Rotary electric machine and stator coil rotary electric machines

This application is based on Japanese Patent Application 2005-096657 filed on Mar. 30, 2005. This application claims the benefit of priority from the Japanese Patent Application, so that the descriptions of which are all incorporated herein by reference.

The present invention relates to rotary electric machines installable in, for example, vehicles, such as passenger automobiles and trucks. In addition, the present invention relates to stator coils for rotary electric machines installable in vehicles, such as passenger automobiles and trucks.

Rotary electric machines have been used for vehicles. One type of the rotary electric machines is disclosed in U.S. Pat. No. 6,784,583 corresponding to Japanese Unexamined Patent Publication No. 2002-247787. The rotary electric machine disclosed in the U.S. Patent Publication has a stator coil consisting of a pair of first and second sets of three-phase windings. The three-phase windings of the first set have junctions serially connected to each other in delta (Δ) configuration, and the three-phase windings of the second set have output and input ends; these input ends are respectively connected in series to the junctions of the delta-connected three-phase windings of the first set.

Use of the above structured first and second sets of three-phase windings allows the number of turns of each winding to be freely set. For example, the number of turns of each winding of the first and second sets is different from that of turns of each winding of normally star-connected three-phase windings.

The U.S. Pat. No. 6,784,583 also discloses a stator coil having a configuration with first and second groups of first and second sets of three-phase windings. In this U.S. Patent Publication, a modification of the configuration such that the first group of the first and second sets of three-phase windings is shifted from the second group of those of three-phase windings by an electric angle of π/6 radian in phase is disclosed. This modification permits magnetic noise caused from the first and second groups of three-phase windings to decrease.

Another one type of the conventional rotary electric machines is disclosed in U.S. Pat. No. 6,800,974 and U.S. Pat. No. 6,617,723, which correspond to Japanese Unexamined Patent Publication No. 2003-180048. The rotary electric machine disclosed in these U.S. Patent Publications consists of first and second sets of normally star-connected three phase windings.

In the U.S. Pat. No. 6,784,583, wiring configuration of the three-phase windings of the first and second sets of the pair of the stator coil is schematically illustrated in FIG. 6 of the Patent Publication as an example. Specifically, in FIG. 6 of the Patent Publication, arrangement of connections between the junctions of the three-phase windings of the first set of the pair and the input ends of the three-phase windings of the second set thereof by leads is illustrated.

The U.S. Pat. No. 6,784,583, however, provides no specific examples of wiring configuration for the three-phase windings of the first and second sets of each of the first and second groups of the stator coil.

Accordingly, there is a need for providing such a specific example of wiring configuration for the three-phase windings of the first and second sets of each of the first and second groups of the stator coil in order to increase the usefulness of the stator coil set forth above.

Particularly, because the number of three-phase windings of the first and second sets of each of the first and second groups of the stator coil is larger than that of three-phase windings of the first and second sets of the pair of the stator coil, a more simplified wring configuration is needed.

In view of the background, an object of at least one aspect of the present invention is to simplify wiring configuration for tree-phase windings of first and second sets of each of first and second groups of a stator coil.

According to one aspect of the present invention, there is provided a rotary electric machine. The rotary electric machine includes a stator core having axially opposing end surfaces and a plurality of substantially circumferentially spaced slots, and a stator coil. The stator coil includes a first group of first and second sets of three-phase windings disposed in part of the slots. The first set includes first three-phase windings each with output ends. The output ends of the first three-phase winding are connected in series to each other to form delta configuration with junctions between the first three-phase windings. The second set includes second three-phase windings having output and input ends. The input ends are respectively connected in series to the junctions of the first three-phase windings. The stator coil includes a second group of third and fourth sets of three-phase windings disposed in another part of the slots. The third set includes third three-phase windings each with output ends. The output ends of the third three-phase winding are connected in series to each other to form delta configuration with junctions between the first three-phase windings. The fourth set includes fourth three-phase windings having output and input ends. The input ends are respectively connected in series to the junctions of the first three-phase windings. The output ends of the first to fourth three-phase windings and the input ends of the second and fourth windings are disposed at one of the opposing end surface sides of the stator core. The output ends of the first and second three-phase windings of the first and second sets included in the first group are separated from the output ends of the third and fourth three-phase windings of the third and fourth sets included in the second group.

According to another aspect of the present invention, there is provided a rotary electric machine. The rotary electric machine includes a stator core having axially opposing end surfaces and a plurality of substantially circumferentially spaced slots, and a stator coil. The stator coil includes a first group of first and second sets of three-phase windings disposed in part of the slots. The first set includes first three-phase windings each with output ends disposed respectively at first circumferential positions in opposition to the stator core. The output ends of the first three-phase winding are connected in series to each other to form delta configuration with junctions between the first three-phase windings. The second set includes second three-phase windings having output and input ends. The input ends are respectively connected in series to the junctions of the first three-phase windings. The stator coil includes a second group of third and fourth sets of three phase windings disposed in another part of the slots. The third set includes third three-phase windings each with output ends disposed respectively at first circumferential positions in opposition to the stator core. The output ends of the third three-phase winding are connected in series to each other to form delta configuration with junctions between the third three-phase windings. The fourth set includes fourth three-phase windings having output and input ends. The input ends are respectively connected in series to the junctions of the third three-phase windings. The output ends of the first to fourth three-phase windings and the input ends of the second and fourth windings are disposed at one of the opposing end surface sides of the stator core. The circumferential positions of the output positions of at least one of the first three-phase windings and the third three-phase windings are disposed to be included in the circumferential positions of the output ends of at least one of the second three-phase windings and the fourth three-phase windings.

According to a further aspect of the present invention, there is provided a stator coil to be provided in a stator core. The stator core has axially opposing end surfaces and a plurality of substantially circumferentially spaced slots. The stator coil includes a first group of first and second sets of three-phase windings disposed in part of the slots. The first set includes first three-phase windings each with output ends. The output ends of the first three-phase winding are connected in series to each other to form delta configuration with junctions between the first three-phase windings. The second set includes second three-phase windings having output and input ends. The input ends are respectively connected in series to the junctions of the first three-phase windings. The stator coil includes a second group of third and fourth sets of three-phase windings disposed in another part of the slots. The third set includes third three-phase windings each with output ends. The output ends of the third three-phase winding are connected in series to each other to form delta configuration with junctions between the third three-phase windings. The fourth set includes fourth three-phase windings having output and input ends. The input ends are respectively connected in series to the junctions of the third three-phase windings. The output ends of the first to fourth three-phase windings and the input ends of the second and fourth windings are disposed at one of the opposing end surface sides of the stator core. The output ends of the first and second three-phase windings of the first and second sets included in the first group are separated from the output ends of the third and fourth three-phase windings of the third and fourth sets included in the second group.

According to a still further aspect of the present invention, there is provided a stator coil. The stator coil includes a first group of first and second sets of three-phase windings disposed in part of the slots. The first set includes first three-phase windings each with output ends disposed respectively at first circumferential positions in opposition to the stator core. The output ends of the first three-phase winding are connected in series to each other to form delta configuration with junctions between the first three-phase windings. The second set includes second three-phase windings having output and input ends. The input ends are respectively connected in series to the junctions of the first three-phase windings. The stator coil includes a second group of third and fourth sets of three phase windings disposed in another part of the slots. The third set includes third three-phase windings each with output ends disposed respectively at first circumferential positions in opposition to the stator core. The output ends of the third three-phase winding are connected in series to each other to form delta configuration with junctions between the third three-phase windings. The fourth set includes fourth three-phase windings having output and input ends. The input ends are respectively connected in series to the junctions of the third three-phase windings. The output ends of the first to fourth three-phase windings and the input ends of the second and fourth windings are disposed at one of the opposing end surface sides of the stator core. The circumferential positions of the output positions of at least one of the first three-phase windings and the third three-phase windings are disposed to be included in the circumferential positions of the output ends of at least one of the second three-phase windings and the fourth three-phase windings.

