Abstract:
A vehicle AC generator includes a stator having stator windings; front frame and rear frame, each rotatably supporting a rotor; a cooling fan fitted to the rotor; first polarity arm and second polarity arm configured to rectify currents of one polarity and another polarity, respectively; a rectifier device configured to rectify an alternating current generated in the stator windings; and a protective cover covering the rectifier device. The rectifier device includes a first heat dissipating plate having rectifier elements forming the first polarity arm, a second heat dissipating plate rectifier elements forming the second polarity arm, and a connection plate formed in waveform-like shape and disposed between the first and second heat dissipating plates, and a passage of a cooling air blown by the cooling fan formed between the first and second heat dissipating plates and between the second heat dissipating plate and the connection plate.

Description:
TECHNICAL FIELD 
     The present invention relates to a vehicle AC generator. 
     BACKGROUND ART 
     In recent years, there is a tendency that output of the vehicle AC generator is becoming higher due to increased demands of electronic devices in a vehicle. A high output of the vehicle AC generator increases an output current and thereby increases the amount of heat of components thereof, which results in reducing a quality service life due to a temperature rise. 
     In particular, a rectifier element rectifying an alternating current generated by the vehicle AC generator is significantly affected by the temperature due to heating, and when the temperature becomes higher than a heat resistance temperature, the service life thereof is reduced sharply. 
     Further, in recent years, ambient temperature around a vehicle AC generator mounted in a vehicle tends to increase due to the space saving of the engine room. Consequently, increase in the amount of heat and the temperature reduction by improving the cooling performance of the rectifier element has become important problems. 
     Under such circumstances, Patent Literature 1 proposes a method for improving the cooling efficiency of the rectifier device, which efficiently takes in and flows an external cooling air into a space between positive rectifier elements (positive arm) and a protective cover and into a space between a rear frame and a second heat dissipating plate of negative rectifier elements (negative arm) to increase the cooling efficiency of heat dissipating plates and thereby reduce temperature of rectifier elements. 
     CITATION LIST 
     Patent Literature 
     
         
         Patent Literature 1: Japanese Unexamined Patent Application Publication No. 11-164538 
       
    
     SUMMARY OF INVENTION 
     Technical Problem 
     In recent years, however, there is a tendency that power demands from the vehicle side are increasing steadily. Due to a significant increase of electric power generated by the vehicle AC generator, the rectifier device cooling method according to Patent Literature 1 has problems in that a heat dissipating area of heat dissipating plates can not be secured due to a limited space, the cooling capacity of heat dissipating plates has reached a saturated state, and temperature of rectifier elements subjected to a high output becomes higher than a heat resistance temperature, which results in sharp reduction of the service life thereof. 
     It is an object of the present invention to provide a vehicle AC generator capable of achieving a high quality and a high output by improving the cooling efficiency of heat dissipating plates of a rectifier device. 
     Solution to Problem 
     In order to solve the foregoing problems, the present invention adopts the means described below. 
     A vehicle AC generator according to an aspect of the present invention comprises a stator comprising stator windings, a front frame and a rear frame, each of which rotatably supports a rotor in the stator facing thereto via a space on the inner circumference of the stator, a cooling fan fitted to the rotor, a first polarity arm configured to rectify a current of one polarity, a second polarity arm configured to rectify a current of another polarity, a rectifier device configured to rectify an alternating current generated in the stator windings, and a protective cover which covers the rectifier device, wherein the rectifier device comprises a first heat dissipating plate having a plurality of rectifier elements forming the first polarity arm, a second heat dissipating plate having a plurality of rectifier elements forming the second polarity arm, and a connection plate in a waveform-like shape disposed between the first heat dissipating plate and the second heat dissipating plate, and passages of cooling air taken in by the cooling fan are provided between the first heat dissipating plate and the connection plate, and between the second heat dissipating plate and the connection plate. 
     Advantageous Effects of Invention 
     According to an aspect of the present invention, a passage of the cooling air formed between the first and second heat dissipating plates forming the rectifier device of the AC generator can be distributed in a balanced manner to the first heat dissipating plate side and the second heat dissipating plate. With this configuration, a vehicle AC generator with a rectifier device capable of improving the cooling performance of rectifier elements can be provided. 
