JP2001045714A - Permanent magnet generator and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a permanent magnet generator of superior power generation coil cooling efficiency, and a method for its manufacture. SOLUTION: Since an inlet part connecting to a through-hole 3e is formed in the inner circumferential wall 3m of a recess 3d in a flywheel 3, all the oil which has entered into an oil trap 15 through a sprag 4 is made to flow into the through-hole 3e through the inlet by centrifugal force, discharged through an outlet connecting to the through-hole 3e formed on a stator 6 side, and reaches a power generating coil 6b. Therefore, the power generating coil can be cooled sufficiently in the oil. In addition, since wear powder discharged into the oil trap 15 from a bearing 12 and the sprag 4 is discharged through the through-hole 3e, wear powder will not deposit in the oil trap 15.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a magnet generator and a method for manufacturing the same, and more particularly to a magnet generator with a clutch mechanism for an internal combustion engine (hereinafter referred to as an "internal combustion engine") and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, a magnet generator has been frequently used as a generator for a motorcycle. In order to obtain high output from the magnet generator, it is important to suppress the temperature rise of the generator coil of the stator.

[0003] As a method of cooling the generator coil of the stator, for example, a method used for a magnet generator disclosed in Japanese Patent Application Laid-Open No. 59-35547 is known. In this magnet generator, a centrifugal fan is provided on a flywheel, and the centrifugal fan air-cools a generator coil of a stator.

There is also known a method in which oil cooled in a stator is generated by directly spraying oil cooled from a window hole provided on an end face of the rotor on the side opposite to the stator with a nozzle to cool the generator coil. If the magnet generator has a clutch mechanism,
In general, the cooling of the power generation coil involves technical difficulties because the oil must pass through a plurality of rotating members before reaching the power generation coil.

FIG. 6 shows an example of a magnet generator with a clutch mechanism.
Shown in In this magnet generator with a clutch mechanism, oil reaches the generating coil 110 via the free wheel gear 108, the sprag 114 and the flywheel 101, or the bearing 105 and the flywheel 101.

A flywheel 101 is provided so as to rotate around the stator 111. A plurality of power generating coils 110 are circumferentially arranged on the stator 111, and a plurality of permanent magnets 109 are circumferentially arranged on the flywheel 101. Flywheel 101 and clutch plate 102
Is fixed so as to rotate with the crankshaft 106. A bearing 105 is provided on the crankshaft 106.
, A free wheel gear 108 is supported. The free wheel gear 108 is driven by a starter (not shown). Rotation of free wheel gear 108 is sprag 1
14, the clutch plate 102, the flywheel 10
8, and to the crankshaft 106.

A stator 111 is mounted on an engine body (not shown).
Is provided with an injection unit 107 for circulating oil. The injection unit 107 injects oil into holes 112 formed in the bearing 105 and the free wheel gear 108.
Oil is supplied to the bearing 105, hole 112 and sprag 11
4 and is supplied to the concave portion 104 formed in the flywheel 101. As the flywheel 101 rotates, centrifugal force acts on the oil accumulated in the concave portion 104, and the oil is injected into the power generation coil 110 through the oblique hole 103 formed in the flywheel 101.

[0008]

In the above-described magnet generator with a clutch mechanism, the oil accumulated in the concave portion 104 is injected into the power generation coil 110 by centrifugal force. Hole 1
03 must be formed.

However, such oblique holes 103
Are bearings 105, sprags 106 and recesses 104
From the boss 113 of the flywheel 101
It is formed in the vicinity. For this reason, the oil injection position becomes far from the power generation coil 110. The piercing position is the boss 1
13, it is not possible to increase the hole diameter due to a problem in strength. Further, since the oil moves to the outermost peripheral portion of the concave portion 104 due to centrifugal force, the injection portion 107
Some of the oil injected from the nozzle does not enter the oblique hole 103. Therefore, it is difficult to supply a large amount of oil to the power generation coil 110, and there has been a problem that a sufficient cooling effect cannot be obtained.

[0010] In addition, when the oblique hole 103 is drilled, drilling is more difficult than in the case where drilling is performed in parallel with the axis of the flywheel 101, and the number of steps is increased or the processing equipment is complicated. Therefore, there is a problem that the manufacturing cost increases.

