• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The invention relates to a starter for a motor vehicle comprising an electric machine provided with a rotor (9) comprising: - a body (91) of cylindrical shape mounted on a shaft (14), - a collector (20) comprising a set electrically conductive blades (18), - notches (92) formed on an outer periphery of the body (91) of the rotor (9), and - a coil formed by a set of conductors (93) inserted at least in part at the interior of the notches (92) and electrically connected to the blades (18) of the collector (20), characterized in that the conductors (93) inserted in the notches (92) are based on aluminum for a starter having a lower power at 1.3kW.
    公开号:FR3013532A1
    申请号:FR1361288
    申请日:2013-11-18
    公开日:2015-05-22
    发明作者:Nicolas Labbe；Jean Sebastien Metral；Raphael Andreux
    申请人:Valeo Equipements Electriques Moteur SAS；
    IPC主号:
    专利说明:

    [0001] The invention relates to a motor starter of low power with optimized size. The invention finds a particularly advantageous, but not exclusive, application with starter systems so-called "stop and start" for stopping and restarting the engine of the vehicle according to particular traffic conditions. In order to start a heat engine, especially a motor vehicle, it is known to use a starter provided with a launcher capable of transmitting a rotation energy of the starter to a crankshaft of the engine through a crown starting. This launcher is mounted on a drive shaft. In one embodiment, a speed reducer is interposed between this drive shaft and the shaft of an electric machine.
    [0002] This electric machine comprises on the one hand, a rotor, also called armature and on the other hand, a stator, also called inductor, mounted coaxially around the rotor. The stator has several permanent magnets or coil poles (electromagnets). The rotor comprises a body in the form of a bundle of sheets and conductors forming the winding inserted in longitudinal notches formed at the outer periphery of the sheet bundle. The conductors have welded ends on the blades of a collector on which brushes are rubbed for feeding the winding. The thermal engines may have a reduced dimensioning because of the improvement of their efficiency or their combined use with an electric traction motor in the case of hybrid vehicles. Car manufacturers therefore need to reduce the size of corresponding starters with a reduced power requirement, and to reduce the size under the hood of the vehicle.
    [0003] Conventionally, the rotors are provided with a winding made of copper which has the advantage of having good electrical conductivity compared to other materials, which makes it possible to reduce the size of the rotors. Regarding the possible option of using a more resistive material than copper, such as aluminum, it is well known that this leads, for the same level of torque produced, to a longer electrical machine, so more voluminous. The curves of Figs. 1A, 1A ', 1B, 1B' and 1C are curves which represent the armature length versus torque and are Pareto fronts, i.e. join optimal definition points with different design features. These characteristics are: the number of notches; conductor wire diameter; lead wire material; thickness of ferrite magnets; breech thickness. Indeed, one obtains these fronts of optimums (thanks to the use of algorithms) leaving free 5 characteristics of design and under stress of resistance of armature, (essential in starter because one needs a rather weak resistance to ensure the power but also of sufficient importance to ensure a low voltage drop at the battery during the initial call of current The current curves / armature length are made according to a supply law of a straight voltage / current characterized for OA a voltage of 11.5V, with a source resistance of 10 mili OHm across the starter.This measurement is made according to ISO 8856. The torque corresponds to the maximum torque (locked rotor) at the output of a gearbox of 4.62 In other words, a torque of 50 nm corresponds to a maximum rotor torque of approximately 10.82 Nm.
    [0004] Figure 1A shows a curve of a starter rotor whose conductor is copper. This curve shows the optimum points taking into account the 5 characteristics mentioned above. In a known manner, the shorter the length of the armature, the lower the torque. Figure 1A 'shows a curve of a starter rotor whose conductor is aluminum. This curve shows the optimum points taking into account the 5 characteristics mentioned above.