     Other objects, features and advantages of the present invention will be more apparent on consideration of the following description of embodiments thereof with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a cross sectional view showing an overall configuration of a vehicle AC generator according to a first embodiment of the present invention. 
         FIG. 2  is a rear-side perspective view of the vehicle AC generator with a protective cover removed, according to the first embodiment of the present invention. 
         FIG. 3  is a perspective view of a rectifier according to the first embodiment of the present invention. 
         FIG. 4  is an exploded view of the rectifier according to the first embodiment of the present invention. 
         FIG. 5  is a rear-side front view of the rectifier according to the first embodiment of the present invention. 
         FIG. 6  is a cross sectional view taken from line A-A of  FIG. 5 . 
         FIG. 7  is a cross sectional view taken from line B-B of  FIG. 6 . 
         FIG. 8  is a cross sectional view taken from line C-C of  FIG. 6 . 
         FIG. 9  is a rear-side front view of a rectifier according to a second embodiment of the present invention. 
         FIG. 10  is a cross sectional view taken from line E-E of  FIG. 9 . 
         FIG. 11  is a rear-side front view of a rectifier according to a third embodiment of the present invention. 
         FIG. 12  is a cross sectional view taken from line O-F of  FIG. 11 . 
         FIG. 13  is a cross sectional view taken from line O-G of  FIG. 11 . 
         FIG. 14  is a rear-side front view of a vehicle AC generator with a protective cover removed, according to a fourth embodiment of the present invention. 
         FIG. 15  is a cross sectional view taken from line J-J of  FIG. 14 . 
         FIG. 16  is a cross sectional view taken from line K-K of  FIG. 14 . 
         FIG. 17  is a cross sectional view taken from line L-L of  FIG. 14 . 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Hereinafter, embodiments are described with reference to the accompanying drawings. 
     [First Embodiment] 
     The configuration of a vehicle AC generator according to a first embodiment of the present invention is described with reference to  FIG. 1  and  FIG. 2 . 
       FIG. 1  is a cross sectional view showing an overall configuration of the vehicle AC generator according to the first embodiment of the present invention, and  FIG. 2  is a rear-side perspective view of the vehicle AC generator with a protective cover removed. 
     The vehicle AC generator  31  comprises a rotor  4  and a stator  5 . The rotor  4  comprises a shaft  2  at the center thereof, a front-side nail-shaped magnetic pole  9  and a rear-side nail-shaped magnetic pole  10 . Each of the nail-shaped magnetic poles are formed with a magnetic material and disposed on each side of the shaft  2  so as to cover field windings  11  by sandwiching from both sides. Further, the front nail-shaped magnetic pole  9  and the rear nail-shaped magnetic pole  10  are disposed in such a manner that nail-shaped portions thereof face to each other, and one nail-shaped magnetic pole engages with another corresponding nail-shaped magnetic pole. 
     The rotor  4  is disposed on the inner peripheral side of the stator  5  by facing each other via a small space. The shaft  2  of the rotor  4  is inserted through an inner ring of a front bearing  3  and a rear bearing  8  and supported therein in a rotatable manner. 
     The stator  5  comprises a stator iron core  6  and stator windings  7 . The stator iron core  6  comprises a plurality of laminated thin steel sheets formed in an annular shape, and projected teeth on the inner peripheral side thereof, with a slot formed between respective teeth. Stator windings  7  of respective phases are fitted by inserting into corresponding slots across multiple teeth, and both ends of the stator  5  are held by a front frame  16  and a rear frame  17 . 
     A pulley  1  is fitted to one end portion of the shaft  2 . A slip ring  12  is provided at the other end portion of the shaft  2  and is in contact with a brush  13  to supply electric power to field windings  11 . Further, a front fan  14  and a rear fan  15  are provided on both end faces of the front nail-shaped magnetic pole  9  and the rear nail-shaped magnetic pole  10  in the rotor  4 . The front fan  14  and the rear fan  15  are cooling fans having a plurality of vanes on the outer peripheral side thereof, and are configured to distribute air by a centrifugal force caused by rotation thereof to intake external air and discharge air used to cool down internal components, to the outside. 