On the other hand, when a flywheel is provided with a centrifugal fan and the generator coil of the stator is air-cooled by the centrifugal fan, the air moves only on the stator side, and the cooling effect is lower than when the generator coil is cooled with oil. Is inferior.

The present invention has been made in order to solve such a problem, and an object of the present invention is to provide a magnet generator having high cooling efficiency of a power generation coil and a method of manufacturing the same. Another object of the present invention is to provide a magnet generator capable of reducing the manufacturing cost and a method for manufacturing the same.

[0013]

According to the magnet generator of the present invention, for example, the oil is removed from the gap of the sprag provided in the clutch, the gap of the bearing provided between the free wheel gear and the shaft, and the like. Oozes out and the coolant such as engine oil flows into the recess of the flywheel.
The coolant stored in the concave portion moves radially outward of the concave portion by centrifugal force generated by rotation of the flywheel, and moves along the inner peripheral wall when reaching the inner peripheral wall of the concave portion. Because the inlet of the through hole is formed in the inner peripheral wall,
All the coolant flows from the inlet into the through hole. The coolant that has flowed into the through hole is discharged from a discharge port formed at the end face on the stator side at the bottom of the flywheel. The coolant discharged from the outlet moves to the stator side by inertia and reaches the power generating coil.

According to the first aspect of the present invention, since the inlet of the through hole is formed in the inner peripheral wall of the concave portion, the coolant flowing into the concave portion from the passage of the clutch portion is subjected to centrifugal force. All flow into the through hole from the inlet and are discharged from the outlet to reach the power generation coil. Therefore, the power generation coil can be sufficiently cooled by the coolant. Further, since abrasion powder discharged from the clutch portion to the recess of the flywheel is discharged to the stator through the through hole, the abrasion powder does not enter the bearings and sprags serving as the sliding portions, so that smooth sliding can be achieved. You can keep moving.

According to the magnet generator of the present invention, since the axis of the through hole is parallel to the axis of the flywheel,
It is easy to drill through holes. Therefore, the manufacturing cost of the magnet generator can be reduced.

According to the magnet generator of the third aspect of the present invention, since the tapered portion extending from the inlet to the outlet is formed in the through hole, the cooling flowing into the through hole from the inlet by centrifugal force. The liquid can move toward the outlet without staying in the through hole. Therefore, it is possible to increase the amount of the coolant supplied to the power generation coil.

According to the magnet generator of the fourth aspect of the present invention, the injection unit injects the coolant toward the intake hole formed in the free wheel gear. For this reason, the amount of the coolant supplied to the passage of the clutch unit can be increased. Therefore, the amount of coolant flowing into the recess from the passage increases, and the amount of coolant supplied to the power generation coil increases.

According to the magnet generator of the fifth aspect of the present invention, the flywheel has a wheel portion on which a permanent magnet is disposed, a boss portion into which a shaft portion is inserted, and a radially outward direction from the boss portion. And a flange formed integrally with a flange portion formed with a concave portion. Therefore, the man-hour for assembling the flywheel can be reduced.

According to the magnet generator of the present invention, the flywheel has a wheel portion on which a permanent magnet is disposed, a boss portion formed separately from the wheel portion and having a shaft portion inserted therein, A flange portion formed radially outward from the boss portion and to which the wheel portion is fixed. By configuring the flywheel from a plurality of members, a versatile flywheel can be realized. For example, by replacing a plurality of bosses according to the outer diameter of the crankshaft at the time of manufacturing, it becomes possible to attach the same wheel to a plurality of types of crankshafts. In addition, since the through-hole includes the first through-hole formed in the flange portion and the second through-hole formed in the wheel portion, the shape of the through-hole can be diversified. For example, by forming the second through hole at a position farther from the axis of the boss portion than the first through hole, the coolant can be discharged to the power generation coil side from a position closer to the power generation coil.

