratio linking part 41 of grooving incorporating section 42, thus, as linking part 41 easy deformation of the 1st and the 2nd coil-end, even linking part 41 touches each other, also be not easy to damage insulating coating 14, improve insulating properties.
Because the stamped groove 48 of metal pattern 47 is made of groove width wide the 1st stamped groove 48a and the 2nd narrow stamped groove 48b of groove width, therefore, the line part 56a of coil unit 56 is easily mounted in the stamped groove 48, can improve stamping press again.Because line part 56a by depression bar 49a pushing plastic deformation, pushes in the 2nd stamped groove 48b from the 1st stamped groove 48a simultaneously, therefore, the line part 56a with circular cross-section can be deformed into the rectangle cross section simply again.At this moment, line part 56a extends to the stamped groove direction, and the insulating coating on 42 long limits, grooving incorporating section also extends attenuation.And connect airtight by insulator 13 and grooving 11a side wall surface on the long limit (par) of grooving incorporating section 42, so the heat that can effectively grooving incorporating section 42 be taken place is transmitted to stator core 11.The result is dispelled the heat from having big heat release area stator core 11 by the heat of grooving incorporating section 42 generations of stator coil 36.The temperature that can restrain stator 35 rises.
Example 8
Described example 7 is to carry out punching press by 46 pairs of 1 coil units 56 of punching press anchor clamps, but in this example 8, shown in Figure 22 (a) and (b), also can carry out punching press by 46 pairs of 2 coil units 56 of punching press anchor clamps.
Thus, adopt this example 8,, can reduce manufacturing process as long as carry out the punching press of 1 coil unit 56.
What described example 8 illustrated is to carry out punching press by 46 pairs of 2 winding wire coil units 56 of punching press anchor clamps, but does not limit 2 by coil unit 56 numbers of punching press anchor clamps 46 punching press together.For example, when the coil block 57 of package in stator core 11 is 3, also can carry out punching press by 46 pairs of 3 coil units 56 of punching press anchor clamps.
Example 9
Described example 7 is made coil block 57 by carried out punching press by 46 pairs of coil units of punching press anchor clamps 56.In this example 9, after making coil block 57, on the grooving incorporating section 42 that is deformed into the rectangle cross section of coil block 57, coat the 2nd insulating coating 14a again by drawing.
That is, shown in Figure 23 (a), the line part 56a with coil unit 56 that the conductor lines 39 of circular cross-section makes has circular cross-section.If carry out punching press by 46 pairs of these coil units 56 of punching press anchor clamps, then line part 56a is deformed into the rectangle cross section and becomes grooving incorporating section 42 shown in Figure 23 (b).Then, the 2nd insulating coating 14a is coated on the grooving incorporating section 42.Thus, grooving incorporating section 42 forms the double-layer structural of insulating coating 14 and the 2nd insulating coating 14a shown in Figure 23 (c).
In described example 7, when making coil block 57 by punching press anchor clamps 46, copper wires 60 plastic deformations of line part 56a, the insulating coating 14 that is coated on simultaneously on the long limit, rectangle cross section also extends the thickness attenuation.Thus, in the long limit and the bight of grooving incorporating section 42 breaking of insulating coating 14 can be taken place, become the reason of defective insulation.
Yet, adopt this example 9, after making coil block 57 by drawing, owing to coating the 2nd insulating coating 14a on the grooving incorporating section 42 in the rectangle cross section that is deformed into coil block 57, so the insulating coating that coats on the grooving incorporating section 42 becomes the double-layer structural of insulating coating 14 and the 2nd insulating coating 14a, with the obstruction of breaking that takes place on the insulating coating 14, can improve insulating properties by the 2nd insulating coating 14a.
The following describes the material of insulating coating 14.
The insulating coating 14 that coats copper wires 60 requires good adherence owing to implement drawing.For this reason, insulating coating 14 preferably uses the adherence fortified resin of polyester imine resin etc.
Owing on the 2nd insulating coating 14a, do not implement drawing, therefore, preferably use the heat-resistant resin of polyamide-imide resin etc. again.
In addition, even use and insulating coating 14 and the same resin of the 2nd insulating coating 14a, owing to adopted the double-layer structural of insulating coating, breaking on the insulating coating 14 that is caused by drawing stopped up by the 2nd insulating coating 14a, can obtain the effect that insulating properties improves.Again, if insulating coating 14 uses the adherence fortified resins, the 2nd insulating coating 14a uses heat-resistant resin, then is not easy to produce during drawing and breaks, and can restrain softening of the insulating coating that causes because of the heating of stator spiral, can further improve insulating properties.
Example 10
In this example 10, as shown in figure 24, coil block 57 coincidences are 3 layers and are wrapped in stator core 11.Promptly, the coil of each phase of stator coil forms the ripple web-like coil of 6 bendings.And in each grooving 11a, the length direction in 42 rectangle cross sections, 6 grooving incorporating sections is with radially consistent, and assortment becomes row.