    [0005] It can be seen that to have a smaller rotor length, it is preferable that the conductor is copper. Surprisingly, we can see on the curve 1B, which is a curve prolonging that of 1 A towards the small powers, that when the torque is lower than 55N.m is a maximum rotor torque of 11.9 Nm, the curve is flat, that is to say that the length for an optimum rotor remains at 100mm. However, the invention departs from the unexpected finding that, in a certain range of reduced power of the starter, it is the use of aluminum and non-copper conductors that ensures the desired electromechanical performance at minimum machine volume electric. Indeed, it can be seen that contrary to the curve B of the copper, the curve of the aluminum of Figure 1B 'the length of the starter rotor decreases if the torque decreases. Indeed, as is clear from Figure 1C, which represents the set of curves 1A, 1A ', 1B, 1B' for the power ranges of the range Pi, the search for a minimum active volume of armature to given torque leads to use a copper armature winding rather than aluminum. Indeed, on this range Pi, the length of an aluminum armature LAI is greater than the length LCu of a copper armature. However, for the definition of low power machines, the search for a minimum active volume at a given torque leads to the use of aluminum rather than copper. Indeed, for this type of machine, the use of copper as is conventionally required would require a longer machine (with the same outside diameter) to obtain a sufficiently high resistance for armature winding. It can be seen that on the range P2, the length of an aluminum armature LAI becomes less than the length LCu of a copper armature.
    [0006] FIG. 2 represents the evolution of a characteristic quantity defined as the integral J of the difference e between the active length of an aluminum armature (LAI) and the active length of a copper armature (LCu) at same couple produces. This figure clearly shows that beyond an extremum E dimensioning, the use of aluminum makes it possible to obtain a shorter machine, and therefore more compact than with copper.
    [0007] Extremum E is obtained for a torque of 50N.m associated with an integral value J of about 1830mm.Nm, which corresponds to a power of about 1.3kW of the electric machine. By X, Xkw of starter means the power of a maximum starter according to a supply law of a straight voltage / current characterized for OA a voltage of 11.5V, with a source resistance of 10 mili OHm across the starter. This measurement is made according to ISO 8856. The invention therefore relates to a starter for a motor vehicle comprising an electric machine provided with a rotor comprising: - a cylindrical body mounted on a shaft, - a collector comprising a set of blades electrically conductive, - notches formed on an outer periphery of the rotor body, and - a coil formed by a set of conductors inserted at least partly inside the notches and electrically connected to the collector blades, characterized in that the conductors inserted in the notches are aluminum-based for a starter having a power of less than 1.3kW.
    [0008] The invention also relates to a starter for a motor vehicle comprising an electric machine provided with a rotor comprising: - a cylindrical body mounted on a shaft, - a collector comprising a set of electrically conductive blades, - notches arranged on a periphery. external rotor body, and - a coil formed by a set of conductors inserted at least partly inside the slots and electrically connected to the collector blades, characterized in that the conductors inserted in the notches are based on aluminum for a starter having a maximum torque of less than 10.82N.m according to a supply law of a straight voltage / current characterized for OA a voltage of 11.5V, with a source resistance of 10 milli Ohm across the starter.
    [0009] Indeed, it can be seen that for starters below this threshold, it is preferable to have aluminum slot conductors even if the characteristics of: number of notches are modified; conductor wire diameter; lead wire material; thickness of ferrite magnets; breech thickness. Indeed, a starter having its aluminum conductors having the same characteristics as a starter having its copper conductors (rotor length etc ...) will have a larger max torque. In one embodiment, the conductors inserted into the slots are based on aluminum for a power range of between 1 and 1.2 kW. In one embodiment, portions of each conductor located inside said slots are made of an alloy consisting predominantly of aluminum. In one embodiment, the conductors are pin-shaped.
    [0010] According to one embodiment, said electric machine comprises a stator having an outer diameter of the order of 60 mm. According to one embodiment, said rotor has an outer diameter of the order of 44mm. According to one embodiment, said rotor has a length of the order of 30 mm.
    [0011] In one embodiment, the rotor has between 2 "and 29 notches.
    [0012] According to one embodiment, said rotor comprises 23 notches. In one embodiment, said rotor has 19 notches. In one embodiment, said rotor has 25 notches. According to one embodiment, said rotor comprises 29 notches.
