Patent Application
20190334421
This application claims the benefit of Japanese Patent Application No. 2018-087329, filed Apr. 27, 2018.
The present invention relates to a brushless winding field rotational electric machine disposed on an outer periphery of a rotation member.
Patent Document 1 discloses a rotational electric machine in which magnetic flux is supplied from a field coil at rest to a rotor.
In the rotational electric machine described above, the field coil has a substantially rectangular sectional shape, which limits the freedom of designing, and thus it may be difficult to have a necessary winding cross-sectional area.
It is an object of the present invention to provide a rotational electric machine that can improve use efficiency of a space in which a field coil is disposed and increase the freedom of designing.
To achieve the object, the present invention is configured as described below.
According to a first aspect of the present invention, a brushless winding field rotational electric machine positioned between a rotation member and a case enclosing the rotation member includes: a stator, which is held to the case, including an alternating-current coil configured to generate a rotation magnetic field by alternating current; a field core, which is held to the case, including a field coil to be excited by direct current; and a rotor disposed on an outer periphery of the rotation member and rotatably held about a rotational axis relative to the stator and the field coil. The field coil includes a plurality of coil winding layers stacked in a radial direction of the rotational axis. A cross-sectional area along an axial direction of the rotational axis, of a coil winding layer closest to the rotational axis in the radial direction of the rotational axis among the plurality of coil winding layers is smaller than a cross-sectional area along the axial direction of the rotational axis, of a coil winding layer farthest from the rotational axis in the radial direction of the rotational axis.
According to a second aspect of the present invention, a brushless winding field rotational electric machine positioned between a case enclosing a rotation member and the rotation member includes: a stator, which is held to the case, including an alternating-current coil configured to generate a rotation magnetic field by alternating current; a field core, which is held to the case, including a field coil to be excited by direct current; and a rotor disposed on an outer periphery of the rotation member and rotatably held about a rotational axis relative to the stator and the field coil. The field coil includes a plurality of coil winding layers stacked in a radial direction of the rotational axis. The plurality of coil winding layers include: a first coil winding layer; and a second coil winding layer adjacent to the first coil winding layer in the radial direction of the rotational axis and having a dimension different from a dimension of the first coil winding layer in an axial direction of the rotational axis.
According to the first aspect of the present invention, the field coil includes the plurality of coil winding layers stacked in the radial direction, and the cross-sectional area of the coil winding layer closest to the rotational axis in the radial direction among the plurality of coil winding layers, along the axial direction of the rotational axis is smaller than the cross-sectional area of the coil winding layer farthest from the rotational axis in the radial direction, along the axial direction of the rotational axis. According to the second aspect of the present invention, the field coil includes the plurality of coil winding layers stacked in the radial direction, and the plurality of coil winding layers include: the first coil winding layer; and the second coil winding layer adjacent to the first coil winding layer in the radial direction and having a dimension different from the dimension of the first coil winding layer in the axial direction of the rotational axis. With such configurations, the sectional shape of the field coil along the axial direction of the rotational axis can be, for example, a substantially L shape or a stepped shape in accordance with a space in which the field coil is disposed, and thus the use efficiency of the space in which the field coil is disposed can be improved to increase the freedom of designing.
An embodiment of the present invention will be described below in detail with reference to the accompanying drawings.
As illustrated in
The stator 3 has a cylindrical member non-rotatably fixed and held to the case 5 and including a plurality of slots for winding an alternating-current coil 14. The stator includes the alternating-current coil 14 and generates a rotation magnetic field by alternating current flowing through the alternating-current coil 14.
The field coil 2 is shifted relative to the stator 3 and the rotor 1 in the rotational axis 7, and fixed and held to the case 5 on the transmission 9 side of the stator 3. When the field coil 2 is excited by direct current, magnetic flux (illustrated with an arrow in
Specifically, as illustrated in
In other words, the plurality of coil winding layers 201 to 204 include the first coil winding layer 202, and the second coil winding layer 203 adjacent to the first coil winding layer 202 in the radial direction of the rotational axis 7 and having a dimension different from that of the first coil winding layer 202 in the axial direction of the rotational axis 7.
In the field coil 2, wire winding starts at one end (edge farther from the rotor 1, indicated by S in
The field coil 2 is formed of a winding wire having a substantially rectangular section, but the present invention is not limited thereto. The field coil 2 may be formed of, for example, a winding wire having a substantially circular or substantially square section in accordance with designing of the rotational electric machine 10, for example.
As illustrated in
The rotor 1 is fixed to the outer periphery of the starting device 4. The outer peripheral surface of the rotor 1 faces the inner peripheral surface of the stator 3 and an end face of the rotor 1 on the transmission side faces an end face of the field coil 2 on the engine side. The rotor 1 is held rotatably relative to the stator 3 and the field coil 2 about the rotational axis 7
A first air gap 11 is formed between the stator 3 and the rotor 1 so that magnetic flux is transferred between the stator 3 and the rotor 1. The first air gap 11 extends in the axial direction of the rotational axis 7 between the inner peripheral surface of the stator 3 and the outer peripheral surface of the rotor 1.
