ROTATING ELECTRIC MACHINE PROVIDED WITH A WINDING HEAD

Abstract

Rotating electric machine provided with an axis X. The machine comprises a front part and a rear part. The machine comprises a rotor of axis X comprising two axial end surfaces, each provided with fan blades. The axial surfaces located on the side of the front part and on the side of the rear part. A stator comprises a stator body having slots. The stator comprises a winding installed in the slots and forming a front winding head and a rear winding head. The rotor and the stator are placed in a casing. The front winding head completely masks the blades of the axial surface located on the front side of the machine, along a direction perpendicular to axis X.

Claims

1. Rotating electric machine (100) provided with an axis X, said machine comprising a front part (16) and a rear part (17) relative to axis X, said machine comprising: a rotor (2) of axis X which comprises two axial end surfaces (81, 82) which are provided with fan blades (26) allowing a flow of cooling air, the two axial surfaces (81, 82) being located on the side of the front part (16) and on the side of the rear part (17) of the machine respectively; a stator (50) which comprises a stator body (4) having slots (93) and surrounding said rotor (2), said stator (50) comprising a winding (5) installed in said slots (93) forming a front winding head (51) which extends from an axial end of the stator body (4) towards the front part (16) of the machine and a rear winding head (53) which extends from another axial end of the stator body (4) towards the rear part (17) of the machine (100); a casing (1) in which the rotor and the stator are placed, wherein the front winding head (51) completely masks the blades (26) of the axial surface (81) located on the front side of the machine, along a direction perpendicular to axis X.

2. Machine (100) according to claim 1, wherein the level along axis X of the front winding head (51) is higher or equal to the level along axis X of the masked blades (26).

3. Machine (100) according to claim 1, wherein the winding heads comprise wires (90) provided with two axial portions (91) extending along axis X and a transverse portion (92) extending in a plane perpendicular to axis X, the front winding head forming spacings (94) located between the transverse portions (92) and the stator body (4) and wherein said spacings (94) allow passage of the cooling air.

4. Machine (100) according to claim 1, wherein the winding (5) installed in the slots is offset relative to the stator body (4), so that the front winding head (51) completely masks the blades (26) of the axial surface (81) located on the front side of the machine, while the blades (26) of the axial surface (82) located on the rear side of the machine axially overlap rear winding head (53).

5. Machine according to claim 1, wherein the front winding head (51) has a form allowing reduced flow velocity of the cooling air for a given flow rate.

6. Machine according to claim 5, wherein the winding head (51) comprises a head having a conical form.

7. Machine according to claim 1, comprising a flow window of cooling air (101, 102) which is defined between the casing (1) and the front winding head (51), the thickness of the casing being reduced to the level of this window (101, 102) to allow an increase of said window (101, 102).

8. Machine according to claim 1, wherein the R1 ratio, defined as the division of the difference between the height of the front winding head (Ha) and the height of the rear winding head (Hb) by the height of the stator body (4), ranges between 1 and 5%.

9. Machine according to claim 1, wherein the R2 ratio of the external diameter (Dext) to the internal diameter (Dint) ranges between 1.30 and 1.32.

10. Machine according to claim 1, wherein the rotor (2) comprises a number of pairs of poles different from that of the number of blades (26) of each of the two axial end surfaces (81, 82).

11. Method for constructing a rotating electric machine (100) provided with an axis X, said machine (100) comprising a front part (16) and a rear part (17) relative to axis X and moreover comprising: a rotor (2) of axis X which comprises two axial end surfaces (81, 82) which are provided with fan blades (26) allowing a flow of cooling air, the two axial surfaces (81, 82) being located on the side of the front part and on the side of the rear part (17) of the machine (100) respectively; a stator (50) which comprises a stator body (4) having slots (93) and surrounding said rotor (2), said method comprising a winding stage (601) of copper wires in said slots (93) so as to form a front winding head (51) which extends from an axial end of the stator body (4) towards the front part (16) of the machine (100) and a rear winding head (53) which extends from another axial end of the stator body (4) towards the rear part (17) of the machine (100), wherein, after the winding stage, the method moreover comprises an offsetting stage (602) along an axial direction of the winding relative to the stator body (4), so that the axial front winding head (51) completely masks the blades (26) of the axial surface (81) located on the front side of the machine (100), along a direction perpendicular to axis X.