According to the method of manufacturing a magnet generator of the present invention, since the hole is drilled in the axial direction of the flywheel so as to intersect the outer periphery of the concave portion and communicate the inside and the outside of the bottom portion of the flywheel, one cycle of the drilling is performed. A through hole having an inlet formed in the inner peripheral wall of the concave portion can be formed by drilling. Therefore, the manufacturing cost of the magnet generator according to the first to fifth aspects of the present invention can be reduced.

[0021]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing a first embodiment of the present invention; (First Embodiment) FIG. 1 shows a magnet generator with a clutch mechanism according to a first embodiment of the present invention. The magnet generator with a clutch mechanism of this embodiment is directly connected to an engine crankshaft of a motorcycle. In this embodiment, the permanent magnet 10 installed on the flywheel 3 rotates around the power generation coil 6b with the rotation of the crankshaft 13, so that an electromotive force is generated in the power generation coil 6b. Electric power is supplied to an electric system such as a battery and an ignition device.

A stator 6 is fixed by bolts 9 to an engine case cover 8 attached to an engine body (not shown). Power generation coil 6b wound around stator 6
Are fixed to the outer peripheral portion in a ring shape. The crankshaft 13 as a shaft is rotatably supported by a bearing fixed to the engine body, and protrudes into the internal space of the engine case cover 8.

The free wheel gear 1 is supported by a crankshaft 13 with a bearing 12 interposed therebetween. The bearing 12 has a gap between the crankshaft 13 and the free wheel gear 1 for allowing oil to permeate from the engine body side to the flywheel 3 side. A plurality of intake holes 1a are formed in the free wheel gear 1 and arranged in the circumferential direction. The free wheel gear 1 is driven to rotate by a starter (not shown). The injection unit 11 is a free wheel gear 1
The oil is injected into the intake hole 1a and the bearing 12 as a coolant stored in the engine body.

A sprag 12 is provided between the free wheel gear 1 and the clutch plate 2. The sprag 12 is a so-called one-way clutch, and when the free wheel gear 1 tries to rotate relative to the clutch plate in a predetermined one direction,
The torque of the free wheel gear 1 is transmitted to the clutch plate 2,
When the free wheel gear 1 relatively rotates in the opposite direction, the torque of the free wheel gear 1 is not transmitted to the clutch plate 2. The sprags 4 constitute a passage between the flywheel 1 and the clutch plate 2 for allowing oil to permeate from the engine body side to the flywheel 3 side. The annular clutch plate 2 meshes with the sprag 12 and is fixed to the flange 3 b of the flywheel 3 by bolts 5. The clutch part is composed of a sprag 4 and a clutch plate 2.

The flywheel 3 is provided to face the stator 6. The flywheel 3 has a cylindrical boss 3
a, a molded body including a cylindrical wheel portion 3c and a disk-shaped flange portion 3b connecting the boss portion 3a and the wheel portion 3c. The boss 3a is connected to the crankshaft 13
The inner wall 3g is formed in a tapered shape so as to fit into the tapered portion 13a formed at the end of the inner wall. The crankshaft 13 and the boss 3a are fixed by bolts 7.
A plurality of permanent magnets 10 are installed in the circumferential direction on the inner peripheral side of the wheel portion 3c. Peripheral edge 3 of wheel 3c
By caulking f, the case 14 becomes the peripheral edge 3f.
And the permanent magnet 10 is pressed against the inner peripheral wall of the wheel portion 3c so that the permanent magnet 10 does not separate from the flywheel 3 by impact.

FIG. 2 is a plan view of the flywheel 3 as viewed from the engine body side. A concave portion 3d, a clutch mounting seat 3h, and a clutch fixing wall 3k are formed concentrically on the outer wall of the flange portion 3b on the engine body side in a radially outward direction from the center. Since the clutch mounting seat portion 3h is formed so as to be raised one step around the concave portion 3d, the concave portion 3d
Is formed with an inner peripheral wall 3m. The clutch fixing wall 3k is further raised one step around the clutch mounting seat 3h. A plurality of bolt holes 3j are formed in the clutch mounting seat 3h and are arranged in the circumferential direction of the flywheel 3.