Other objects and aspects of the invention will become apparent from the following description of embodiments with reference to the accompanying drawings in which:

FIG. 1 is a partially axial sectional view illustrating an alternator according to an embodiment of the present invention;

FIG. 2 is a wiring diagram of a stator coil according to the embodiment of the present invention;

FIG. 3 is a supplementary wiring diagram of a first group of first and second sets of three-phase windings included in the stator coil;

FIG. 4 is a supplementary wiring diagram of a second group of first and second sets of three-phase windings included in the stator coil;

FIG. 5 is a winding diagram development of part of the stator coil according to the embodiment of the invention;

FIG. 6 is a winding diagram development of part of the stator coil according to the embodiment of the invention;

FIG. 7 is a winding diagram development of part of the stator coil according to the embodiment of the invention;

FIG. 8 is a view schematically illustrates wiring configuration of the three-phase windings of the first and second sets of the first and second groups according to the embodiment;

FIG. 9 is a perspective view of conductor segments forming a stator coil according to a modification of the embodiment;

FIG. 10 is a perspective view of the conductor segments shown in FIG. 9 being inserted in corresponding slots of a stator core of a stator according to the modification;

FIG. 11 is a partially cross sectional enlarged view schematically illustrating part of the stator according to the modification;

FIG. 12 is a perspective view schematically illustrating a second coil end portion of the stator coil according to the modification;

FIG. 13 is a perspective view schematically illustrating a first coil end portion of the stator coil according to the modification; and

FIG. 14 is an enlarged winding diagram development of part of the stator coil according to the modification of the embodiment, which corresponds to part of the winding diagram development of FIG. 6 .

An embodiment of the present invention will be described hereinafter with reference to the accompanying drawings.

Referring to the drawings, in which like reference characters refer to like parts in several views, particularly to FIG. 1 , there is illustrated an alternator 1 for vehicles, as an example of rotary electric machines.

The alternator 1 installed in, for example, a vehicle includes a stator 2 , a rotor 3 , a frame 4 , a refer assembly 5 , a voltage regulator and so on.

The stator 2 is composed of a stator core 22 . The stator core 22 has, for example, a substantially annular shape and first and second annular axial end surfaces. The stator core 22 also has a plurality of (e.g. 96) slots 24 (see FIGS. 5 to 7 and 10 to 13 ). For example, slot numbers of # 1 to # 96 are sequentially allocated in the 96 slots (see FIGS. 5 to 7 ). The slots 24 are formed through the stator core 22 and are circumferentially arranged at given intervals. The circumferential interval of adjacent slots defines a slot pitch corresponding to an electric angle of, for example, π/6 radian.

The stator core 22 is fixed to an inner peripheral wall of the frame 4 . The stator 2 is also composed of a stator coil 23 . The stator coil 23 is wound in the slots 24 of the stator core 22 . The stator core 22 further has insulators 27 inserted between conductor portions of the stator coil 23 disposed in the slots 24 and inner peripheral surfaces of the slots 24 to insulate therebetween.

The stator coil 23 is composed of first and second groups 23 A and 23 B of first and second sets of three-phase windings. The second group 23 B of first and second sets of three-phase windings is shifted by an electric angle of π/6 radian (30 degrees) in phase from the first group 23 A of first and second sets of three-phase windings.

The stator coil 23 has first and second coil end portions CE 1 and CE 2 anally opposed to each other and projecting from the first and second axial end surfaces of the stator core 22 . For example, ends of windings of each phase included in the first and second groups 23 A and 23 B are drawn out from one of the first and second coil end portions CE 1 and CE 2 of the stator coil 23 . In the embodiment, ends of windings of each phase included in the first and second groups 23 A and 23 B are drawn out from the first coil end portion CE 1 of the stator coil 23 . Further details on each of the first and second groups 23 A and 23 B of first and second sets of three-phase windings will be described hereinafter.

The rotor 3 is attached to a rotary shaft 6 rotatably supported in the frame 4 by bearings so that it is disposed within the stator core 22 . One end of the rotary shaft 6 is linked to a pulley 20 such that the rotary shaft 6 is rotatably driven by an engine (not shown) mounted in the vehicle through the pulley 20 .

Specifically, the rotor 3 is composed of a Lundell type (claw pole) core 7 . The Lundell type core 7 has a pair of opposing circuit plates axially assembled to the rotary shaft 6 and a plurality of claw portions extending from the outer peripheral side of the circular plates. The claw portions of one of the circuit plates and those of the other thereof are alternatively arranged in the circumferential direction of the rotor 3 .

The rotor 3 is also composed of field windings 8 provided between the circular plates of the pole core 7 , slip rings 9 and 10 , and brushes. The slip rings 9 and 10 and the brushes are configured to provide electrical connections between the field windings 8 and a power supply. The rotor 3 is also composed of a diagonal flow cooling fan 11 and a centrifugal cooling fan 12 that allow cooling air to be delivered into the frame 4 by the rotation of the fans 11 and 12 together with that of the rotor 3 . For example, the number of the claw portions is twelve, which corresponds to the number of poles of the rotor 3 , and six slots of the stator core 22 correspond to each pole.

The frame 4 is configured to accommodate the stator 2 and the rotor 3 such that the stator core 22 is fixedly disposed around the outer periphery of the pole core 7 such that the inner periphery of the stator core 22 is opposite to the outer periphery of the pole core 7 with a predetermined air gap. Specifically, the frame 4 is composed of a front frame 4 A and a rear frame 4 B, which are fastened to each other by a plurality of fastening bolts 43 . This fastening structure fixedly supports the stator 2 in the frame 4 .

The rectifier assembly 5 includes first and second rectifiers 5 A and 5 B, and the first and second rectifiers 5 A and 5 B are connected to six output leads extending from the first and second groups 23 A and 23 B of first and second sets of three-phase windings. The rectifier assembly 5 is configured to convert a three-phase AC (Alternating Current) voltage applied from the stator coil 23 into a DC voltage using both positive and negative half cycles of the three-phase AC voltage.

In the alternator 1 described above, a field current is applied to the field winding 8 through the slip rings 9 and 10 and the brushes while the field windings 8 of the rotor 3 is rotating based on torque applied from the engine through the pulley 20 . In this situation, the field current flowing trough the field windings 8 magnetize the claw portions of one of the circuit plates to the north (N) pole, and those of the other thereof to the south (S) pole. The rotation of the alternately magnetized north and south poles create magnetic fluxes, and the created magnetic fluxes induce a three-phase AC voltage in the stator coil 23 . The induced three-phase AC voltage is rectified by the rectifier 5 , thereby generating a DC voltage. The voltage regulator is configured to control the field current flowing through the field windings 8 in response to the alternator output voltage.

Next, the stator 2 will be described in detail hereinafter.

As illustrated in FIGS. 2 to 4 , the stator coil 23 of the stator 2 is composed of the first and second groups 23 A and 23 B of first and second sets of three-phase windings. The first group 23 A consists of first and second sets 330 A and 340 A of three-phase windings.

