JP3736466B2 - Magnet generator - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a structure of a power generator coil of a magnet generator, particularly an inner type magnet generator (a magnet generator in which a rotor is disposed on the inside and a power generating coil is disposed on the outside).
[0002]
[Prior art]
2. Description of the Related Art A power generation coil that is formed in an annular shape by combining a plurality of power generation coil elements in the circumferential direction is known as a power generation coil of an inner type magnet generator. This type of power generation coil has a configuration in which a plurality of cores protrude inward from the inner peripheral surface of the annular yoke, and a winding is wound around each core via a bobbin for insulation.
[0003]
[Problems to be solved by the invention]
However, when a magnet generator is used in a vibrant environment such as a motorcycle, according to the conventional power generation coil, each power generation coil element has a cantilever structure as described above. The front end portion of the power generating coil element vibrates, and the coupling portion fixed at the outer peripheral portion is loosened, causing problems such as disconnection in the power generating coil.
[0004]
The present invention solves the above-mentioned problems of the prior art, and even when used in an environment with severe vibration, the generator coil element is kept fixed and does not loosen. The purpose is to provide.
[0005]
[Means for Solving the Problems]
According to the first aspect, each power generating coil element is fixed by the fixing portion at the outer peripheral portion of the power generating coil and is fixed by the spacer at the inner peripheral portion of the power generating coil. However, it is possible to suppress the vibration of the tip portion of the power generating coil element, and it is possible to prevent problems such as the disconnection and the disconnection of the coupling portion fixed at the outer peripheral portion. In addition, it is possible to provide an inexpensive spacer with a simple configuration.
[0007]
According to the second aspect of the present invention, since the power generating coil elements are coupled to each other in the circumferential direction, in the case of a fixing portion in which the central core is located on the outer circumferential core and is fixed by groove coupling in the conventional radial direction (Japanese Patent Laid-Open No. 2001). -11192)), the thickness in the radial direction needs to be increased in order to secure the strength. On the other hand, the thickness in the radial direction can be reduced, and the generator can be downsized.
[0008]
According to the third aspect , when the heated housing is cooled during shrink fitting, the outer peripheral surface of the power generating coil is pressurized by the contraction of the housing, and the power generating coil is firmly fixed.
[0009]
According to the fourth aspect of the present invention, when the heated housing cools during shrink fitting, a part of the housing bulges into the recess due to the shrinkage of the housing and solidifies, thereby further strengthening the rotation preventing function of the power generation coil. Can be demonstrated.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0011]
1 is a side sectional view of a state in which a magnet generator according to an embodiment is attached to a pedestal, FIG. 2 is a front view of the magnet generator, and FIG. 3 is a state in which a spacer is removed from the magnet generator. FIG. 4 is a developed view when the power generation coil is viewed from the shaft, FIG. 5 and FIG. 6 are main part front views showing modifications of the spacer receiving portion, and FIG. 7 is a spacer. FIG. 8 is an exploded view similar to FIG. 4 showing a main part front view showing a modified example of the receiving part and showing a relationship with the modified example of the spacer with respect to the spacer receiving part. FIG. Each figure is shown.
[0012]
1 to 4, reference numeral 100 denotes a magnet generator, and reference numeral 200 denotes a pedestal of the magnet generator 100. Magnet generator 100 has a shaft 1 connected to a crankshaft of an engine by a spline or the like. The shaft 1 is press-fitted and fixed to the rotor 2. The main body portion 21 of the rotor 2 includes an outer peripheral portion 22 formed of an arcuate part or an annular permanent magnet, and an inner peripheral portion 23 formed of an annular (small-diameter cylindrical) laminated core. Consists of Annular rotor-side spacers 24 are respectively disposed on the left and right ends of the main body 21. Both rotor-side spacers 24 are arranged with the end portion 25a of the magnet protection case 25 in a state where the end portion 25a of the magnet protection case 25 is arranged together with the main body portion 21 inside the magnet protection case 25 made of a thin cylindrical nonmagnetic material. It is integrated with the main body 21 by caulking inward. The shaft 1 is rotatably held by bearings 5 disposed on the pedestal 200 and the housing 4, respectively.