Three through-holes 3e are formed at equal intervals in the circumferential direction at positions between the clutch mounting seat 3h and the recess 3d. Therefore, the inner peripheral wall 3m of the recess 3d is
e, an opening as an inlet is formed in the inner peripheral wall 3m. The axis of the through hole 3e is parallel to the axis of the flywheel 3, that is, the axis of the boss 3a. The opening of the through hole 3e formed in the outer wall of the flange portion 3b on the stator side constitutes a discharge port. The number of the through holes 3e is not limited to three, and it is sufficient that at least one through hole is formed.

The flywheel 3 and the clutch plate 2 are fixed by bolts 5, and the clutch plate 2 comes into contact with the clutch mounting seat 3h. When the flywheel 3 and the clutch plate 2 are fixed in this way, the wall surface of the concave portion 3d, the end surface of the sprag 4, the end surface of the free wheel gear 1, the bearing 1
2 and an oil reservoir 15 surrounded by the outer wall surface of the crankshaft 13. The oil sump 15 communicates with the space on the engine body side through a gap formed in the bearing 12 and the sprag 4, and communicates with the space on the stator 6 side through the through hole 3e.

The configuration of the magnet generator with the clutch mechanism according to the first embodiment of the present invention has been described above. Hereinafter, the operation of the magnet generator with the clutch mechanism will be described. (a) Engine Start When the starter rotates, the torque of the starter is transmitted to the free wheel gear 1. When the free wheel gear 1 tries to rotate with respect to the stopped clutch plate 2, the torque of the free wheel gear 1 is transmitted to the clutch plate 2 by the sprags 4. When torque is transmitted from the starter to the clutch plate 2, the flywheel 3 and the crankshaft 13 rotate, and the crankshaft 13 reciprocates a cylinder (not shown). When the crankshaft 13 is rotating at a predetermined speed or more, the engine starts when the fuel spray supplied to the combustion chamber is ignited.

When the cylinder reciprocates due to the combustion and expansion of the air-fuel mixture in the combustion chamber, the angular speed at which the clutch plate 2 rotates by the torque of the crankshaft 13 is increased by the torque of the starter.
Exceeds the angular velocity at which it rotates. By operating the sprags 4, the crankshaft 13 and the free wheel gear 1 can rotate at different angular velocities. After the reciprocation of the cylinder is stabilized, the starter is stopped.

(B) Power generation by magnet generator When the crankshaft 13 rotates, the flywheel 3
Rotates together with the crankshaft 13. At this time,
Since the permanent magnet 10 rotates around the power generation coil 6b,
An electromotive force is derived from the power generation coil 6b.

During the rotation of the crankshaft 13, the injection unit 1
1 keeps injecting oil stored in the engine body into the intake hole 1 a and the bearing 12. The oil thus injected passes through the gap between the bearing 12 and the sprag 4 and is stored in the oil sump 15. The oil stored in the oil reservoir 15 moves as indicated by a plurality of arrows in FIG. 2 due to centrifugal force generated as the flywheel 3 rotates. That is, the oil moves radially outward from the center of the oil reservoir 15 due to centrifugal force, and moves along the inner peripheral wall 3m when reaching the inner peripheral wall 3m of the concave portion 3d.
When the oil moves along the inner peripheral wall 3m and reaches the opening of the through hole 3e, the oil flows into the through hole 3e from the opening by centrifugal force. At this time, the oil is sprayed by the centrifugal force and flows into the through hole 3e. The mist oil flowing into the through hole 3e is discharged from an opening of the through hole 3e formed on the stator side of the flywheel 3. The mist oil discharged from the opening moves in the radial direction of the flywheel 3 by inertia and reaches the power generating coil 6b.

The oil injected into the power generation coil 6b in this way has a low temperature because it has passed through a cooling device such as an oil cooler, and can cool the power generation coil 6b. The oil that has reached the power generation coil 6b flows along the inner wall surface of the engine case cover 8 and returns to the engine body.

According to the magnet generator with a clutch mechanism of the first embodiment, since the through hole 3e is formed at a position radially outward from the flange portion 3a of the flywheel 3, the diameter of the through hole 3e is increased. Can be taken. Therefore, the amount of oil injected into the power generation coil 6b per unit time can be increased. Further, since the position where the through hole 3e is formed is close to the power generation coil 6b, the power generation coil 6b is efficiently provided.
Oil can be injected into the Therefore, the cooling efficiency of the power generation coil 6b is high.