The second air gap 12 is formed between the field core 6 and the rotor 1 so that magnetic flux is transferred between the field coil 2 and the rotor 1. The second air gap 12 extends in the radial direction orthogonal to the axial direction of the rotational axis 7 between the end face of the rotor 1 on the transmission side in the axial direction of the rotational axis 7 and an end face of the field core 6 on the engine side.
Accordingly, the field coil 2 is shifted in parallel relative to the rotor 1 in the axial direction of the rotational axis 7 through the second air gap 12.
As illustrated in
The first magnetic pole 21 is made of a soft magnetic body such as iron, and includes a plurality of pawl portions 21b each having, for example, a rectangular thin plate shape and protruding from a first circular ring portion 21a in the axial direction of the rotational axis 7. The pawl portions 21b are disposed at constant intervals, for example, at equal intervals in the circumferential direction, and have equal lengths in the axial direction of the rotational axis 7. The outer peripheral surface of each pawl portion 21b is disposed along the outer peripheral surface of the first circular ring portion 21a. The pawl portion 21b does not contact the second magnetic pole 22 even when the first magnetic pole 21 and the second magnetic pole 22 are combined with each other, and a radial direction gap 16 is formed in the radial direction of the rotational axis 7.
The second magnetic pole 22 is made of a soft magnetic body such as iron and disposed on an inner side of the first magnetic pole (in the present embodiment, the first circular ring portion 21a) through the radial direction gap 16 in a radial direction of the rotational axis 7. The second magnetic pole 22 includes a second circular ring portion 22a disposed partially overlapping the first magnetic pole (in the present embodiment, the first circular ring portion 21a) and a plurality of convex portions 22b. Each of the plurality of convex portions 22b, which has a rectangular plate shape for example, protrudes from an outer peripheral surface of the second circular ring portion 22a in the radial direction of the rotational axis 7 and has a circumferential direction gap 17 in a circumferential direction of the rotational axis 7. The convex portions 22b are disposed at constant intervals, for example, at equal intervals in the circumferential direction, and have equal heights in the radial direction of the rotational axis 7. The convex portions 22b have equal lengths in the axial direction of the rotational axis 7 and are shorter than the pawl portions 21b. The outer peripheral surface of each convex portion 22b is disposed on one circle having a center at the rotational axis of the rotor 1. Each convex portion 22b extends to an end edge of the second circular ring portion 22a on the engine side to form a first leading end lock portion 22c, but does not extend to an end edge of the second circular ring portion 22a on the transmission side to form a circular ring fitting portion 22d having a small width with no convex portion 22b. The first magnetic pole 21 is moved relative to the second magnetic pole 22 in the axial direction of the rotational axis 7 to insert each pawl portion 21b of the first magnetic pole 21 into a middle part of the circumferential direction gap 17 between the convex portions 22b adjacent thereto so that the pawl portions 21b and the convex portions 22b are alternately arranged in the circumferential direction of the rotational axis 7. In this case, the first circular ring portion 21a of the first magnetic pole 21 can be disposed on the outside of the fitting portion 22d with the radial direction gap 16 interposed therebetween. In the assembled state as illustrated in
The magnetic pole holder 23 is a circular ring member made of a non-magnetic body such as aluminum or austenitic stainless steel. The magnetic pole holder 23 includes, for example, on the outer periphery side, an engagement portion 23a that engages and fixes a first leading end lock portion 21c of each pawl portion 21b of the first magnetic pole 21 and engages and fixes a second leading end lock portion 22c of each convex portion 22b of the second magnetic pole 22. The first leading end lock portion 21c and the second leading end lock portion 22c are engaged with the engagement portion 23a and fixed by bolting, shrink fitting, or brazing. Accordingly, the first magnetic pole 21 and the second magnetic pole 22 are fixed and held to each other in a non-contact manner by the magnetic pole holder 23.
As a specific example, the first leading end lock portions 21c of the pawl portions 21b of the first magnetic pole 21 and the second leading end lock portions 22c of the convex portions 22b of the second magnetic pole 22 are formed as stepped portions, and fixedly held in the radial direction of the rotational axis 7 when the stepped portions are each engaged with an engagement recess of the engagement portion 23a. As an example, the second leading end lock portions 22c are disposed at the leading ends of the convex portions 22b, but may be disposed at the leading end of the second circular ring portion 22a. With this configuration, when the first magnetic pole 21 and the second magnetic pole 22 are magnetized as magnetic flux flows from the field coil 2, the magnetic pole holder 23 as a non-magnetic body can eliminate magnetic short circuit to efficiently perform the magnetization and can mechanically hold the first magnetic pole 21 and the second magnetic pole 22. In addition, since the first leading end lock portions 21c of the pawl portions 21b of the first magnetic pole 21 are engaged and fixed by the engagement portion 23a of the magnetic pole holder 23, expansion of the pawl portions 21b due to rotational centrifugal force can be prevented to improve rotational strength.