Wherein, being positioned at, all side end faces of the grooving incorporating section 42a of perisphere form circular-arc, the outer circumference side edge face that is positioned at the grooving incorporating section 42b of outermost perisphere forms circular-arc, that is, being positioned at, grooving incorporating section 42a, the 42b of perisphere and outermost perisphere position form the shot shape.
Adopt this example 10, form the shot shape owing to be positioned at the grooving incorporating section 42b of outermost perisphere position, therefore, with coil block 57 from radially installed inside when the grooving 58a of laminate core 58 (grooving 11a) goes up, coil block 57 can be inserted smoothly.Again, the damage of the insulating coating 14 that the side wall surface friction because of the leading section of grooving incorporating section 42b and grooving 58a causes can be restrained, insulating properties can be improved.
Again, the grooving incorporating section 42a of perisphere position forms the shot shape owing to be positioned at, therefore, with laminate core 58 looped-shaped bendings the time, can restrain the touching of T-shaped 58b (11b) flange part 58c (11c) Yu the grooving incorporating section 42a of laminate core 58.Thus, the damage of the insulating coating 14 that the flange part 58c friction because of the leading section of grooving incorporating section 42a and grooving 58b causes can be restrained, insulating properties can be improved.
Wherein, as shown in figure 25, forming of grooving incorporating section 42a, 42b: can be after and become at bearing surface and to form by the pushing of depression bar 49a by stopping before smooth with the bottom of the 2nd stamped groove 48b of line part 56a with the bottom butt of a pair of line part 56a and the 2nd stamped groove 48b.
Again, grooving incorporating section 42a do not need with it whole in all side end faces form circular-arcly, and the radius of curvature of interior all side corner sections of grooving incorporating section 42a is got final product greater than the radius of curvature in outer circumferential side bight at least.Equally, grooving incorporating section 42b does not need to form circular-arcly with its whole outer circumference side edge face is all, and the radius of curvature in the outer circumferential side bight of grooving incorporating section 42b is got final product greater than the radius of curvature of interior all side corner sections at least.
In addition, described each example is that the connecting portion by having circular cross-section connects the grooving incorporating section, but the cross sectional shape of connecting portion do not limit, as long as the flat cross sectional shape of right and wrong.So-called non-flat cross sectional shape is meant the cross section that omnibearing diameter equates substantially, can be circular, square, the cross sectional shape of regular polygon etc.Again, rectangle, endless belt (レ-ス ト ラ Star Network) shape, shot shape prismatic shapes can be adopted so long as flat cross sectional shape gets final product in the grooving incorporating section.
Claims (15)
1. the stator of a vehicle-mounted dlternator has the stator core that forms a plurality of groovings and the conductor lines of coated insulation overlay film is wrapped in the stator coil that forms in the described grooving, it is characterized in that,
Described stator coil comprises: grooving incorporating section, n the 1st coil-end, n the 2nd coil-end,
In described a plurality of groovings, take in the described grooving of 2n root incorporating section respectively, wherein n is an integer, described grooving incorporating section forms the rectangle cross section respectively, and the tabular surface of described grooving incorporating section closely contacts with the side wall surface of this grooving, and the depth direction along grooving in each grooving is arranged into 1 row; Described n the 1st coil-end is each grooving centering of deciding the grooving number separating, axial the 1st end face side in described stator core, by the continuous conductor line of circular cross-section, the described grooving incorporating section that will be accommodated in two groovings on the cutting groove depth direction diverse location is connected in series; Described n the 2nd coil-end is each grooving centering of deciding the grooving number separating, and in the 2nd axial end face side of described stator core, the described grooving incorporating section that will be accommodated in two groovings on the cutting groove depth direction diverse location is connected in series,
Axial the 1st end face side in described stator core, to in described two groovings, be accommodated in n the 1st coil-end that the described grooving incorporating section on the cutting groove depth direction diverse location is connected in series and constitute the 1st coil-end group along circumferentially arranging with 1 kerf spacing, in axial the 2nd end face side of described stator core, will in described two groovings, be accommodated in n the 2nd coil-end that the described grooving incorporating section on the cutting groove depth direction diverse location is connected in series and constitute the 2nd coil-end group along circumferentially arranging with 1 kerf spacing.
2. the stator of vehicle-mounted dlternator as claimed in claim 1 is characterized in that, described the 2nd coil-end is formed by the continuous conductor line with circular cross-section.
3. the stator of vehicle-mounted dlternator as claimed in claim 1 or 2 is characterized in that, the end area of the described grooving of sectional area ratio incorporating section of coil-end with circular cross-section is big.
4. the stator of vehicle-mounted dlternator as claimed in claim 2, it is characterized in that, the cross sectional shape that is accommodated in the locational described grooving of the outermost radial outside incorporating section in the described grooving is that the angle radius of curvature of radial outside is bigger than the angle radius of curvature of radially inner side.