     A front-side cooling air  26  enters through an air window of the front frame  16 , passes through the front fan  14  and is discharged through the air window of the front frame  16  while being blown to coil ends of the stator windings  7 . A rear-side cooling air  27  enters through openings of a protective cover  25 , passes through a rectifier device  18  and an IC regulator  30 , passes through a rear fan  15  through an air window provided at a center portion of the rear frame, and is discharged through the air window of the rear frame  17  while being blown to coil ends of the stator windings  7 . 
     According to the present embodiment, the stator windings  7  comprise two pairs of three-phase windings, and a lead wire of each winding is connected to the rectifier device  18 . The rectifier device  18  comprises rectifier elements such as diodes and forms a full-wave rectifying circuit. For example, in the case of the diode, a cathode terminal is connected to a rectifier element connection plate  19 . An anode terminal is electrically connected to a main body of the vehicle AC generator. The protective cover  25  serves to protect the rectifier device  18 . 
     Next, power generating operation is described. 
     First, as the engine starts, rotation is transmitted from a crank shaft to a pulley  1  via a belt, and the rotor  4  is rotated via the shaft  2 . Here, when DC current is supplied from a brush  13  to field windings  11  provided on the rotor  4  via a slip ring  12 , a magnetic flux circling around inner and outer circumference of the field windings  11  occurs and thereby N-pole and S-pole are formed alternately in the circumferential direction on the front nail-shaped magnetic pole  9  and the rear nail-shaped magnetic pole  10  in the rotor  4 . The magnetic flux generated by the field windings  11  passes the stator iron core  6  through an N-pole of the front nail-shaped magnetic pole  9 , circles around the stator windings  7 , and reaches an S-pole of the rear nail-shaped magnetic pole  10  in the rotor, whereby a magnetic circuit circling the rotor  4  and the stator  5  is formed. The magnetic flux thus generated on the rotor interlinks with the stator windings  7  and generates an alternating voltage on each of U-phase, V-phase and W-phase stator windings  7 , or a three-phase alternating voltage as a whole. 
     The alternating voltage thus generated is subjected to a full-wave rectification by the rectifier device  18  comprising rectifier elements such as diodes, and is converted to a DC voltage. The rectified DC voltage is regulated to a constant voltage by the IC regulator  30  which controls a current supplied to the field windings  11 . 
     Next, the configuration of the rectifier device of the vehicle AC generator according to the present embodiment is described with reference to  FIG. 2  to  FIG. 8 . 
       FIG. 3  is a perspective view of the rectifier device according to the first embodiment of the present invention.  FIG. 4  is an exploded view of the rectifier device according to the first embodiment of the present invention.  FIG. 5  is a rear-side front view of the rectifier according to the first embodiment of the present invention.  FIG. 6  is a cross sectional view taken from line A-A of  FIG. 5 .  FIG. 7  is a cross sectional view taken from line B-B of  FIG. 6 .  FIG. 8  is a cross sectional view taken from line C-C of  FIG. 6 . 
     As shown in  FIG. 3  and  FIG. 4 , the rectifier device  18  of the vehicle AC generator  31  comprises a first heat dissipating plate  20  and a second heat dissipating plate  21 , which are disposed opposite to each other. The first heat dissipating plate  20  comprises six positive rectifier elements  22  (positive arm), and the second heat dissipating plate  21  comprises six negative rectifier elements  23  (negative arm). 
     A rectifier element connection plate (connection terminal plate)  19  forming a full-wave rectifying circuit by connecting rectifier elements is provided between the first heat dissipating plate  20  and the second heat dissipating plate  21 . The terminal plate also serves to keep a predetermined electrical insulation distance between the first heat dissipating plate  20  and the second heat dissipating plate  21 . 
     The rectifier element connection plate  19  comprises an insulating material portion  19   a  of resin mold and a terminal  19   b  made of iron or copper by insert molding, and forms a rectifier circuit by connecting the respective rectifier elements. The vehicle AC generator  31  functions when the stator windings  7  and the IC regulator  30  are connected to each other. 