In the rotational electric machine 10 configured as described above, field coil magnetic flux 15 occurs when the field coil 2 is energized. The field coil magnetic flux 15 starts from the field core 6 and returns to the field core 6 through a second air gap 212, the first magnetic pole 21 of the rotor 1, the first air gap 11, the stator 3, the first air gap 11, the second magnetic pole 22 of the rotor 1, and the second air gap 212. In this case, for example, when the field coil 2 is energized with direct current, the field coil magnetic flux 15 is generated and the first magnetic pole 21 and the second magnetic pole 22 are magnetized, for example, as a north pole and a south pole, respectively.
The following describes a case in which the rotational electric machine 10 as a starter executes a start function in such a rotational electric machine 10. An inverter (not illustrated) is driven based on a start command of the engine 8 to cause three-phase alternating current to flow through the stator 3 and magnetize the stator 3, and cause current to flow through the field coil 2. Current is caused to flow through the field coil 2, thereby exciting the first magnetic pole 21 and the second magnetic pole 22 of the rotor 1. As a result, the rotor 1 starts rotation relative to the stator 3, and electromotive force having induction voltage is generated at the stator 3.
Thereafter, when the induction voltage increases in accordance with the rotational speed of the rotor 1 and the rotational speed reaches an initial explosion rotational speed lower than an idling rotational speed corresponding to idling of the engine 8, which completes start of the engine 8, the drive of the inverter is stopped. Since then, transition is automatically made to a power generation mode in which the rotational electric machine 10 executes an electric generation function as an electric generator to hold predetermined induction voltage (request voltage).
In the power generation mode, the excitation current is adjusted so that the induction voltage is constant at the predetermined induction voltage to continuously excite the field coil 2. The excitation current is adjusted so that the magnetization force of the rotor decreases as the rotational speed increases and the induction voltage is kept constant. When the field coil 2 is not excited, the advance of the three-phase alternating current is adjusted by the inverter so that the induction voltage is constant at the predetermined induction voltage. Further, the above-described two methods may be combined to achieve the adjustment. With this control, the rotational electric machine 10 functions as an electric generator when the rotor 1 rotates.
As a result, when connected to the engine 8, the rotational electric machine 10 can start the engine and function as a generator (electric generator) in traveling.
In the rotational electric machine 10, the field coil 2 includes the plurality of coil winding layers 201 to 204 stacked in the radial direction of the rotational axis 7. The cross-sectional area along the axial direction of the rotational axis 7, of the coil winding layer 204 closest to the rotational axis 7 in the radial direction of the rotational axis 7 among the plurality of coil winding layers 201 to 204 is smaller than the cross-sectional area along the axial direction of the rotational axis 7, of the coil winding layer 201 farthest from the rotational axis 7 in the radial direction of the rotational axis 7. In other words, the field coil 2 includes the plurality of coil winding layers 201 to 204 stacked in the radial direction of the rotational axis 7. The plurality of coil winding layers 201 to 204 include the first coil winding layer 202, and the second coil winding layer 203 adjacent to the first coil winding layer 202 in the radial direction of the rotational axis 7 and having a dimension different from that of the first coil winding layer 202 in the axial direction of the rotational axis 7. With this configuration, the sectional shape of the field coil 2 along the axial direction of the rotational axis 7 can be, for example, a substantially L shape in accordance with a space in which the field coil 2 is disposed, and thus the use efficiency of the space in which the field coil 2 is disposed can be improved to increase the freedom of designing.
The magnetic path 40 includes a first magnetic path 41 extending in the axial direction of the rotational axis 7 so that magnetic flux flows from the rotor 1 toward the field core 6, and a second magnetic path 42 extending in the axial direction of the rotational axis 7 and disposed with the gap 43 from the first magnetic path 41 in the radial direction so that magnetic flux flows from the field core 6 toward the rotor 1. The field coil 2 is disposed from a first end portion 43a of the gap 43 closer to the rotor 1 to a second end portion 43b farther from the rotor 1 in the axial direction of the rotational axis 7. With such a configuration in which the field core 6 is longer in the axial direction than in the radial direction, magnetic short circuit (in other words, magnetic flux leakage) in the magnetic path 40 of the field core 6 can be reduced.
In the field coil 2, wire winding starts at one end of a coil winding layer 204 closest to the rotational axis 7 among the plurality of coil winding layers 201 to 204 in the axial direction of the rotational axis 7, and ends at one end of a coil winding layer 201 farthest from the rotational axis 7 among the plurality of coil winding layers 201 to 204 in the axial direction of the rotational axis 7. With this configuration, it is possible to easily obtain the field coil 2 having a sectional shape along the axial direction of the rotational axis 7 in accordance with a space in which the field coil 2 is disposed.
As illustrated in
As illustrated in
Any embodiments or modifications among various embodiments or modifications described above may be combined with each other as appropriate to achieve effects of each embodiment or modification. It is possible to combine embodiments, examples, or an embodiment and an example, and it is also possible to combine features in different embodiments or examples.
A rotational electric machine according to the aspect of the present invention is applicable to, for example, a vehicle or a power generation device.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2018-087329 | Apr 2018 | JP | national |