The first set 330 A includes a U-phase winding 330 U 1 , a V-phase winding 330 V 1 , and a W-phase winding 330 W 1 whose output ends are connected to each other in delta-configuration. The second set 340 A includes an X-phase winding 340 X 1 , a Y-phase winding 340 Y 1 , and a Z-phase winding 340 Z 1 each having output and input ends. The input ends X 1 , Y 1 , and Z 1 of the X-, Y-, and Z-phase windings 340 X 1 , 340 Y 1 , and 340 Z 1 of the second set 340 A are respectively connected in series to the junctions (output ends) of the delta-connected U-, V-, and W-phase windings 330 U 1 , 330 V 1 , and 330 W 1 of the first set 330 A. The output ends X 1 ′, Y 1 ′, and Z 1 ′ of the three-phase windings 340 X 1 , 340 Y 1 , and 340 Z 1 of the second set 340 A serve respectively as output leads of the first group 23 A.

The U-, V-, and W-phase winding 330 U 1 , 330 V 1 , and 330 W 1 are arranged to be shifted from each other by four slot pitches corresponding to an electric angle of 2π/3 radian, and connected to each other to form the delta-connected three-phase winding 330 A.

Each of the slots # 1 to # 96 includes a first layer to a fourth layer located from the inside to the outside of the stator core 22 . In FIGS. 5 to 7 , the first, second, third, and fourth layers are respectively illustrated schematically by chain, dashed, solid, and chain double-dashed lines.

Specifically, as illustrated in FIGS. 5 to 7 , the U-phase winding 330 U 1 is disposed in slots # 55 , # 61 , # 67 , . . . every six slot pitches corresponding to one pole pitch. For example, part of the U-phase winding 330 U 1 being disposed in the slots # 55 and # 61 consists of:

a first portion inserted in the slot # 55 at the fourth layer thereof,

a second portion inserted in the slot # 61 at the third layer thereof,

a first turn portion continuously connecting between one end of the first portion projecting from the slot # 55 at the second coil end portion side of the core 22 and that of the second portion projecting from the slot # 61 thereat,

a third portion inserted in the slot # 55 at the second layer thereof,

a second turn portion continuously connecting between the other end of the second portion projecting from the slot # 61 at the first coil end side of the core 22 and one end of the third portion projecting from the slot # 55 thereat,

a fourth portion inserted in the slot # 61 at the first layer thereof, and

a third turn portion continuously connecting between the other end of the third portion projecting from the slot # 55 at the second coil end portion side of the core 22 and one end of the fourth portion projecting from the slot # 61 thereat.

Similarly, the V-phase winding 330 V 1 is inserted in slots # 51 , # 57 , # 63 , . . . every six slot pitches corresponding to one pole pitch; these slots # 51 , # 57 , # 63 , . . . are respectively shifted from slots # 55 , # 61 , # 67 , . . . by four slot pitches. The W-phase winding 330 W 1 is wound in slots # 47 , # 53 , # 59 , . . . every six slot pitches corresponding to one pole pitch; these slots # 47 , # 53 , # 59 are respectively shifted from slots # 51 , # 57 , # 63 , . . . by four slot pitches.

The X-, Y-, and Z-phase windings 340 X 1 , 340 Y 1 , and 340 Z 1 are arranged to be shifted from each other by four slot pitches corresponding to the electric angle of 2π/3 radian.

Specifically, as illustrated in FIGS. 5 to 7 , the X-phase winding 340 X 1 is disposed in slots # 62 , # 68 , # 74 , . . . every six slot pitches corresponding to one pole pitch. Similarly, the Y-phase winding 340 Y 1 is inserted in slots # 58 , # 64 , # 70 , . . . every six slot pitches corresponding to one pole pitch; these slots # 58 , # 64 , # 70 , . . . are respectively shifted from slots # 62 , # 68 , # 74 , . . . by four slot pitches. The Z-phase winding 340 Z 1 is wound in slots # 54 , # 60 , # 66 , . . . every six slot pitches corresponding to one pole pitch; these slots # 54 , # 60 , # 66 , . . . are respectively shifted from slots # 58 , # 64 , # 70 , . . . by four slot pitches.

The first set 330 A of the three-phase windings 330 U 1 , 330 V 1 , and 330 W 1 and the second set 340 A of the three-phase windings 340 X 1 , 340 Y 1 , and 340 Z 1 are arranged to be shifted from each other by one slot pitch (the electric angle π/6).

The connection of the junctions of the delta-connected U-, V-, and W-phase windings 330 U 1 , 330 V 1 , and 330 W 1 to the input ends X 1 , Y 1 , and Z 1 of the X-, Y-, and Z-phase windings 340 X 1 , 340 Y 1 , and 340 Z 1 is preferably welded to form three weld portions 332 A, 334 A, and 336 A. This provides serial connection between the delta-connected first set 330 A of three-phase windings and the second set 340 A of three-phase windings. The output ends X 1 ′, Y 1 ′, and Z 1 ′ of the X-, Y-, and Z-phase windings 340 X 1 , 340 Y 1 , and 340 Z 1 are coupled to the first rectifier 5 A.

The second group 23 B consists of first and second sets 330 B and 340 B of three-phase windings.

The first set 330 B includes an X-phase winding 330 X 2 , a Y-phase winding 330 Y 2 , and a Z-phase winding 330 Z 2 , whose output ends are connected to each other in delta-configuration. The second set 340 B includes a U-phase winding 340 U 2 , a V-phase winding 340 V 2 , and a W-phase winding 340 W 2 each having output and input ends. The input ends U 2 , V 2 , and W 2 of the U-, V-, and W-phase windings 340 U 2 , 340 V 2 , and 340 W 2 of the second set 340 B are respectively connected in series to the junctions (output ends) of the delta-connected X-, Y-, and Z-phase windings 330 X 2 , 330 Y 2 , and 330 Z 2 of the first set 330 B. The output ends U 2 ′, V 2 ′, and W 2 ′ of the three-phase windings 340 U 2 , 340 V 2 , and 340 W 2 of the second set 340 B serve respectively as output leads of the second group 23 B.

The X-, Y-, and Z-phase winding 330 X 2 , 330 Y 2 , and 330 X 2 are arranged to be shifted from each other by four slot pitches corresponding to the electric angle of 2π/3 radian, and connected to each other to form the delta-connected three-phase winding 330 B.

Specifically, as illustrated in FIGS. 5 to 7 , the X-phase winding 330 X 2 is disposed in slots # 32 , # 38 , # 44 , . . . every six slot pitches corresponding to one pole pitch. For example, part of the X-phase winding 330 X 2 being disposed in the slots # 32 and # 38 consists of:

a first portion inserted in the slot # 32 at the fourth layer thereof,

a second portion inserted in the slot # 38 at the third layer thereof,

a first turn portion continuously connecting between one end of the first portion projecting from the slot # 32 at the second coil end portion side of the core 22 and that of the second portion projecting from the slot # 38 thereat,

a third portion inserted in the slot # 32 at the second layer thereof,

a second turn portion continuously connecting between the other end of the second portion projecting from the slot # 38 at the first coil end side of the core 22 and one end of the third portion projecting from the slot # 32 thereat,

a fourth portion inserted in the slot # 38 at the first layer thereof, and

a third turn portion continuously connecting between the other end of the third portion projecting from the slot # 32 at the second coil end portion side of the core 22 and one end of the fourth portion projecting from the slot # 38 thereat.