     The rectifier device  18  is mounted in the rear frame  17  as shown in  FIG. 2 . The second heat dissipating plate  21  of the rectifier device  18  is in direct contact with the rear frame  17  and configured to transmit the amount of heat generated by negative rectifier elements  23  to the second heat dissipating plate  21  and release heat directly to the rear frame  17  to secure a heat dissipating area and thereby improve the cooling performance. 
     On the side of the first heat dissipating plate  20 , a plurality of cooling fans are provided on an inner circumference of the protective cover to expand the heat dissipating area by efficiently utilizing a space within the protective cover  25 , and a cooling air flowing from the outside is blown thereto to cool down positive rectifier elements. 
     In particular, speed of the cooling air passing in the rotating axis direction becomes fast in cooling fins on the inner circumference, so that cooling effects can be drastically improved by providing a lot of cooling fins thereat. 
     As described above, however, increase of power demands from the vehicle side in recent years significantly increases an output current of the vehicle AC generator which generates high output. 
     To solve the problem, an aspect of the present invention improves the cooling performance of the rectifier device  20  by efficiently utilizing a cooling air passing between the first heat dissipating plate  20  and the second heat dissipating plate  21 . 
     A specific embodiment is described with reference to  FIG. 5  to  FIG. 8 . 
     The cooling air flows at a relatively high speed between the first heat dissipating plate  20  and the second heat dissipating plate  21 , so that heat transfer efficiency of nearby heat dissipating plates is high and effective in cooling the rectifier elements. 
     According to a conventional configuration, the rectifier element connection plate  19  between the first heat dissipating plate  20  and the second heat dissipating plate  21  is configured to be in contact with the second heat dissipating plate  21 . This configuration lowers heat transfer efficiency of the rectifier element connection plate  19  disposed between the first heat dissipating plate  20  and the second heat dissipating plate  21 , and consequently lowers cooling performance. The first heat dissipating plate  20  is provided partially with multiple spaces formed in a recessed shape through which a cooling air passes, which improve heat transfer efficiency of the first heat dissipating plate  20  and thereby contribute to temperature reduction of positive rectifier elements  22 . 
     According to an aspect of the present invention, cooling performance of the second heat dissipating plate  21  is improved without impairing cooling performance of the first heat dissipating plate  20 . 
       FIG. 5  is a rear-side front view of the rectifier device according to the present embodiment, and  FIG. 6  is a cross sectional view taken from line A-A of  FIG. 5 . 
     As shown in  FIG. 6 , according to an aspect of the present invention, one side of the rectifier element connection plate  19  is in contact with the first heat dissipating plate  20 , and the other side thereof faces a space  29  formed apart from the second rectifier element connection plate  21 . Further, one side thereof faces a space  28  formed apart from the first heat dissipating plate  20 , and the other side is in contact with the second heat dissipating plate  21 . That is, the rectifier element connection plate  19  is formed in a waveform-like shape. 
     For this reason, as shown in  FIG. 7  which is a cross sectional view taken from line B-B of  FIG. 6 , a cooling air  27   a  passes through the space  28  between the first heat dissipating plate  20  and the rectifier element connection plate  19  in a same manner as the conventional configuration. Consequently, heat transfer efficiency of the first heat dissipating plate  20  is not impaired, and temperature of positive rectifier elements remains same as the conventional configuration. 
     Further, as shown in  FIG. 8  which is a cross sectional view taken from line C-C of  FIG. 6 , a cooling air  27   b  passes through the space  29  between the second heat dissipating plate  21  and the rectifier element connection plate  19 , so that cooling performance of the second heat dissipating plate  21  is improved and thereby temperature of negative rectifier elements  23  is reduced. 
     In such a manner, by forming the rectifier element connection plate  19  (terminal plate) in a waveform-like shape, a cooling air passing through between the first heat dissipating plate  20  and the second heat dissipating plate  21  can be distributed in a balanced manner to sides of the first heat dissipating plate  20  and the second heat dissipating plate  21 , so that temperature of negative rectifier elements  23  can be reduced without pairing cooling performance of positive rectifier elements  22 . 