Further, since the oil stored in the oil reservoir 15 flows into the through hole 3e from the opening formed in the inner peripheral wall 3m of the concave portion 3d by centrifugal force, the oil does not accumulate in the concave portion 3d. And bearing 12
Almost all of the oil injected into the generator coil 6b
Supplied to Therefore, the cooling efficiency of the power generation coil 6b is high.

Furthermore, since the axis of the through hole 3e is formed parallel to the axis of the flywheel 3, the through hole 3e can be easily drilled, and the manufacturing cost of the magnet generator can be reduced. It is.

Further, abrasion powder discharged from the sprag 4, the bearing 12 and the like to the oil reservoir 15 can be discharged from the through hole 3e together with the oil. The abrasion powder discharged from the through hole 3e flows along the inner wall surface of the engine case cover 8 together with the oil and returns to the engine body. The abrasion powder circulated to the engine body can be removed by an oil filter. Next, a plurality of modifications of the magnet generator with a clutch mechanism according to the first embodiment of the present invention will be described with reference to FIG.

(Modification 1) As shown in FIGS. 3 (A) and 3 (B), in Modification 1, a shallow hole is drilled at a position straddling the recess 3d and the clutch mounting seat 3h to introduce the through hole. 17 are formed. 3h clutch mounting seat
A through-hole 16 is formed in the oil reservoir, and the oil reservoir and the space on the stator 6 side communicate with each other through the introduction portion 17 and the through-hole 16.

In the first modification, the opening area of the through hole formed by cutting the inner peripheral wall 3m by the introduction portion 17 can be increased. For this reason, the amount of oil per unit time flowing from the oil reservoir to the through hole can be increased. Therefore, the amount of oil supplied to the power generation coil 6b increases, and the cooling efficiency of the power generation coil 6b can be increased.

(Modification 2) As shown in FIGS. 3 (C) and 3 (D), in modification 2, the stator 6 side of the through hole 18 formed at the position extending over the recess 3d and the clutch mounting seat 3h. Is formed with a tapered portion 18. Therefore, oil can be injected into the power generation coil 6b without storing the oil in the through hole 18, and the cooling efficiency of the power generation coil 6b can be increased.

(Second Embodiment) FIG. 4 shows a magnet generator with a clutch mechanism according to a second embodiment of the present invention. Parts that are substantially the same as in the first embodiment are given the same reference numerals, and descriptions thereof are omitted. In the second embodiment, the flywheel 20 is composed of two members.

The flywheel 20 comprises a molded body comprising a boss 21b and a flange 21a, and a wheel. The boss 21b is inserted into a tapered portion 13a formed at the end of the crankshaft 13, and the crankshaft 13 and the boss 21b are fixed by bolts 7. Flange portion 2 extends radially outward from boss portion 21b
1a is formed. The flange portion 21a is fixed to the wheel portion 20a by a rivet (not shown) or the like.

As shown in FIG. 5B, a first through hole 21d is formed in the flange portion 21a at a position straddling the clutch mounting seat portion 3h and the concave portion 3d. Therefore, the inner peripheral wall 3m of the recess 3d is partially cut off by the first through hole 21d, and an opening as an inlet is formed in the inner peripheral wall 3m. The axis of the first through hole 21d is parallel to the axis of the boss 21b. In addition, as shown in FIG.
The opening on the stator 6 side is chamfered to form a tapered portion 21e.
Is formed.

As shown in FIG. 5A, the wheel portion 20
The second through hole 2 communicating with the first through hole 21d is provided on the bottom surface of the first through hole 21d.
0b is formed. The axis of the second through hole 20b is the boss 2
1b is parallel to the axis. The second through hole 20b is the first through hole 21
It is formed at a position farther from the axis of the boss 21b than d. The opening of the second through hole 20b formed on the end face on the stator side at the bottom of the wheel portion 21a constitutes a discharge port.