Similarly, the Y-phase winding 330 Y 2 is inserted in slots # 28 , # 34 , # 40 , . . . every six slot pitches corresponding to one pole pitch; these slots # 28 , # 34 , # 40 , . . . are respectively shifted from slots # 32 , # 38 , # 44 , . . . by four slot pitches. The Z-phase winding 330 Z 2 is wound in slots # 24 , # 30 , # 36 , . . . every six slot pitches corresponding to one pole pitch; these slots # 24 , # 30 , # 36 , . . . are respectively shifted from slots # 28 , # 34 , # 40 , . . . by four slot pitches.

The U-, V-, and W-phase windings 340 U 2 , 340 V 2 , and 340 W 2 are arranged to be shifted from each other by four slot pitches corresponding to the electric angle of 2π/3 radian.

Specifically, as illustrated in FIGS. 5 to 7 , the U-phase winding 340 U 2 is disposed in slots # 37 , # 43 , # 49 , . . . every six slot pitches corresponding to one pole pitch. Similarly, the V-phase winding 340 V 2 is inserted in slots # 33 , # 39 , # 45 , . . . every six slot pitches corresponding to one pole pitch; these slots # 33 , # 39 , # 45 are respectively shifted from slots # 37 , # 43 , # 49 , . . . by four slot pitches. The W-phase winding 340 W 2 is wound in slots # 29 , # 35 , # 41 , . . . every six slot pitches corresponding to one pole pitch; these slots # 29 , # 35 , # 41 are respectively shifted from slots # 33 , # 39 , # 45 , . . . by four slot pitches.

The first set 330 B of the three-phase windings 330 X 2 , 330 Y 2 , and 330 Z 2 and the second set 340 B of the three-phase windings 340 U 2 , 340 V 2 , and 340 W 2 are arranged to be shifted from each other by one slot pitch corresponding to the electric angle of π/6.

The connection of the junctions of the delta-connected X-, Y-, and Z-phase windings 330 X 2 , 330 Y 2 , and 330 Z 2 to the input ends U 2 , V 2 , and W 2 of the U-, V-, and W-phase windings 340 U 2 , 340 V 2 , and 340 W 2 is preferably welded to form three weld portions 332 B, 334 B, and 336 B. This provides serial connection between the delta-connected first set 330 B of three-phase windings and the second set 340 B of three-phase windings. The output ends U 2 ′, V 2 ′, and W 2 ′ of the U-, V-, and W-phase windings 340 U 2 , 340 V 2 , and 340 W 2 are coupled to the second rectifier 5 B.

Specifically, the second turn portions of the windings of each of the first and second groups 23 A and 23 B projecting from the first axial end surface of the stator core 22 constitute the first coil end portion CE 1 of the stator coil 23 . The first turn portions of the windings of each of the first and second groups 23 A and 23 B projecting from the second axial end surface of the stator core 22 constitute the second coil end portion CE 2 of the stator coil 23 .

FIG. 8 schematically illustrates wiring configuration of the three-phase windings of the first and second sets of the first and second groups 23 A and 23 B. As illustrated in FIG. 8 , circled reference characters U 1 and U 1 ′ represent draw-out positions of the ends of the U-phase winding 330 U 1 from the first coil end portion side of the stator core 22 . Specifically, connection leads 25 extend from the draw-out positions of the U-phase winding 330 U 1 so that they correspond to the ends of the U-phase winding 330 U 1 .

Similarly, circled reference characters V 1 and V 1 ′ represent draw-out positions of the ends of the V-phase winding 330 V 1 from the first coil end portion side of the stator core 22 , and connection leads 25 extend from the draw-out positions of the V-phase winding 330 V 1 so that they correspond to the ends of the V-phase winding 330 V 1 . Circled reference characters W 1 and W 1 ′ represent draw-out positions of the ends of the W-phase winding 330 W 1 from the first coil end portion side of the stator core 22 , and connection leads 25 extend from the draw-out positions of the W-phase winding 330 W 1 so that they correspond to the ends of the W-phase winding 330 W 1 .

Circled reference characters X 1 and X 1 ′ represent draw-out positions of the ends of the X-phase winding 340 X 1 from the first coil end portion side of the stator core 22 . Connection and output leads 25 and 26 extend from the draw-out positions of the X-phase winding 340 X 1 so that they correspond to the ends of the X-phase winding 340 X 1 . Similarly, circled reference characters Y 1 and Y 1 ′ represent draw-out positions of the ends of the Y-phase winding 340 Y 1 from the first coil end portion side of the stator core 22 . Connection and output leads 25 and 26 extend from the draw-out positions of the Y-phase winding 340 Y 1 so that they correspond to the ends of the Y-phase winding 340 Y 1 . Circled reference characters Z 1 and Z 1 ′ represent draw-out positions of the ends of the Z-phase winding 340 Z 1 from the first coil end portion side of the stator core 22 . Connection and output leads 25 and 26 extend from the draw-out positions of the Z-phase winding 340 Z 1 so that they correspond to the ends of the Z-phase winding 340 Z 1 .

Like the first group 23 A, circled reference characters U 2 and U 2 ′ represent draw-out positions of the ends of the U-phase winding 340 U 2 from the first coil end portion side of the stator core 22 . Connection and output leads 25 and 26 extend from the draw-out positions of the U-phase winding 340 U 2 so that they correspond to the ends of the U-phase winding 340 U 2 . Similarly, circled reference characters V 2 and V 2 ′ represent draw-out positions of the ends of the V-phase winding 340 V 2 from the first coil end portion side of the stator core 22 . Connection and output leads 25 and 26 extend from the draw-out positions of the V-phase winding 340 V 2 so that they correspond to the ends of the V-phase winding 340 V 2 . Circled reference characters W 2 and W 2 ′ represent draw-out positions of the ends of the W-phase winding 340 W 2 from the first coil end portion side of the stator core 22 . Connection and output leads 25 and 26 extend from the draw-out positions of the W-phase winding 340 W 2 so that they correspond to the ends of the W-phase winding 340 W 2 .

Circled reference characters X 2 and X 2 ′ represent draw-out positions of the ends of the X-phase winding 340 X 2 from the first coil end portion side of the stator core 22 , and connection leads 25 extend from the draw-out positions of the X-phase winding 340 X 2 so that they correspond to the ends of the X-phase winding 340 X 2 . Similarly, circled reference characters Y 2 and Y 2 ′ represent draw-out positions of the ends of the Y-phase winding 340 Y 2 from the first coil end portion side of the stator core 22 , and connection leads 25 extend from the draw-out positions of the Y-phase winding 340 Y 2 so that they correspond to the ends of the Y-phase winding 340 Y 2 . Circled reference characters Z 2 and Z 2 ′ represent draw-out positions of the ends of the Z-phase winding 340 Z 2 from the first coil end portion side of the stator core 22 , and connection leads 25 extend from the draw-out positions of the Z-phase winding 340 Z 2 so that they correspond to the ends of the Z-phase winding 340 Z 2 .

Note that the specification will describe the draw-out positions from the first coil end portion side of the stator coil 23 , which are represented by X 1 and X 1 ′ and the like, as the positions of both ends of corresponding windings. In addition, circled reference numerals illustrated in FIG. 8 represent circumferential positions of both ends of each winding included in the first and second groups 23 A and 23 B, which are related to the slot numbers of the slots 24 illustrated in FIGS. 5 to 7 .