12. Machine (100) according to claim 2, wherein the winding heads comprise wires (90) provided with two axial portions (91) extending along axis X and a transverse portion (92) extending in a plane perpendicular to axis X, the front winding head forming spacings (94) located between the transverse portions (92) and the stator body (4) and wherein said spacings (94) allow passage of the cooling air.

13. Machine (100) according to claim 2, wherein the winding (5) installed in the slots is offset relative to the stator body (4), so that the front winding head (51) completely masks the blades (26) of the axial surface (81) located on the front side of the machine, while the blades (26) of the axial surface (82) located on the rear side of the machine axially overlap rear winding head (53).

14. Machine (100) according to claim 3, wherein the winding (5) installed in the slots is offset relative to the stator body (4), so that the front winding head (51) completely masks the blades (26) of the axial surface (81) located on the front side of the machine, while the blades (26) of the axial surface (82) located on the rear side of the machine axially overlap rear winding head (53).

15. Machine according to claim 2, wherein the front winding head (51) has a form allowing reduced flow velocity of the cooling air for a given flow rate.

16. Machine according to claim 3, wherein the front winding head (51) has a form allowing reduced flow velocity of the cooling air for a given flow rate.

17. Machine according to claim 4, wherein the front winding head (51) has a form allowing reduced flow velocity of the cooling air for a given flow rate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0055] The invention will be better understood on reading the following description and on examining the accompanying figures. These figures are given on a purely illustrative, but by no means restrictive, basis of the invention.

[0056] FIG. 1, already described, illustrates a cross-section of a rotating electric machine according to the prior art;

[0057] FIG. 2, already described, is a perspective view of a rotor according to the prior art;

[0058] FIG. 3 illustrates a cross-section of a rotating electric machine in the form of an alternator according to a first embodiment of the invention;

[0059] FIG. 4 is a perspective view of a winding head for a rotating electric machine according to the invention;

[0060] FIG. 5 illustrates a stator body for the rotating electric machine according to the invention;

[0061] FIG. 6 illustrates curves of a sound level of the noise according to the number of revolutions and type of machine;

[0062] FIG. 7 illustrates a cross-section of a rotating electric machine in the form of an alternator according to a second embodiment of the invention; and

[0063] FIG. 8 illustrates a method according to the invention.

[0064] Identical, similar or analogous components keep the same reference symbol from one figure to the next.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0065] FIG. 3 illustrates a rotating electric machine 100 provided with an axis X according to the invention.

[0066] This machine is distinguished from the machine illustrated on FIG. 1 particularly in that winding head 51 completely masks blades 26 of fan 23.

[0067] Machine 100 comprises a first part formed in particular by front flange 16 and a second part formed in particular by rear flange 17. These two parts are called front and rear according to their position relative to axis X. More precisely the front part is located on the side of pulley 12 while the rear part is located on the side of electric cover 70.

[0068] Rotor 2 is of axis X and comprises two axial end surfaces 81 and 82 which are provided with blades 26 of fans 23, 24 allowing a flow of cooling air for example by centrifugal ejection. Two surfaces 81 and 82 are located on the side of the front part and on the side of the rear part of the machine respectively. The two axial surfaces 81 and 82 are each located in one of the two planes perpendicular to axis X which delineate rotor 2.

[0069] Stator 50 comprises a winding 5 installed in the slots forming a front winding head 51 which extends from an axial end of the stator body 4 towards the front part of the machine and a rear winding head 53 which extends from another axial end of the stator body towards the rear part of machine 1.