[0013]
On the outer peripheral surface of the rotor 2, that is, the outer peripheral surface of the magnet protection case 25, an annular (generally thick cylindrical) power generation coil 3 serving as a stator is disposed oppositely through a slight gap. As shown in FIG. 2, the power generating coil 3 includes a plurality (12 in this example) of power generating coil elements 31 combined in the circumferential direction. Each power generating coil element 31 includes a core (laminated core) 36 made of a magnetic material having an H-shaped cross section, for example, a steel material. The core 36 includes a shaft portion 36a whose axial direction coincides with the radial direction from the center portion of the shaft 1, an inner flange portion 36b extending in a right angle direction (circumferential direction) from the inner end portion of the shaft portion 36a, And an outer flange portion 36c extending in a right angle direction (circumferential direction) from the outer end portion of the portion 36a. A winding portion 37 configured by winding a winding around a bobbin for insulation from the core 36 is provided on the shaft portion 36a.
[0014]
The inner end surface of the inner flange portion 36b faces the outer peripheral surface of the rotor 2 with a slight gap. A side peripheral surface of the inner flange portion 36b, that is, a surface orthogonal to the axial direction of the shaft 1 is covered with an annular nonmagnetic portion 36i extending from the bobbin. A concave groove (spacer receiving portion) 36j as shown in FIG. 3 is formed in the left and right side portions of the non-magnetic portion 36i, that is, in a portion parallel to the axis of the shaft 1, as shown in FIG. A U-shaped wire (spacer) 5A made of a nonmagnetic material is press-fitted into a space formed between the concave grooves 36j of the adjacent power generating coil elements 31, and the inner peripheral portion of the power generating coil 3 is a spacer. It is firmly fixed by 5A. The shape of the groove 36j is not limited to the circular arc shape as shown in FIG. 3, but is V-shaped or U-shaped as shown in FIGS. May be. Furthermore, the left-right direction side part of the nonmagnetic part 36i may be comprised by the smooth surface (spacer receiving part) 36k which does not have the grooved groove 36j, as shown to FIG. 7 (A). However, in this case, as a spacer, a plate material 5B with a spring made of a non-magnetic material as shown in FIG. 7B is used, and the smooth surface 36k is pressed by the elastic force of the spring 5a, and each power generating coil element 31 is used. A compressive force is applied to the inner flange portion 36b of the power generating coil 3 so that the power generating coil 3 is firmly fixed at the inner peripheral portion. Although not shown, the spacer is composed of a linear ring and a plurality of rod-shaped portions extending in parallel in the same direction from the linear ring, and each rod-shaped portion is press-fitted into the spacer receiving portion 36k. You may make it use what was comprised.
[0015]
The outer flange portion 36c is longer than the inner flange portion 36b, and uneven portions 36d and 36e are formed at both ends thereof. Two adjacent power generating coil elements 31 are coupled by a core coupling portion 36f formed at the end of the outer flange portion 36c. In the core coupling portion 36f, the uneven portion 36d of the outer flange portion 36c of one power generating coil element 31 and the uneven portion 36e of the outer flange portion 36c of the other power generating coil element 31 are fitted to each other. Further, a concave portion 36g is formed on the outer peripheral surface of the core coupling portion 36f, that is, the surface facing the inner peripheral surface of the housing 4, and welding or the like is performed on the mating surfaces of the concave and convex portions 36d and 36e through the concave portion 36g. For example, the coupling strength between the concavo-convex portions 36d and 36e is increased, and the assembly property is improved because the coil element 31 is integrated when shrink fitting into the housing 4 (reference numerals in FIGS. 2 and 3). 36h represents a convex portion during welding). Reference numeral 38 denotes a part of the bobbin that partially covers the end portion of the outer flange portion 36c (end portion in the direction coinciding with the axial direction of the shaft 1).
[0016]
The power generating coil 3 as described above is fixed to the inner peripheral surface of a housing 4 made of a magnetic material such as steel. The inner peripheral surface of the housing 4 is in pressure contact with the outer flange portion 36c of each power generating coil element. Further, a part 41 of the inner peripheral surface of the housing 4 bulges into the concave portion 36g of the core coupling portion 36f, and further exerts the effect of preventing the power generating coil 3 from rotating.
[0017]
Next, in the process of manufacturing the magnet generator 100 configured as described above, a plurality of power generating coil elements 31 are assembled and fixed to the housing 4, and further, the method of fixing the power generating coil 3 at the inner peripheral portion in order. explain.