5. the stator of vehicle-mounted dlternator as claimed in claim 2, it is characterized in that, be accommodated in the angle radius of curvature cross sectional shape bigger that described grooving incorporating section on the radially inner side in the described grooving forms radially inner side than the angle radius of curvature of radial outside.
6. the stator of vehicle-mounted dlternator as claimed in claim 1 or 2 is characterized in that, the insulating coating of the described tabular surface that closely contacts with described groove side wall of described grooving incorporating section is thinner than the insulating coating of radial outside and inside line.
7. the stator of vehicle-mounted dlternator as claimed in claim 1 or 2 is characterized in that, described grooving incorporating section is overmolding to 2 layers with insulating coating.
8. the stator of vehicle-mounted dlternator as claimed in claim 7 is characterized in that, lower floor's insulating coating that described insulating coating is made up of the adherence fortified resin and be made of the upper strata insulating coating that heat-resistant resin is formed.
9. the stator of vehicle-mounted dlternator as claimed in claim 1 or 2, it is characterized in that, the described the 1st and the 2nd coil-end group's structure be, the the described the 1st and the 2nd coil-end axial relative with from the rising portions of grooving incorporating section and the described stator core between the top, and the diagonal portion that makes inclination carries out assortment along circumferential contact.
10. the stator of vehicle-mounted dlternator as claimed in claim 1 or 2, it is characterized in that described grooving incorporating section has than in the rising portions of the grooving incorporating section of the axioversion of the stator core on the coil-end that has circular cross-section relatively and the high hardness of diagonal portion between the top.
11. the stator of vehicle-mounted dlternator as claimed in claim 1 or 2 is characterized in that, the described stator coil lead-out wire that extends from the described the 1st and the 2nd coil-end group's a side has circular cross-section.
12. the manufacture method of the stator of a vehicle-mounted dlternator is characterized in that, comprising:
Make the operation of banded coil unit, the line part of this ribbon coil unit is by the connecting portion connection and with the assortment of decided kerf spacing, this adjacent line part forms the grooving incorporating section of internal layer of cutting groove depth direction and the state that staggers that outer field grooving incorporating section replaces owing to this connecting portion, with 2 conductor lines with circular section shape of coated insulation overlay film described kerf spacing of deciding that staggers mutually, and this line part being overlapped conductor lines that back assortment forms to staggering with 1 kerf spacing separately, with described decide the kerf spacing assortment identical several to after formation;
With the line part drawing of described coil unit is the rectangle cross sectional shape and the operation of making coil block;
The line part of described coil block is inserted from the grooving open side in the grooving of laminate core of Nogata body and this coil block is installed in operation on the laminate core;
To the described laminate core looped-shaped bending, the end face of this laminate core is involutory mutually of described coil block be installed, and this laminate core end face is welded incorporate operation.
13. the manufacture method of the stator of vehicle-mounted dlternator as claimed in claim 12 is characterized in that, in described coil block production process, with the overall drawing of all line parts of described coil block.
14. the manufacture method of the stator of vehicle-mounted dlternator as claimed in claim 12 is characterized in that, in described coil block production process, with the overall drawing of all line parts of a plurality of described coil blocks.
15. the manufacture method as the stator of each described vehicle-mounted dlternator in the claim 12 to 14 is characterized in that, the line part that has at described coil block applies the operation that forms the 2nd insulating coating.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB021475393A CN100440687C (en) | 2002-10-11 | 2002-10-11 | Stator of alternating-current generator for vehicle and manufacturing method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB021475393A CN100440687C (en) | 2002-10-11 | 2002-10-11 | Stator of alternating-current generator for vehicle and manufacturing method thereof |
Publications (2)
| Publication Number | Publication Date |
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| CN1489259A CN1489259A (en) | 2004-04-14 |
| CN100440687C true CN100440687C (en) | 2008-12-03 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNB021475393A Expired - Lifetime CN100440687C (en) | 2002-10-11 | 2002-10-11 | Stator of alternating-current generator for vehicle and manufacturing method thereof |
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| Country | Link |
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| CN (1) | CN100440687C (en) |
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| CN101330240B (en) * | 2007-06-19 | 2011-02-09 | 三菱电机株式会社 | AC generator for vehicle |
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| US6137201A (en) * | 1997-05-26 | 2000-10-24 | Denso Corporation | AC generator for vehicles |
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| CN106099596B (en) * | 2010-10-13 | 2019-10-18 | 贺利氏材料工艺有限责任两合公司 | The contact containing noble metal on the spring support of moment of flexure with rotational symmetry |
| CN101984543A (en) * | 2010-12-14 | 2011-03-09 | 南车株洲电机有限公司 | Insulating production process method of large alternating current machine stator core stretching screw |
| CN101984543B (en) * | 2010-12-14 | 2012-11-28 | 南车株洲电机有限公司 | Insulating production process method of large alternating current machine stator core stretching screw |
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