[0070] In electric machine 100 illustrated on FIG. 3, front winding head 51 completely masks blades 26 of axial surface 81 located on the front side of the machine, along a direction perpendicular to axis X.

[0071] For this purpose, the level along axis X of front winding head 51 is higher or equal to the level along axis X of masked blades 26. A plane 85 passing between two wheels 7 and 8 of rotor 2 is defined by a dotted line on FIG. 3.

[0072] A plane 83 comprising the axial end of front winding head 51 is defined, said axial end corresponding to the point of winding head 51 furthest from stator body 4 along axis X. This plane is illustrated by a dotted line on FIG. 3.

[0073] A plane 84 comprising the axial end of blades 26 is defined, said axial end corresponding to the point of blades 26 furthest from wheel 7 along axis X. This plane is illustrated by a dotted line on FIG. 3.

[0074] Thus level of winding head 51 is understood to mean the distance between plane 83 and plane 85 and similarly, level of blades 26 of axial surface 81 is understood to mean the distance between plane 84 and plane 85. For example, it may be proposed that the difference between the level of winding head 51 and the level of blades 26 of axial surface 81 ranges between 0 and 1 mm.

[0075] Stator body 4 for example is formed by a stack of steel sheets having a height Hs defined as the distance between two planes perpendicular to axis X delineating the stator body.

[0076] Front 51 and rear 53 winding heads each exhibit a height defined as the distance between the plane perpendicular to axis X comprising the point of the winding head furthest from the stator body and one of the two planes perpendicular to axis X delineating the stator body.

[0077] According to an embodiment of the invention, height Ha of front winding head 51 is 23 mm, height Hb of rear winding head 53 is 22 mm and height Hs of the stack of steel sheets forming body 4 of stator 50 is 35 mm.

[0078] Thus, when defining a R1 ratio, allowing the difference between the front winding head and the rear winding head to be related to the height of winding head body 4, R1=23−22/35=0.0285 is obtained.

[0079] According to an embodiment of the invention, it may be proposed that the height of the front winding head is adjusted relative to the rear winding head, so that the R1 ratio ranges between 1 and 5%, for example between 2 and 4%.

[0080] This difference in level between front winding head 51 and rear winding head 53 can be obtained by offsetting winding 5 relative to the stator body.

[0081] According to an embodiment illustrated on FIG. 3, winding 5 installed in the slots is offset relative to the stator body, so that front winding head 51 completely masks blades 26 of axial surface 81 located on the front side of the machine, while blades 26 of axial surface located 82 on the rear side of the machine axially overlap rear winding head 53.

[0082] By masking blades 26 of axial surface 81 located on the front side of the machine, the noises generated by the air speed centrifuged by these blades 26 are greatly reduced.

[0083] Indeed, the front winding head will thus act as screen for the noises of the centrifugal air flows, these air flows allowing the machine to be cooled by circulation of an air flow on front winding head 51 in particular.

[0084] For the purpose of illustration, FIG. 3 shows the flow of cooling air in the front part of the machine. This flow comprises an aspiration of the cooling air through openings 60 of the flange, its centrifugal ejection by blades 26, then its passage in the space between front winding head 51 and front flange 16 to cool the front winding head, and finally its exit through openings 61.

[0085] Rear winding head 53 is less critical for the noise, because the flows are more erratic in particular due to the presence of the electronic part being cooled and axial flows which make the centrifugal flows less dominant. Thus, even if rear winding head 53 masks blades 26 of axial surface 82 located on the rear side of the machine to a lesser extent because of the shift towards the front of winding 5, a reduction in the total noise is obtained.

[0086] Among the noises generated by a rotating rotor, certain harmonics related to the geometry of the rotor are dominant. In particular, the number of blades of the rotor on axial surface 81 located on the front side, the number of blades of the rotor on axial surface 82 located on the rear side and the number of pairs of poles can be cited. The intention according to the invention is to prevent these numbers from being identical which a summation of several harmonics of the same order would induce.