[0018]
First, the plurality of power generating coil elements 31 are combined and fixed in the circumferential direction. At this time, the two adjacent power generating coil elements 31 are coupled to each other by fitting the uneven portions 36d and 36e of the core coupling portion 36f to each other. Then, welding is performed on the mating surfaces of the concave and convex portions 36d and 36e through the concave portion 36g of the core coupling portion 36f as necessary. Next, the assembled power generation coil 3 is disposed inside the heated housing 4 and the housing 4 is cooled, so that the power generation coil 3 is shrink-fitted (hot-inserted) on the inner peripheral surface of the housing 4. During the shrink fitting, when the housing 4 thermally expanded by heating is cooled, the housing 4 contracts, so that the inner peripheral surface of the housing 4 is solidified in a state of being in pressure contact with the outer peripheral surface of the outer flange portion 36c of the power generating coil 3. As a result, the coupling strength of the power generating coil 3 is improved. Further, as shown in FIG. 3, a part 41 of the inner peripheral surface of the housing 4 partially swells and solidifies in the recess 36g of the core coupling portion 36f, thereby further exerting the detent action of the power generating coil 3. To do.
[0019]
Thereafter, the spacer 5A or 5B is press-fitted between the groove grooves 36j or the smooth surface 36k facing each other, and the power generating coil 3 is fixed at the inner peripheral portion.
[0020]
In the magnet generator 100 manufactured in this way, the power generating coil 3 is fixed at the outer peripheral portion by a fixing portion (such as the core coupling portion 36f) and the inner peripheral portion is fixed by the spacer 5A or 5B. For this reason, even if it is used in an environment subject to severe vibration, the vibration of each power generating coil element 31 can be prevented, so that each power generating coil element 31 vibrates and eliminates problems such as loosening of the core coupling portion and power generating coil disconnection. can do.
[0021]
Further, the adjacent power generating coil elements 31 are coupled by fitting the concave and convex portions 36d and 36e to each other at the core coupling portion 36f of the outer flange portion 36c of the core 36. That is, it fixes by connecting the core 36 of each power generating coil element 31 in the circumferential direction. For this reason, in the conventional technique (Japanese Patent Laid-Open No. 2001-112192) in which the central core and the outer peripheral core are fixed in the radial direction, it is necessary to set the thickness in the radial direction to be thick in order to increase the bonding strength. On the other hand, the thickness of the outer flange portion 36c can be set to a thin wall that can function as the magnetic path B1 as shown in FIG. Further, since the housing 4 is made of a magnetic material, the housing 4 also forms a magnetic path B2 as shown in FIG. 8, and the thickness is further reduced compared to the case where a nonmagnetic material is used for the housing 4. The magnet generator 100 can be downsized.
[0022]
【The invention's effect】
According to the magnet generator of the present invention, vibration of the power generation coil element can be prevented even under an environment subject to severe vibration, and problems such as loosening of the core coupling portion and disconnection of the power generation coil can be solved. In addition, the generator can be downsized.
[Brief description of the drawings]
FIG. 1 is a side sectional view of a state in which a magnet generator according to an embodiment of the present invention is attached to a pedestal.
FIG. 2 is a front view of the magnet generator.
FIG. 3 is a front view showing a part of the magnet generator with a spacer removed.
FIG. 4 is a development view when a power generation coil is viewed from a shaft as a viewpoint.
FIG. 5 is a front view of an essential part showing a modified example of a spacer receiving part.
FIG. 6 is a front view of an essential part showing another modification of the spacer receiving part.
7 is a front view of a main part showing still another modified example of the spacer receiving portion, and a developed view similar to FIG. 4 and showing a relationship between the spacer receiving portion and a modified example of the spacer. FIG. .
FIG. 8 is an explanatory diagram of a magnetic path of a power generation coil.
[Explanation of symbols]
100 Magnet generator 3 Generator coil 31 Generator coil element 36 Core 36d, 36e Uneven portion 36f Core coupling portion (fixed portion)
36g Concave part 36j Concave groove (spacer receiving part)
36k smooth surface (spacer receiving part)
4 Housing 5A U-shaped wire (spacer)
5B Plate with spring (spacer)

Claims (4)

A magnet generator including an annular power generation coil formed by combining a plurality of power generation coil elements in the circumferential direction, and a fixed portion for fixing each power generation coil element at the outer periphery of the power generation coil, and power generation for each power generation coil element A magnet power generation comprising a spacer that is fixed at an inner periphery of the coil , and the spacer is formed of a U -shaped wire that is press-fitted into a space formed between the concave grooves of adjacent power generation coil elements. Machine.   The fixing portion has a concavo-convex portion formed on a circumferential end surface of the core of each power generating coil element, and the power generating coil elements are fixed by fitting the concavo-convex portions between adjacent power generating coil elements to each other. The magnet generator according to claim 1, wherein:   The magnet generator according to claim 2, wherein the power generation coil is shrink-fitted on an inner peripheral surface of a housing made of a magnetic material.   The magnet generator according to claim 3, wherein a concave portion is formed on a surface of the core facing the inner peripheral surface of the housing.

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