    [0013] According to one embodiment, said electric machine comprises a stator provided with poles formed by permanent magnets. According to one embodiment, the stator poles are six in number. In one embodiment, the conductors have a diameter of between 1.5 and 2 millimeters.
    [0014] The invention will be better understood on reading the description which follows and on examining the figures which accompany it. These figures are given for illustrative but not limiting of the invention. FIGS. 1A, 1A 'and 1B, 1B' already described, show the evolution of the armature lengths of copper and aluminum as a function of the torque produced for the same external diameter of the electric machine and the same electrical resistance; FIG. 1C, already described, shows the evolution of the armature lengths of copper and aluminum as a function of the torque produced for the same external diameter of the electric machine and the same electrical resistance; FIG. 2, already described, is a representation, obtained from the curves of FIG. 1, of the evolution of a characteristic quantity defined as the integral of the difference between the active length of an aluminum armature and the active length of a copper armature with the same torque produced. Figure 3 shows a longitudinal sectional view of a thermal engine starter according to the present invention; Figure 5 shows a cross-sectional view of the two conductor layers positioned within the notches of the rotor. Identical, similar or similar elements retain the same references from one figure to another.
    [0015] Referring to Figure 3, the starter 1 according to the invention comprises a drive shaft 2, a launcher 3 mounted on the shaft 2 and an electric machine 5 operating in motor mode composed of an inductor stator 8 and an armature rotor 9 mounted coaxially along an axis X. The stator 8 surrounds the rotor 9 integral with a shaft 14. The machine 5 comprises a carcass 51 mounted on a metal support 12 of the starter 1 intended to be fixed on a part fixed of the motor vehicle. In known manner, the stator 8 comprises in one embodiment a plurality of permanent magnets forming the poles of the stator 8 and carried by the inner periphery of the cylinder head 10. Alternatively, as shown in the embodiment of FIG. the poles are formed by windings 11 each positioned around a polar mass 15 integral. The polar masses 15 are fixed with screws 16 to the cylinder head 10, here metallic, as described in the document FR2611096. Each winding 11 is composed of a continuous conductor wound around the polar mass 15 in the direction of its thickness so as to form concentric contiguous turns of increasing diameter as best seen in Figures 2 to 5 of EP749194. The axis of each winding is radial with respect to the X axis of the rotor 9. A gear reduction gear 13 of the epicyclic gear type is preferably interposed between a rear end of the drive shaft 2 and the shaft 14 of the electric motor 5. Brooms 17 rub on conductive blades 18 of a manifold 20 to supply the rotor winding. The brushes 17 belong to a brush holder 23 equipped with guiding cages and receiving brushes 17. These brushes 17 are biased towards the conductive blades 18 by resilient means 25 of the spring type. The brush holder 23 is secured to a rear flange 24 having in the central portion a housing for mounting a needle bearing. The bearing of the rear flange 24 serves for the rotational mounting of one end of the shaft 14 of the electric motor 5. The starter 1 also comprises an electromagnetic contactor 29 extending parallel to the electric motor 5 while being implanted radially over this one. The contactor 29 has a metal tank 30 carried by the support 12, and equipped with an excitation coil 33 provided with at least one winding. A shoulder of the tank 30 makes it possible to ensure the axial setting of a fixed core 34. Terminals 37, 38 are shaped to each form a fixed contact inside the tank 30. One of the terminals 37 is intended to to be connected to the positive terminal of the battery of the vehicle, the other terminal 38 is connected to the input of the stator winding of the stator 8 and the brushes 17 of positive polarity. In known manner, during the excitation of the coil 33, a movable core 40 is attracted by magnetic attraction towards the fixed core 34 to, on the one hand, act after catching a game on a rod 41 carrying a contact mobile 42 to cause the closing of the contacts of the contactor 29 and power the electric motor 5 of the starter 1, and secondly, actuate a control lever 45 of the launcher 3. The drive shaft 2 is rotatably mounted in a bearing before 46 of the support 12. This bearing 46 is constituted by way of example by a needle bearing or alternatively by a plain bearing. This shaft 2 carries at the front a stop 48 adjacent to the bearing 46 to limit the movement of the launcher 3. The launcher 3 is slidably mounted on the drive shaft 2, and comprises a drive pinion 50, a driver 51 configured to be actuated by the pivoting control lever 45, and a freewheel device 52 for example of the roller type installed between the driver 51 and the pinion 50. The upper end of the lever 45 is mounted in known knuckle fashion. on a rod connected elastically to the movable core 40 via a spring, said spring tooth against tooth, housed in the movable core 40.