[0087] Indeed, for a given sound volume of the noise components, with several noise components of the same harmonic order, the perceived sound volume is louder than with several noise components having different harmonic orders.

[0088] Thus to avoid this, it may be proposed that rotor 2 comprises a number of pairs of poles different from that of the number of blades 26 of the two axial end surfaces 81, 82 respectively. For example, the number of pairs of pole is 8, while the number of blades is 11 or 13.

[0089] The performance of the cooling of the machine and in particular of front winding head 51 is related to the flow of cooling air blown by blades 26 of the axial surface located on the front side of the machine. On the other hand, the noise generated by these flows is directly related to the air velocity. Thus, in order to minimize this noise, it may be proposed in particular that front winding head 51 has a form allowing a reduced ejection velocity of the air for a given ejection rate. Thus, while keeping a given air speed, it is possible to minimize the flow velocity of the cooling air.

[0090] For this purpose, a winding head form allowing the surface of the air flow to be increased can be envisaged for example. Indeed, for a given speed, the velocity can thus be lowered while increasing the surface of the flow.

[0091] FIG. 4 illustrates a detail of stator 50 according to the invention. It comprises a stator body 4, a winding 5 installed in slots 93, the winding forming front winding head 51 and rear winding head 53.

[0092] It is envisaged that the winding heads comprise wires 90 provided with two axial portions 91 extending along axis X and a transverse portion 92 extending in a plane perpendicular to axis X, front winding head 51 forming spacings 94 located between the transverse portions and stator body 4.

[0093] These spacings 94 allow passage of the air. Thus a surface of the flow which increases and therefore a reduction in the flow velocity and in the noise are obtained for a given speed.

[0094] In the embodiment illustrated on FIG. 4, the winding heads comprise groups of wires which extend between two slots. The wires of these groups of wires comprise two axial portions 91 and a transverse portion 92. Thus these groups of wires substantially exhibit the shape of a rectangle.

[0095] It may be proposed according to another embodiment that the form of each of these groups is triangular or conical, which makes it possible to substantially increase the surface of the centrifugal flow of the flows in order to limit their velocity. However, in this case a compromise must be respected, because the function of sound screen of the winding head can be limited by these forms. For this purpose, it may be proposed that winding head 51 comprises a head having a conical form, the head being the part of the winding head axially furthest from stator body 4. The head comprises the axial end of front winding head 51. Thus a good compromise between reduction in the velocity and conservation of the screen function is achieved.

[0096] FIG. 5 illustrates stator 50 according to an embodiment.

[0097] This stator comprises stator body 4 provided with slots 93 with tooth roots. It is delineated by an internal diameter Dint and an external diameter Dext. According to the embodiment it comprises 72 slots, Dint=96 mm and Dext=126 mm. Other numbers of slots could be envisaged, 36, 48, 60, 84, 96 for example.

[0098] Thus, when defining a R2 ratio of the external diameter to the internal diameter, R2=126/96=1.3125 is obtained.

[0099] The noise emitted by a rotating electric machine comprises many components each with a particular harmonic order. Every one of these components has a sound level dependant on the geometry of the elements of the rotor and/or stator. In particular, the noise comprises an even-order harmonic component 12 which is related to the number of claws of the rotor and the number of winding heads of the stator. The noise also comprises an odd-order harmonic component 11 which is related to the number of fan blades of the rotor. The noise has a sound level which is the sum of the sound levels of all these components.

[0100] So as to evaluate the advantage offered by the invention, it is expedient to compare one of the sound levels of the noise emitted by the machine according to the invention as a function of a number of revolutions of the rotor with a sound level corresponding to the noise emitted by a machine of the prior art. For this purpose, FIG. 6 shows two groups of curves 112 and 113. Group 112 illustrates a sound level of the rotating electric machine as illustrated on FIG. 1 while group 113 illustrates a sound level of the rotating electric machine as illustrated on FIG. 3.