     Further, to make temperature of positive rectifier elements  22  and temperature of negative rectifier elements  23  equal to each other, a space width W 1  and a space height h 1  on the side of the first heat dissipating plate, and a space width W 2  and a space height h 2  on the side of the second heat dissipating plate may be adjusted as shown in  FIG. 6 . According to the present embodiment, the space height h 1  on the side of the first heat dissipating plate and the space height h 2  on the side of the second heat dissipating plate are equal to each other, while the space width W 1  on the side of the first heat dissipating plate and the space width W 2  on the side of the second heat dissipating plate are adjusted to keep a balance between temperature of positive rectifier elements and temperature of negative rectifier elements. In the case of the example shown in  FIG. 6 , the space width W 2  on the side of the second heat dissipating plate is 1.1 to 1.3 times the space width W 1  on the side of the first heat dissipating plate. It is preferable that space widths W 1 , W 2  are 4.5 mm or wider, and space heights h 1 , h 2  are 3.2 mm or higher. 
     [Second Embodiment] 
     Next, a second embodiment is described based on  FIG. 9  and  FIG. 10 . 
       FIG. 9  is a rear-side front view of a rectifier according to the second embodiment. 
       FIG. 10  is a cross sectional view taken from line C-C of  FIG. 9 . 
     According to the present embodiment, a cooling fin  20   a  formed on the first heat dissipating plate  20  is disposed in a space  28  on the side of the first heat dissipating plate, whereby the heat dissipating area can be expanded. Further, by blowing a cooling air  27   a  thereto, heat transfer efficiency of the first heat dissipating plate can be improved and thereby temperature of positive rectifier elements  22  can be reduced. 
     In the same manner, the heat dissipating area also can be expanded by disposing, in a space  29  on the side of the second heat dissipating plate, a cooling fin  21   a  formed on the first heat dissipating plate  20 . Further, by blowing a cooling air  28   a  thereto, heat transfer efficiency of the first heat dissipating plate can be improved and thereby temperature of positive rectifier elements  23  can be reduced. Thus, compared to the first embodiment, cooling performance of the rectifier device can be further improved by disposing cooling fins in spaces  28  on the side of the first heat dissipating plate and in spaces  29  on the side of the second heat dissipating plate. 
     [Third Embodiment] 
     Next, a third embodiment is described based on  FIG. 11 ,  FIG. 12  and  FIG. 13 . 
       FIG. 11  is a rear-side front view of a rectifier device according to the third embodiment.  FIG. 12  is a cross sectional view taken from line O-F of  FIG. 11 .  FIG. 13  is a cross sectional view taken from line O-G of  FIG. 11 . 
     As shown in  FIG. 12 , a positive rectifier element  22  is disposed in a space  28  on the side of the first heat dissipating plate, and a cooling air  27   a  is guided to pass through the space  28  on the side of the first heat dissipating plate to directly cool down the positive rectifier element  22 , whereby temperature reduction effect can be improved. 
     Further, as shown in  FIG. 13 , a negative rectifier element  23  is disposed in a space  29  on the side of the second heat dissipating plate, and a cooling air  27   b  is guided to pass through the space  29  to directly cool down the negative rectifier element  23 , whereby temperature reduction effect can be improved. Further, since the negative rectifier element  23  and the rear frame  17  are in direct contact with each other, heat is dissipated directly to the rear frame  17  having a large heat dissipating area, whereby temperature reduction effect of the negative rectifier element  23  is improved. 
     Compared to the first and second embodiments, the present embodiment disposes the positive rectifier element  22  in the space  28  on the side of the first heat dissipating plate, and the negative rectifier element  23  in the space  29  on the side of the second heat dissipating plate, so that the cooling air passing through the spaces can be utilized for cooling down both of the rectifier elements and thereby cooling performance of the rectifier elements can be improved. 
     [Fourth Embodiment] 
     A fourth embodiment is described based on  FIGS. 14 ,  15 ,  16  and  17 . 