The second embodiment of the present invention shows that the present invention can be applied even when the wheel portion and the boss portion are formed by different members. According to the second embodiment, since the through hole is constituted by the first through hole 21d and the second through hole 20b, the discharge port can be formed radially outside the flywheel 26 from the inlet. Therefore, the oil that has flowed into the through hole through the inlet from the concave portion 3d reaches the outlet while moving radially in the through hole by centrifugal force, and reaches the outlet through the vicinity of the power generating coil 6b.
Injected toward. The through hole has a tapered portion 21e.
Is formed, it is possible to prevent oil from accumulating in the through hole.

In the embodiments of the present invention described above,
Although the sprag 4 has been described as constituting a passage through which the coolant flows from the free wheel gear side to the flywheel side, the passage may be a through hole or the like formed in the clutch plate.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a magnet generator with a clutch mechanism according to a first embodiment of the present invention.

FIG. 2 is a plan view of the flywheel according to the first embodiment of the present invention as viewed from an engine body side.

3A and 3B are views showing a flywheel according to a modification of the first embodiment of the present invention, wherein FIG. 3A is a plan view of the flywheel according to Modification 1 as viewed from the engine body side, and FIG. (C) is a plan view of the flywheel according to the modified example 2 as viewed from the engine body side, and (D) is the D-line thereof.
FIG. 4 is a sectional view taken along line D.

FIG. 4 is a sectional view showing a magnet generator with a clutch mechanism according to a second embodiment of the present invention.

FIG. 5 is a view showing a flywheel according to a second embodiment of the present invention, wherein (A) is a plan view seen from a stator side,
(B) is a plan view as seen from the engine body side.

FIG. 6 is a sectional view showing a conventional magnet generator with a clutch mechanism.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 free wheel gear 1a intake hole 2 clutch plate (clutch portion) 3 flywheel 3a boss portion 3b flange portion 3c wheel portion 3d concave portion 3e through hole 4 sprag 6 stator 6b generating coil 10 permanent magnet 11 injection portion 13 crankshaft ( Shaft) 21e Taper

 ──────────────────────────────────────────────────続 き Continued on the front page F-term (reference) SS09 5H621 BB07 GA01 GA04 GB11 HH05 JK08 JK11 JK15 JK17 JK19

Claims (7)

[Claims] 1. A magnet generator in which a permanent magnet provided on a flywheel rotates around a stator by rotation of a shaft portion, and generates an electromotive force from a power generation coil arranged in a circumferential direction of the stator. A flywheel having a bottomed cylindrical shape, provided on the shaft portion, facing the stator, and having a recess formed in an outer wall of the bottom portion on the side opposite to the stator, and anti-fixation of the flywheel. A free wheel gear provided on the child side and supported by the shaft so as to be rotatable relative to the shaft; a clutch provided between the flywheel and the free wheel gear; and an inner peripheral wall of the recess. And a discharge hole formed in the bottom end of the flywheel on the side of the stator on the stator side. 2. The magnet generator according to claim 1, wherein an axis of the through hole is parallel to an axis of the flywheel. 3. The magnet generator according to claim 1, wherein the through hole has a tapered portion extending from the inlet to the outlet. 4. The freewheel gear has an intake hole at a position facing the passage, and an injection unit that injects the coolant toward the intake hole on a side opposite to the flywheel of the freewheel gear. The magnet generator according to claim 1, 2, or 3, further comprising: 5. The flywheel has a wheel portion on which the permanent magnet is disposed, a boss portion into which the shaft portion is inserted, and the recess portion formed radially outward from the boss portion. The magnet generator according to any one of claims 1 to 4, further comprising a molded body integrally formed with the flange portion. 6. The flywheel includes a wheel portion on which the permanent magnet is disposed, a boss portion formed separately from the wheel portion and into which the shaft portion is inserted, and a radially outward direction from the boss portion. And a flange portion to which the wheel portion is fixed, wherein the through hole is formed by a first through hole formed in the flange portion and a second through hole formed in the wheel portion. The magnet generator according to any one of claims 1 to 4, wherein: 7. The method of manufacturing a magnet generator according to claim 1, wherein the flywheel is so formed as to intersect the outer periphery of the concave portion and communicate with the inside and outside of the bottom portion of the flywheel. A method for manufacturing a magnet generator, comprising a step of drilling in an axial direction.