[0101] Axis 110 illustrates the number of revolutions in rpm. This axis 110 comprises a lower limit 117 with a value of 9000 rpm for example and an upper limit 118 with a value of 18000 rpm for example. Axis 110 is graduated in 1000's and comprises secondary graduations of 500. Axis 110 moreover comprises an intermediate value 119 of 13204 rpm.

[0102] Axis 111 illustrates the value of the sound level expressed in dBW (A). This axis 111 comprises a lower limit 115 with a value of 85 dBW (A) for example and an upper limit 116 with a value of 105 dBW (A) for example. Axis 111 is graduated in 1's.

[0103] As known by the person skilled in the art, a value expressed in dBW (A) indicates an evaluation in decibels of a sound level with weighting A of the standard IEC 61672-1. This weighting is designed to take account of the average sensitivity of the ear of a person whose hearing is considered normal for each waveband. This weighting thus enables a sound level perceived by a user of the automotive vehicle to be illustrated.

[0104] For example, the sound level of the groups of curves 112 and 113 illustrated on FIG. 6 is that of the odd-order component 11, also known as harmonic order 11.

[0105] Thus the group of curves 113 comprises 3 curves each representing the sound level of the harmonic order 11 according to the number of revolutions of the rotor for an electric machine known by the person skilled in the art. Group of curves 112 comprises 3 curves representing the sound level of the harmonic order 11 according to the number of revolutions of the rotor for an electric machine in which front winding head 51 masks the blades of the fans of axial end surface 81 located on the front side of the machine by means of a shift of winding 5 towards the front of the machine, so that height Ha is greater by 1 mm than height Hb.

[0106] Thus a reduction in the sound level of about 3 dB for the harmonic 11 is noted for similar machines, while the overall sound level (not illustrated) is reduced by about 1 dB.

[0107] FIG. 7 illustrates a machine according to a second embodiment of the invention. This machine comprises two flow windows 101 and 102 of the cooling air which are defined between casing 1 and front winding head 51, the thickness of casing 1 being reduced to the level of these windows 101, 102 to allow an increase of said window. Thus, for a given air speed, the flow velocity can be reduced and therefore the noise can be abated.

[0108] For example, as illustrated on FIG. 7, the thickness of the front flange can be reduced by 1 mm.

[0109] FIG. 8 illustrates a method for constructing a rotating electric machine 1 as illustrated on FIGS. 3 and 7.

[0110] With reference to FIG. 3, this electric machine is provided with an axis X and comprises a front part 16 and a rear part 17 relative to axis X.

[0111] The machine moreover comprises a rotor 2 of axis X comprising two axial end surfaces 81, 82 which are provided with fan blades 26 allowing a flow of cooling air for example by centrifugal ejection. These two axial surfaces 81, 82 are located on the side of the front part and on the side of rear part 17 of machine 1 respectively.

[0112] The machine moreover comprises a stator 50 which includes a stator body 4 having slots 93 and surrounds said rotor 2.

[0113] The method illustrated on FIG. 8 comprises: [0114] a winding stage 601 of copper wires in said slots 93 so as to form a front winding head 51 which extends from an axial end of stator body 4 towards front part 16 of machine 1 and a rear winding head 53 which extends from another axial end of stator body 4 towards rear part 17 of machine 1, [0115] an offsetting stage 602 along an axial direction of the winding relative to stator body 4, so that axial front winding head 51 completely masks blades 26 of axial surface 81 located on the front side of machine 1, along a direction perpendicular to axis X.

[0116] The invention is applicable to rotors having blades 26 higher, or equal, at the level of axial surface 81 located on the front side of the machine, than at the level of axial surface 82 located on the rear side of the machine. The invention is also applicable to rotors having blades 26 higher at the level of the axial surface 82 located on the side rear machine than at the level of axial surface 81 located on the front side of the machine. The invention is applicable to all types of fan blades, whether they are centrifugal or mixed.