For example, FIGS. 6 and 8 clearly show that the ends X 1 and X 1 ′ of the X-phase winding 340 X 1 are drawn out from the first coil end portion side of the stator core 22 at the circumferential position identical with that of the slot # 59 . Note that the first portion of the X-phase winding 340 X 1 from which the end X 1 extends is actually inserted in the slot # 56 shifted counterclockwise from the slot # 59 by three slots. In addition, the second portion of the X-phase winding 340 X 1 from which the end X 1 ′ extends is actually inserted in the slot # 62 shifted clockwise from the slot # 59 by three slots. This can be established in the ends of each of the remaining windings.

In the embodiment, as illustrated in FIG. 8 , the first grouped ends U 1 , U 1 ′, V 1 , V 1 ′, W 1 , W 1 ′, X 1 , X 1 ′, Y 1 , Y 1 ′, Z 1 , and Z 1 ′ of the windings of the first and second sets 330 A and 340 A included in the first group 23 A and the second grouped ends U 2 , U 2 ′, V 2 , V 2 , W 2 , W 2 ′, X 2 , X 2 ′, Y 2 , Y 2 ′, Z 2 , and Z 2 ′ of the windings of the first and second sets 330 B and 340 B included in the second group 23 B are so arranged that the first grouped ends are separated from the second grouped ends in a circumferential direction of the stator core 22 .

In other words, the first grouped ends of the windings of the first 6 and second sets 330 A and 340 A included in the first group 23 A and the second grouped ends of the windings of the first and second sets 330 B and 340 B included in the second group 23 B are disposed not to be overlapped onto the second grouped ends.

Moreover, when focusing on the first group 23 A, the circumferential positions of the ends U 1 , U 1 ′, V 1 , V 1 ′, W 1 , and W 1 ′ included in the first set 330 A are arranged in a circumferential direction of the stator core 22 between the ends X 1 , X 1 ′, Y 1 , and Y 1 ′ of the windings included in the second set 340 A and the ends Z 1 and Z 1 ′ of the windings included therein (see FIGS. 6 and 8 ).

In addition, the tip ends X 1 , U 1 ′, and V 1 of the windings 340 X 1 , 330 U 1 , and 330 V 1 are respectively drawn out by the corresponding connection leads 25 to be bundled together in a group so that the bundled tip ends X 1 , U 1 ′, and V 1 of the windings 340 X 1 , 330 U 1 , and 330 V 1 are welded to form the weld portion 332 A. Similarly, the tip ends Y 1 , V 1 ′, and W 1 of the windings 340 Y 1 , 330 V 1 , and 330 W 1 are respectively drawn out by the corresponding connection leads 25 to be bundled together in a group so that the bundled tip ends Y 1 , V 1 ′, and W 1 of the windings 340 Y 1 , 330 V 1 , and 330 W 1 are welded to form the weld portion 334 A. Moreover, the tip ends U 1 , W 1 ′, and Z 1 of the windings 330 U 1 , 330 W 1 , and 340 Z 1 are respectively drawn out by the corresponding connection leads 25 to be bundled together in a group so that the bundled tip ends U 1 , W 1 ′, and Z 1 of the windings 330 U 1 , 330 W 1 , and 340 Z 1 are welded to form the weld portion 336 A.

The weld portions 332 A, 334 A, and 336 A of the tip ends (X 1 , U 1 ′, V 1 ), (Y 1 , V 1 ′, W 1 ), and (U 1 , W 1 ′, Z 1 ) are arranged in a circumferential direction of the stator core 22 to be separated from the remaining tip ends (X 1 ′, Y 1 ′; Z 1 ′) and the corresponding leads 25 drawn out from the tip ends (X 1 ′, Y 1 ′, Z 1 ′). In addition, the weld portions 332 A, 334 A, and 336 A of the tip ends (X 1 , U 1 ′, V 1 ), (Y 1 , V 1 ′, W 1 ), and (U 1 , W 1 ′, Z 1 ) are locally disposed in opposition to the inner peripheral side of the first axial end surface of the core 22 (the radially inner edge side of each of the slots 24 of the core 22 ).

Moreover, as illustrated in FIG. 8 , the tip ends of the windings, which form each of the weld portions 332 A, 334 A, and 336 A, are aligned, and are arranged in a circumferential direction of the stator core 22 over the radially inner edge side of the slots 24 . Furthermore, the tip end of the winding disposed at the middle of the ends of the windings forming each of the weld portions extends in the axial direction of the core 22 .

For example, when focusing on the weld portion 332 A, as illustrated in FIG. 8 , the tip ends X 1 , U 1 ′, and V 1 of the windings 340 X 1 , 330 U 1 , and 330 V 1 , which form the weld portion 332 A, are aligned in a circumferential direction of the stator core 22 , and are arranged over the radially inner edge side of the slots 24 . Furthermore, the end U 1 ′ (connection lead 25 ) of the winding 330 U 1 disposed at the middle of the tip ends X 1 , U 1 ′, and V 1 of the weld portion 332 A extends in the axial direction of the core 22 without extending any circumferential directions. The arrangement features of the weld portion 332 A can be established in the remaining weld portions 334 A and 336 A.

In addition, the weld portions 332 A, 334 A, and 336 A are aligned in the circumferential direction of the core 22 . Moreover, one end (connection lead) of the winding drawn out from one of the slots 24 for one of the weld portions 332 A, 334 A, and 336 A is arranged to intersect with one end of the winding drawn out from another one of the slots 24 for another one of the weld portions 332 A, 334 A, and 336 A such that the one end of the winding drawn out from the one of the slots 24 jumps over the one end of the winding drawn out from another one of the slots 24 ; this one of the weld portions 332 A, 334 A, and 336 A is disposed forwardly in a predetermined circumferential direction from another one of the weld portions 332 A, 334 A, and 336 A.

For example, assuming that, in FIG. 8 , the predetermined circumferential direction is the counterclockwise direction, the end Y 1 (lead 25 ) of the winding 340 Y 1 drawn out from the corresponding one of the slots 24 for the weld portion 334 A disposed forwardly in the counterclockwise direction from the weld portion 332 A is disposed to intersect with the end V 1 (lead 25 ) of the winding 330 V 1 drawn out from another one of the slots 24 for the weld portion 332 A such that the end Y 1 of the winding 340 Y 1 jumps over the end V 1 of the winding 330 V 1 .

Similarly, when focusing on the second group 23 B, the circumferential positions of the ends X 2 , X 2 ′, Y 2 , Y 2 ′, Z 2 , and Z 2 ′ included in the first set 330 B are arranged circumferentially between the ends W 2 , W 2 ′, V 2 , and V 2 ′ of the windings included in the second set 3403 and the ends U 2 and U 2 ′ of the windings included therein (see FIGS. 5 and 7 ).

In addition, the tip ends W 2 , Z 2 ′, and Y 2 of the windings 340 W 2 , 330 Z 2 , and 330 Y 2 are respectively drawn out by the corresponding connection leads 25 to be bundled together in a group so that the bundled tip ends W 2 , Z 2 , and Y 2 of the windings 340 W 2 , 330 Z 2 , and 330 Y 2 are welded to form the weld portion 3321 . Similarly, the tip ends V 2 , Y 2 ′, and X 2 of the windings 340 V 2 , 330 Y 2 , and 330 X 2 are respectively drawn out by the corresponding connection leads 25 to be bundled together in a group so that the bundled ends V 2 , Y 2 ′, and X 2 of the windings 340 V 2 , 330 Y 2 , and 330 X 2 are welded to form the weld portion 334 B. Moreover, the tip ends Z 2 , X 2 ′, and U 2 of the windings 330 Z 2 , 330 X 2 , and 340 U 2 are respectively drawn out by the corresponding connection leads 25 to be bundled together in a group so that the bundled tip ends Z 2 , X 2 , and U 2 of the windings 330 Z 2 , 330 X 2 , and 340 U 2 are welded to form the weld portion 336 B.