    [0016] In known manner, the driver 51 is internally provided with helical splines in complementary engagement with external helical teeth carried by the drive shaft 2. The launcher 3 is thus animated by a helical movement when it is moved. by the lever 45 in the direction of the stop 48 to come, via its pinion 50, in engagement with the starting ring of a heat engine 5.
    [0017] It is clear that the freewheel device 52 can be replaced by a conical clutch device or a clutch provided with several friction discs, as described in the document FR2978500. Similarly, it is clear that the launcher 3 as an alternative is located outside the support 12. Figure 4 shows the rotor 9 having a body 91 mounted on the shaft 14 of axis X. This body 91 in the form of sheet package has an outer periphery of cylindrical shape. Notches 92 are formed longitudinally at the outer periphery of the body 91. To form the winding, here corrugated type, a set of conductors 93 are threaded inside each of these notches 92.
    [0018] The ends of the conductors 93 are welded to the electrically conductive blades 18 of the collector 20. In an exemplary embodiment, the blades 18 are made of copper. The blades 18 are carried by a support 94 of plastic material integral with the shaft 14. The support 94 of the collector is, for a good temperature resistance, thermosetting plastic material, such as a thermosetting phenolic plastics material such as bakelite. In this case, the manifold 20 which has blades 18 extending longitudinally side by side on the outer periphery of the support 94 is of the "drum" type. However, alternatively, the collector 20 used may be a flat type collector.
    [0019] More specifically, each conductor 93 pin-shaped has two branches 931, 932 connected by a bottom 933 so as to form a U. The conductors 93 are based on aluminum. Preferably, these conductors 93 are made of an alloy consisting mainly of aluminum, that is to say with an aluminum content greater than or equal to 50%. In an exemplary embodiment, this alloy consists almost exclusively of aluminum, that is to say that the aluminum content exceeds 90% and preferably 95%. At a minimum, the portions of each conductor 93 located inside the notches 92 corresponding to the branches 931, 932 are made of this alloy. The ends of the conductors 93 may however be made of copper to facilitate their welding on the blades 18 of the collector 20. Each conductor 93 is preferably coated with an electrically insulating layer, such as enamel.
    [0020] The conductors 93 are threaded inside the notches 92 on two distinct layers: the upper layer and the lower layer. If one of the branches 931, 932 is positioned in the lower layer then the other branch 931, 932 is in the upper layer and vice versa. The cross section of the conductors 93 may be round or square or rectangular. The portions of the conductors 93 projecting from the end faces of the body 91 of the rotor 9 form the buns of the winding. To ensure a radial retention of the conductors 93 in the buns and thus avoid the effects of centrifugal force, frets 96 are positioned respectively around the buns.
    [0021] As can be seen in FIG. 5, a slot insulator 97 is positioned around the branches 931, 932 of the conductors. In this case, this insulator 97 has an S-shaped section. This insulation makes it possible not to harm the conductors 93 (coated with the thin layer of enamel) when they are mounted in the sheet metal package of the rotor 9 provided by definition of burrs and fluted for force fitting of the rotor plate package. In addition, the clearance between the insulation 97 and the edges of the notches 92 is filled by an impregnating varnish. Alternatively, the conductors 93 pin-shaped are replaced by winding son. In a preferred embodiment, for a starter having a power of 1kW, the stator 8, which has six poles, has a yoke 10 having an outer diameter of the order of 60mm. The rotor 9 has an outer diameter of about 44 mm and a length of about 30 mm. In addition, the rotor 9 has 25 notches and the armature leads 93 have a diameter of the order of 1.6 mm. For a gearbox of 4.62, the current point / torque of the pinion is of the order of 600 A, we obtain a torque of the order of 15.0 N.m. Thickness of ferrite magnets is 5.9mm, the thickness of the cylinder head is 2.2mm.