       FIG. 14  is a rear-side front view of a vehicle AC generator according to the fourth embodiment.  FIG. 15  is a cross sectional view taken from line J-J of  FIG. 14 .  FIG. 16  is a cross sectional view taken from line K-K of  FIG. 15 . 
     According to the present embodiment, a positive rectifier element  22  is disposed in a space  28  on the side of the first heat dissipating plate, and a cooling air  27  is guided to pass through the space  28  on the side of the first heat dissipating plate, as shown in  FIG. 14  and  FIG. 15 , to directly cool down the positive rectifier element  22  and thereby improve temperature reduction effect. Further, a space  17   a  is provided between the second heat dissipating plate  21  and the rear frame  17 , and a cooling air  27   a  is guided to pass through the space  17   a  between the second heat dissipating plate  21  and the rear frame  17  as shown in  FIG. 16  which is a cross sectional view taken from line K-K of  FIG. 15 , to cool down the second heat dissipating plate  21 . 
     Further, a negative rectifier element  23  is disposed in a space  29  on the side of the second heat dissipating plate, and a cooling air  27   b  is guided to pass through the space  29  on the side of the second heat dissipating plate to directly cool down the negative rectifier element  23  and thereby improve temperature reduction effect. Further, the negative rectifier element  23  and the rear frame  17  are in direct contact with each other, so that heat is dissipated directly to the rear frame  17  having a large heat dissipating area and thereby temperature reduction effect of the negative rectifier element  23  can be improved. 
     According to the present embodiment, negative rectifier elements  23  and the rear frame  17  are disposed in direct contact with each other to cause the rear frame  17  to effect heat dissipation, and a space is provided between the second heat dissipating plate  21  (except portions where negative rectifier elements  23  are disposed) and the rear frame  17  to allow the cooling air to pass therethrough. With this configuration, cooling efficiency can be enhanced compared with the third embodiment. 
     In addition to the embodiments of the present invention described above, other adoptable configurations are listed hereunder. 
     Although the above embodiments are described based on the vehicle AC generator as an embodiment of the rotating electrical machine, the present invention also facing may apply to a vehicle generator motor such as a motor generator serving for both power generation and driving. 
     Although, in the above embodiments, the configuration of the rectifier device is described by citing stator windings comprising two pairs of three-phase windings, stator windings comprising a pair of three-phase windings also can be used. In such a case, a rectifier device can be configured with half the number of positive and negative rectifier elements compared with the embodiments described herein. 
     Although the above embodiments are described based on the premise that a Pn-junction diode is used as a rectifier element, a switching element (power transistor, MOSFET, or the like) also can be used as a rectifier element. 
     Although the present invention has been described in its preferred form, it will be apparent to those skilled in the art that the present invention is not limited thereto and various changes and modifications can be made without departing from the spirit and scope thereof. 
     LIST OF REFERENCE SIGNS 
     
         
           1  Pulley 
           2  Shaft 
           3  Front bearing 
           4  Rotor 
           5  Stator 
           6  Stator iron core 
           7  Stator windings 
           8  Rear bearing 
           9  Front nail-shaped magnetic pole 
           10  Rear nail-shaped magnetic pole 
           11  Field windings 
           12  Slip ring 
           13  Brush 
           14  Front fan 
           15  Rear fan 
           16  Front frame 
           17  Rear frame 
           17   a  Space between second heat dissipating plate and rear frame 
           18  Rectifier device 
           19  Rectifier element connection plate 
           19   a  Insulating material portion 
           19   b  Connection terminal 
           20  First heat dissipating plate 
           21  Second heat dissipating plate 
           22  Positive rectifier element 
           23  Negative rectifier element 
           24  Terminal bolt B 
           25  Protective cover 
           26  Front-side cooling air 
           27  Rear-side cooling air 
           27   a  Cooling air passing through space between first heat dissipating plate and rectifier element connection plate 
           27   b  Cooling air passing through space between second heat dissipating plate and rectifier element connection plate 
           27   c  Cooling air passing through space between second heat dissipating plate and rear frame 
           28  Space between first heat dissipating plate and rectifier element connection plate 
           29  Space between second heat dissipating plate and rectifier element connection plate 
           30  Vehicle AC generator