The weld portions 33213 , 3343 , and 33613 of the tip ends (W 2 , Z 2 ′, Y 2 ), (V 2 , Y 2 ′, X 2 ), and (Z 2 , X 2 ′, U 2 ) are circumferentially arranged to be separated from the remaining tip ends (W 2 ′, V 2 , U 2 ) and the corresponding connection leads 25 drawn out from the ends (W 2 ′, V 2 ′, U 2 ′). In addition, the weld portions 332 B, 334 B, and 336 B of the tip ends (W 2 , Z 2 , Y 2 ), (V 2 , Y 2 ′, X 2 ), and (Z 2 , X 2 ′, U 2 ) are locally disposed to the inner peripheral side of the core 22 (the radially inner edge side of each of the slots 24 of the core 22 ).

Moreover, as illustrated in FIG. 8 , the tip ends of the windings, which form each of the weld portions 332 B, 334 B, and 336 B, are circumferentially aligned, and are arranged over the radially inner edge side of the slots 24 . Furthermore, the tip end of the winding disposed at the middle of the tip ends of the windings forming each of the weld portions in the anal direction of the core 22 .

For example, when focusing on the weld portion 332 B, as illustrated in FIG. 8 , the tip ends W 2 , Z 2 , and Y 2 of the windings 340 W 2 , 330 Z 2 , and 330 Y 2 , which form the weld portion 332 B, are circumferentially aligned, and are arranged over the radially inner edge side of the slots 24 . Furthermore, the end Z 2 ′ (connection lead 25 ) of the winding 330 Z 2 disposed at the middle of the ends W 2 , Z 2 ′, and Y 2 of the weld portion 332 B extends in the axial direction of the core 22 without extending any circumferential directions. The arrangement features of the weld portion 332 B can be established in the remaining weld portions 334 B and 336 B.

In addition, the weld portions 332 B, 334 B, and 336 B are aligned in the circumferential direction of the core 22 . Moreover, one end (connection lead) of the winding drawn out from one of the slots 24 for one of the weld portions 332 B, 334 B, and 336 B is disposed to intersect with one end of the winding drawn out from another one of the slots 24 for another one of the weld portions 332 B, 334 B, and 336 B such that the one end of the winding drawn out from the one of the slots 24 jumps over the one end of the winding drawn out from another one of the slots 24 ; this one of the weld portions 332 B, 334 B, and 336 B is disposed forwardly in a predetermined circumferential direction from another one of the weld portions 332 B, 334 B, and 336 B.

For example, assuming that, in FIG. 8 , the predetermined circumferential direction is the clockwise direction, the end V 2 (connection lead 25 ) of the winding 340 V 2 drawn out from the corresponding one of the slots 24 for the weld portion 334 B disposed forwardly in the clockwise direction from the weld portion 332 B is arranged to intersect with the end Y 2 (connection lead 25 ) of the winding 330 Y 2 drawn out from the corresponding slot for the weld portion 332 B such that the end V 2 of the winding 340 V 2 jumps over the end Y 2 of the winding 330 Y 2 .

As described above, the stator coil 23 of the alternator 1 according to the embodiment includes the first and second groups 23 A and 23 B each having the complicated structure in which the delta-connected three-phase windings and star-connected windings are combined to each other.

Particularly, in the stator coil 23 of the alternator 1 according to the embodiment, the first grouped ends of the three-phase windings of the first and second sets 330 A and 340 A included in the first group 23 A and the second grouped ends of the three-phase windings of the first and second sets 330 B and 340 B of the windings included in the second group 23 B are so arranged that the first grouped ends are circumferentially separated from the second grouped ends.

This configuration allows the lengths of the connection leads 25 included in each of the first and second groups 23 A and 233 B to decrease, making it possible to simplify connections of the respective ends of the three-phase windings included in each of the first and second groups 23 A and 23 B.

In addition, as illustrated in FIGS. 5 , 6 , and 8 , the circumferential positions of the ends of the delta-connected three-phase windings of the first set ( 330 A, 3303 ) are arranged to be circumferentially included in the circumferential positions of the ends of the remaining windings of the second set ( 340 A, 340 B). This allows the connection leads 25 connecting between the output ends of the delta-connected three-phase windings of the first set ( 330 A, 330 B) and the three-phase windings of the second set ( 340 A, 340 B) to locally concentrate in the circumferential direction of the core 22 . This makes it possible to further simplify connections between the output ends of the delta-connected three-phase windings of the first set ( 330 A, 330 B) and the three-phase windings of the second set ( 340 A, 340 B). With simplicity of connections between the output ends of the delta-connected three-phase windings of the first set ( 330 A, 330 B) and the three-phase windings of the second set ( 340 A, 340 B), phase-to-phase insulation of the three-phase windings included in each of the first and second groups 23 A and 23 B can be easily ensured. This permits the stator core 23 and stator 2 to be easily manufactured and downsized.

The output leads 26 of each of the first and second groups 23 A and 23 B are locally arranged in the circumferential direction of the core 22 . Accordingly, even if arrangements of the output leads 26 from the first and second groups 23 A and 23 B are limited to a space in the circumferential direction of the core 22 so as to meet the configuration of the rectifier assembly 5 that is determined not to interfere the brushes and/or the voltage regulator, it is possible to easily adjust the arrangements of the output leads 26 to the limited space. This can prevent complicated wiring configuration.

Moreover, the weld portions between the ends of the three-phase windings of the first set ( 330 A, 340 A) and those of the three-phase windings of the second set ( 3303 , 3403 ) of each of the first and second groups 23 A and 23 B are circumferentially arranged to be separated from the leads 25 drawn out from the output ends of the three-phase windings of the second set ( 340 A, 340 B) of each of the first and second groups 23 A and 23 B. This permits interference between welding jigs for welding of the weld portions and the leads 25 drawn out from the output ends of the three-phase windings to be reduced, making it easy to manufacture the stator coil 23 and stator 2 .

In the embodiment, the weld portions between the ends of the three-phase windings of the first set ( 330 A, 340 A) and those of the three-phase windings of the second set ( 330 B, 340 B) of each of the first and second groups 23 A and 23 B are locally disposed in opposition to the inner peripheral side of the first axial end surface of the core 22 . This allows sufficient spaces between the rear frame 4 B accommodating therein the stator 2 and each weld portion to be easily secured. Thus, it is unnecessary to increase the size of the rear frame 4 B in order to avoid interference between each weld portion and the inner peripheral surface of the rear frame 4 B. This makes it possible to further downsize the stator coil 23 and stator 2 .

Moreover, the ends of the windings, which form each of the weld portions 332 A, 334 A, and 336 A, are circumferentially aligned, and are drawn out from the radially inner edge side of the corresponding slots 24 . This makes it possible to easily bundle the ends of the windings for each of the weld portions and weld them.

Furthermore, the end of the winding disposed at the middle of the ends of the windings forming each of the weld portions extends in the axial direction of the core 22 . That is, the end of the winding disposed at the middle of the ends of the windings forming each of the weld portions extends in the axial direction of the core 22 without extending any circumferential directions. This allows oscillations occurring during rotatable drive of the alternator 1 (rotor 2 ) to decrease.