    [0022] 3013 532 11 The resistance of a 1KW starter is about 7Milliohm while that of a 1.2KW starter is about 5Milliohm. In another preferred embodiment, for the starter having a power of 1.2kW, the stator 8, which has six poles, has a yoke 10 having an outer diameter of the order of 60mm. The rotor 9 has an outer diameter of about 44 mm and a length of about 30 mm. In addition, the rotor 9 has 25 notches and the armature leads 93 have a diameter of the order of 1.9 mm. For a starter having a gearbox of 4.62, the locked rotor condition point and the power supply characteristics mentioned above, the current / torque of the pinion is of the order of 700 A, a torque of the order of 16.8 is obtained. nm The thickness of ferrite magnets is 5.9 mm, the thickness of the yoke is 2.2 mm. It can be seen that the rotor having aluminum conductors is better for all starters below or equal to 1.3kw or even if the length of the rotor is greater than 100mm as the ratio of performance to weight. It can therefore be seen that even if the starter having aluminum rotor conductors and is below 1.3 kw or 11.9 Nm in maximum torque of the rotor according to the aforementioned power characteristic curve, it can not be seen that Not all features of the optimum, the starter will have a smaller rotor than the copper one. Alternatively, the rotor 9 has 23 or 29 notches. Alternatively, the rotor 9 has a lead wire diameter of between 1.4 and 2.3. According to one preference, the stator comprises ferrite magnets to form the poles and the thickness is between 2 and 2.4mm.
    权利要求:
    Claims (12)
    [0001]
    REVENDICATIONS1. Starter for a motor vehicle comprising an electric machine (5) provided with a rotor (9), comprising: - a cylindrical body (91) mounted on a shaft (14), - a collector (20) comprising a set of blades ( 18) electrically conductive, - notches (92) formed on an outer periphery of the body (91) of the rotor (9), and - a coil formed by a set of conductors (93) inserted at least partly inside the notches (92) and electrically connected to the blades (18) of the collector (20), characterized in that the conductors (93) inserted into the notches (92) are based on aluminum for a starter having a power of less than 1.3kW .
    [0002]
    2. Starter according to claim 1, characterized in that the conductors (93) inserted in the slots (92) are based on aluminum for a power range of between 1 and 1.2 kW.
    [0003]
    3. Starter according to claim 1 or 2, characterized in that portions (931, 932) of each conductor (93) located inside said notches (92) are made of an alloy consisting predominantly of aluminum.
    [0004]
    4. Starter according to any one of claims 1 to 3, characterized in that the conductors (93) are pin-shaped.
    [0005]
    5. Starter according to any one of claims 1 to 4, characterized in that said electric machine comprises a stator (8) having an outer diameter of the order of 60mm.
    [0006]
    6. Starter according to any one of claims 1 to 5, characterized in that said rotor (9) has an outer diameter of about 44mm.
    [0007]
    7. Starter according to any one of claims 1 to 6, characterized in that said rotor (9) has a length of the order of 30mm.
    [0008]
    8. Starter according to any one of claims 1 to 7, characterized in that said rotor (9) comprises 19 notches.
    [0009]
    9. Starter according to any one of claims 1 to 7, characterized in that said rotor (9) has 25 notches.
    [0010]
    10. Starter according to any one of claims 1 to 9, characterized in that said electric machine (5) comprises a stator (8) 10 provided with poles formed by permanent magnets.
    [0011]
    11. Starter according to claim 10, characterized in that the poles of the stator (8) are six in number.
    [0012]
    12. Starter according to any one of the preceding claims, characterized in that the conductors (93) have a diameter of between 1.5 and 2 millimeters.