In each of the first and second groups 23 A and 23 B, the weld portions are aligned in the circumferential direction of the core 22 , and one end (lead) of the winding drawn out from the corresponding slot for one of the weld portions disposed forwardly in a predetermined circumferential direction is arranged to intersect with another one end of the winding drawn out from the corresponding slot for another one of the weld portions disposed backwardly in the predetermined circumferential direction from the one of the weld portions such that the one end of the winding jumps over another one end of the winding. This allows arrangement of the weld portions of each of the first and second groups 23 A and 23 B to have the above described regularity. Thus, the regular arrangement of the weld portions of each of the first and second groups 23 A and 23 B makes it possible to easily draw out the ends of the windings for each of the weld portions of each of the first and second groups 23 A and 23 B from the corresponding slots 24 and easily bundle them.

In the embodiment, as a modification of the embodiment, each of the three-phase windings included in the first and second groups 23 A and 23 B is made up of sequentially joined conductor units each with a substantially U or V shaped turn portion as illustrated in FIGS. 9 to 12 . Specifically, the sequent joined conductor units provide a series-connected winding in each phase corresponding to each of the three-phase windings.

In each of the first and second groups 23 A and 23 B, an even number, such as four in the modification, of conductor members arm inserted in each slot 24 . Four conductor members being disposed in one of the slots 24 are aligned in the radial direction and respectively disposed in an innermost layer, an inner middle layer, an outer middle layer, and an outermost layer from the inner periphery of each slot 24 (see FIGS. 10 and 11 ).

A conductor member 231 a disposed in the innermost layer of one of the slots 24 is paired with a conductor member 231 b disposed in the outermost layer of another slot 24 that is spaced apart from the one of the slots 24 by one pole pitch (six slot pitches) in clockwise direction. Similarly, a conductor member 232 a disposed in the inner middle layer of one of the slots 24 is paired with a conductor member 232 b disposed in the outer middle layer of another slot 24 that is spaced apart from the one of the slots 24 by one pole pitch in clockwise direction. The paired conductor members 231 a and 231 b are connected to each other by a continuous U or V shaped turn portion 231 c at the first axial end surface side of the core 22 . The paired conductor members 232 a and 232 b are also connected to each other by a continuous U or V shaped turn portion 232 c at the first axial end surface side of the core 22 .

Accordingly, as illustrated in FIGS. 9 and 10 , at the first axial end surface side of the stator core 22 , a continuous conductor portion consisting of the conductor member 232 a disposed in the inner middle layer, the conductor member 232 b disposed in the outer middle layer, and the turn portion 232 c connecting therebetween is enclosed by a continuous conductor portion consisting of the conductor member 231 a disposed in the innermost layer, the conductor member 231 b disposed in the outermost layer, and the turn portion 231 c connecting therebetween.

Specifically, at the fist axial end surface side of the stator core 22 , the turn portion 232 c as a connection portion between the paired conductor members is surrounded by the turn portion 231 c as a connection portion between the paired conductor members. Connection between the conductor member 232 b inserted in the outer middle layer and the conductor member 232 a inserted in the inner middle layer provides a middle layer coil end. Connection between the conductor member 231 b inserted in the outermost layer and the conductor member 231 a inserted in the innermost layer provides an outer layer coil end disposed at the outer side of the middle layer coil end.

The conductor member 232 a arranged in the inner middle layer of one of the slots 24 is also paired with a conductor member 231 a ′ arranged in the innermost layer of another slot 24 that is one pole pitch clockwise spaced apart from the one of the slots 24 . Similarly, the conductor member 231 b ′ arranged in the outermost layer of one of the slots 24 is also paired with a conductor member 232 b arranged in the outer middle layer of another slot 24 that is one pole pitch clockwise spaced apart from the one of the slots 24 . Junctions between the paired conductor members are disposed at the second axial end surface side of the stator core 22 .

As illustrated in FIGS. 9 to 11 , each reference number with no dash and that with a dash (′) are assigned to the identical portions of different conductor members 231 . Similarly, each reference number with no dash and that with a dash (′) are assigned to the identical portions of different conductor members 232 .

Thus, at the second axial end surface side of the core 22 , as illustrated in FIG. 9 , an outside connection portion 233 b connecting the conductor member 231 b ′ disposed in the outermost layer and the conductor member 232 b disposed in the outer middle layer and an inner side connection portion 233 a connecting the conductor member 231 a ′ disposed in the innermost layer and the conductor member 232 a disposed in the inner middle layer are arranged to be shifted from each other in the radial and circumferential directions. Connection of the outermost conductor member 231 b ′ and the outer middle conductor member 232 b , and that of the innermost conductor member 231 a ′ and the inner middle conductor member 232 a provide two adjacent coil-end layers. The two adjacent coil-end layers are arranged on different concentric circles, respectively.

As illustrated in FIG. 9 , the conductor member 231 a inserted in the innermost layer, the conductor member 231 b inserted in the outermost layer, and the turn portion 231 c provide a U or V shaped large conductor segment 231 . Similarly, the conductor member 232 a inserted in the inner middle layer, the conductor member 232 b inserted in the outer middle layer, and the turn portion 232 c provide a U or V shaped small conductor segment 232 . A basic conductor segment unit 230 consists of a pair of the large conductor segment 231 and the small conductor segment 232 .

The large conductor segment 231 is composed of a pair of straight conductor portions corresponding to the conductor members 231 a and 231 b , and the U- or V-shaped turn portion 231 c . The paired straight conductor portions 231 a and 231 b extending at their one ends from ends of the turn portion 231 c are to be inserted into the slots 24 .

The larger conductor segment 231 is also composed of projecting end portions (legs) 231 g continuing from the other ends of the straight conductor portions 231 a and 231 b and projecting outside the corresponding slots 24 when the straight conductor portions 231 a and 231 b are placed within the slots 24 . The projecting end portions 231 g are bent with a predetermined electric angle with respect to the axial direction of the corresponding slots 24 .

The turn portion 231 c of the large conductor segment 231 is composed of a tip portion and a pair of slant portions 231 f . The paired slant portions 231 f are designed to continue from both ends of the tip portion, slant with a predetermined electric angle with respect to the anal direction of the corresponding slots 24 , and lead to the straight conductor portions 231 a and 231 b , respectively.

Similarly, the small conductor segment 232 is composed of a pair of straight conductor portions corresponding to the conductor members 232 a and 232 b , and the U- or V-shaped turn portion 232 c . The paired straight conductor portions 232 a and 232 b extending at their one ends from ends of the turn portion 232 c are to be inserted into the slots 24 .

The small conductor segment 232 is also composed of projecting end portions (legs) 232 g continuing from the other ends of the straight conductor portions 232 a and 232 b and projecting outside the corresponding slots 24 when the straight conductor portions 232 a and 232 b are placed within the slots 24 . The projecting end portions 232 g are bent with a predetermined electric angle with respect to the axial direction of the corresponding slots 24 .

The turn portion 232 c of the small conductor segment 232 is composed of a tip portion and a pair of slant portions 232 f . The paired slant portions 232 f are designed to continue from both ends of the tip portion, slant with a predetermined electric angle with respect to the axial direction of the corresponding slots 24 , and lead to the straight conductor portions 232 a and 232 b , respectively. The turn portions 231 c and 232 c projecting from the corresponding slots 24 through the first axial end surface side of the core 22 provide the first coil end portion CE 1 (see FIG. 13 ).

The above-described configuration is applied to the conductor segment units 230 disposed in all the slots 24 . A tip end 231 e ′ of the slant portion 231 g ′ extending from the straight conductor portion 231 b ′ inserted in the outermost layer and a tip end 232 e of the slant portion 232 g extending from the straight conductor portion 232 b inserted in the outer middle layer are welded together to form an outside joint portion 233 b . Similarly, a tip end 232 d of the slant portion 232 g extending from the straight conductor portion 232 a inserted in the inner middle layer and a tip end 231 d ′ of the slant portion 231 g ′ extending from the straight conductor portion 231 a ′ inserted in the innermost layer are welded together to form an inside joint portion 233 a . The inside and outside joint portions 233 a and 233 b and the corresponding projecting end portions projecting from the corresponding slots 24 through the second axial end surface side of the core 22 provide the second coil end portion CE 2 (see FIG. 12 ).

In the modification of the embodiment, the above described conductor segment units 230 provide the stator core 23 with the same winding structure as illustrated in FIGS. 5 to 7 .

Specifically, when focusing on the first group 23 A of three-phase windings, six-phase windings that are shifted from one another by an electric angle of π/6 radian in phase are disposed in every six of the slots 24 of the stator core 22 corresponding to one pole-pitch. For example, part of the U-phase winding 330 U 1 that is composed of the conductor segment units 230 being disposed in the slots # 55 and # 61 is illustrated in FIG. 14 corresponding to part of FIG. 6 . In FIG. 14 , circled numerals {circle around ( 1 )}, {circle around ( 2 )}, {circle around ( 3 )}, and {circle around ( 4 )} correspond to the first layer (innermost layer), the second layer (inner middle layer), the third layer (outer middle layer), and the fourth layer (outermost layer) in each of the slots # 55 and # 61 .

As clearly illustrated in FIG. 14 , part of the U-phase winding 330 U 1 being disposed in the slots # 55 and # 61 consists of:

the straight conductor portion 231 b ′ corresponding to the first portion and inserted in the slot # 55 at the fourth layer thereof,

the straight conductor portion 232 b corresponding to the second portion and inserted in the slot # 61 at the third layer thereof,

a set of the slant portions 231 g ′, 232 g , and the inside joint portion 233 b (tip ends 231 e ′, 232 e ), which corresponds to the first turn portion and continuously connecting between one end of the straight conductor portion 231 b ′ projecting from the slot # 55 at the second coil end portion side of the core 22 and that of the straight conductor portion 232 b projecting from the slot # 61 thereat,

the straight conductor portion 232 a corresponding to the third portion and inserted in the slot # 55 at the second layer thereof,

the turn portion 232 c corresponding to the second turn portion and continuously connecting between the other end of the straight conductor portion 232 b projecting from the slot # 61 at the first coil end side of the core 22 and one end of the straight conductor portion 232 a third portion projecting from the slot # 55 thereat,

the straight conductor portion 231 a ′ corresponding to the fourth portion and inserted in the slot # 61 at the first layer thereof, and

a set of the slant portions 232 g , 231 g ′, and the inside joint portion 233 a (tip ends 282 d , 231 d ), which corresponds to the third turn portion continuously connecting between the other end of the straight conductor portion 232 a projecting from the slot # 55 at the second coil end portion side of the core 22 and one end of the straight conductor portion 231 a ′ projecting from the slot # 61 thereat.

Specifically, in the modification, U-phase winding 330 U 1 disposed in one of the slots 24 , V-phase winding 330 V 1 and W-phase winding 330 W 1 respectively disposed in other slots 24 that are spaced apart from the one of the slots 24 by 4 or 8 slot pitches are connected to form a first set 330 A of delta-connected three-phase windings. X-phase winding 340 X 1 , Y-phase winding 340 Y 1 , and Z-phase winding 340 Z 1 , which are respectively inserted in slots respectively spaced apart from the slots for the U-, V-, and W-phase windings are disposed, are respectively connected in series to the three junctions of the delta-connected three-phase winding of the first set 330 A to provide three-phase windings of a second set 340 A.

Similarly, when focusing on the second group 23 B of three-phase windings, six-phase windings that are shifted from one another by an electric angle of π/6 radian in phase are disposed in every six of the slots 24 of the stator core 22 corresponding to one pole-pitch.

X-phase winding 330 X 2 disposed in one of the slots 24 , Y-phase winding 330 Y 2 and Z-phase winding 330 Z 2 respectively disposed in other slots 24 that are spaced apart from the one of the slots 24 by 4 or 8 slot pitches are connected to form a first set 330 B of delta-connected three-phase windings. U-phase winding 340 U 2 , V-phase winding 340 V 2 , and W-phase winding 340 W 2 , which are respectively inserted in slots respectively spaced apart from the slots for the U-, V-, and W-phase windings are disposed, are respectively connected in series to the three junctions of the delta-connected three-phase winding of the first set 330 B to provide three-phase windings of a second set 340 B.

Because both ends (connection and output leads) of the three-phase windings included in each of the first and second groups 23 A and 23 B are drawn out from the turn portions of the conductor segment units 230 , the conductor segment units 230 include some special conductor segment units to provide the connection and output leads. Specifically, as can be seen from the enlarged winding diagram developments of FIGS. 5 and 6 , the tip portion of the turn portion 231 c of some of the conductor segment units 230 is cut, and the cut ends of the tip portion are designed to axially extend as the output leads and parts of the connection leads, thereby forming some of the special conductor segment units.

As described above, in the modification, the first and second groups 23 A and 23 B of thee-phase windings can be formed by the use of the substantially U shaped conductor segment units 230 . This allows the connection and output leads to be arranged at the first coil end CE 1 formed by the turn portions 231 c of the large conductor segments 231 . Accordingly, in addition to the effects obtained by the embodiment, it is possible to weld the ends of the three phase windings and to route the connection and output leads at the turn portion side of the stator coil 23 , thereby more easily manufacturing the stator coil 23 and the stator 2 .

In the embodiment and its modification, the first set ( 330 A, 330 B) of three-phase windings of each of the first and second groups 23 A and 23 B is disposed to be shifted in phase from the second set ( 340 A, 340 B) of three-phase windings of each of the first and second groups 23 A and 23 B by an electric angle of π/6 in phase. This arrangement allows magnetic noise to decrease. In the present invention, the first set ( 330 A, 330 B) of three-phase windings of each of the first and second groups 23 A and 23 B can be disposed to be shifted in phase from the second set ( 340 A, 340 B) of three-phase windings of each of the first and second groups 23 A and 23 B by another electric angle.

Similarly, the second group 23 B of first and second sets of three-phase windings is disposed to be shifted in phase from the first group 23 A of first and second sets of three-phase windings by an electric angle of π/6 radian. This arrangement permits magnetic noise to further decrease. In the present invention, the second group 23 B of first and second sets of three-phase windings can be disposed to be shifted in phase from the first group 23 A of first and second sets of three-phase windings by another electric angle.

In the embodiment and its modification, it is possible to freely set the number of turns of respective three-phase windings included in each of the first and second groups 23 A and 23 B.

In the embodiment and its modification, the present invention is applied to an alternator for vehicles, but the present invention is not limited to the application. Specifically, the present invention can be applied to other types of rotary electric machines, such as motors for vehicles or the like.

While there has been described what is at present considered to be the embodiment and its modification of the present invention, it will be understood that various modifications which are not described yet may be made therein, and it is intended to cover in the appended claims all such modifications as fall within the true spirit and scope of the invention.