    类似技术:
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    同族专利:
    公开号 | 公开日
    FR3013532B1|2017-07-21|
    CN105706338A|2016-06-22|
    WO2015071618A1|2015-05-21|
    EP3072218A1|2016-09-28|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    FR2853940A1|2003-04-18|2004-10-22|Denso Corp|STARTER FOR AN INTERNAL COMBUSTION ENGINE|
    WO2011098447A2|2010-02-12|2011-08-18|Robert Bosch Gmbh|Starting device|
    WO2012041579A2|2010-09-30|2012-04-05|Robert Bosch Gmbh|Armature for an electrical machine|
    FR2611096B1|1987-02-17|1989-05-12|Equip Electr Moteur|CARCASS OF ROTATING ELECTRIC MACHINE|
    FR2735294B1|1995-06-12|1997-07-18|Valeo Equip Electr Moteur|STARTER OF A MOTOR VEHICLE PROVIDED WITH A REDUCED THICKNESS INDUCING COIL.|
    JP2004064848A|2002-07-26|2004-02-26|Nippon Steel Corp|Small dc motor excellent in recycling|
    JP4480334B2|2003-02-28|2010-06-16|新日本製鐵株式会社|Compact DC motor with excellent recyclability|
    CN201312153Y|2008-11-07|2009-09-16|安徽皖南电机股份有限公司|Novel motor rotor structure|
    FR2959361B1|2010-04-27|2015-11-13|Valeo Equip Electr Moteur|ROTATING ELECTRIC MACHINE PARTICULARLY FOR A MOTOR VEHICLE STARTER|
    FR2978500B1|2011-07-26|2015-03-13|Valeo Equip Electr Moteur|LAUNCHER MOBILE ASSEMBLY - GEAR CONTROL LEVER WITH A STARTING CROWN OF A THERMAL MOTOR AND STARTER OF A THERMAL MOTOR COMPRISING SUCH AN ASSEMBLY|
    CN102801253A|2012-08-20|2012-11-28|常州新亚电机有限公司|Motor and controller assembly|WO2017055731A1|2015-09-28|2017-04-06|Valeo Equipements Electriques Moteur|Corrosion-resistant starter rotor for a motor vehicle|
    FR3041829A1|2015-09-28|2017-03-31|Valeo Equip Electr Moteur|STARTER ROTOR FOR MOTOR VEHICLE RESISTANT TO CORROSION|
    FR3043834A1|2015-11-16|2017-05-19|Valeo Equip Electr Moteur|ELECTROMAGNETIC POWER SWITCH PROVIDED WITH AT LEAST ONE ALUMINUM REALIZED COIL|
    FR3090237A1|2018-12-14|2020-06-19|Valeo Equipements Electriques Moteur|Low-wear brush starter comprising a nested winding armature with sections distributed over several pairs of notches|
    法律状态:
    2015-11-30| PLFP| Fee payment|Year of fee payment: 3 |
    2016-11-30| PLFP| Fee payment|Year of fee payment: 4 |
    2017-11-30| PLFP| Fee payment|Year of fee payment: 5 |
    2018-11-29| PLFP| Fee payment|Year of fee payment: 6 |
    2020-10-16| ST| Notification of lapse|Effective date: 20200910 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1361288A|FR3013532B1|2013-11-18|2013-11-18|MOTOR VEHICLE STARTER OF LOW POWER AT OPTIMIZED SIZE|FR1361288A| FR3013532B1|2013-11-18|2013-11-18|MOTOR VEHICLE STARTER OF LOW POWER AT OPTIMIZED SIZE|
    PCT/FR2014/052951| WO2015071618A1|2013-11-18|2014-11-18|Low power starter with optimised size for a motor vehicle|
    EP14809489.9A| EP3072218A1|2013-11-18|2014-11-18|Low power starter with optimised size for a motor vehicle|
    CN201480061167.7A| CN105706338A|2013-11-18|2014-11-18|Low power starter with optimized size for a motor vehicle|
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