Abstract: The present invention provides an aluminum alloy for die castings that has superior castability and corrosion resistance. The amounts of Mn, Fe and Cu contained in the aluminum alloy components for die castings were determined to have a considerable effect on the corrosion resistance of the aluminum alloy. Therefore, the aluminum alloy for die castings of the present invention contains 9.0 to 12.0% by weight of Si, 0.20 to 0.80% by weight of Mg, and 0.7 to 1.1% by weight of Mn+Fe, the Mn/Fe ratio is 1.5 or more, the amount of Cu as impurity is controlled to 0.5% by weight or less, and the remainder is composed of aluminum and unavoidable impurities.

Abstract: The vehicle AC generator includes a frame including an end wall section and a peripheral wall section, a stator core, a stator coil having rear and front coil ends projecting axially rearward and frontward respectively from the stator core, a rotor supported by the frame, and a cooling fan having centrifugal blades and fixed to the rotor. The peripheral wall section has a cooling air discharge opening adjoining the end wall section. The end wall section has a centrifugal-blade-facing portion axially facing the centrifugal blades, and a coil-end-facing portion axially facing the rear coil end. The coil-end-facing portion is bent at a predetermined curvature radius and extending from the centrifugal-blade-facing portion to the cooling air discharge opening. The inner end surface of the coil-end-facing portion is formed with a recess located axially rearwardly of a radial extension line of an inner end surface of the centrifugal-blade-facing portion.

Abstract: In an AC generator for a vehicle, an end cover has two types of parts, one-type part is away from a rib part in a positive cooling fin, and the other-type part is close to the rib part. The rib part projects toward the end cover side. The one-type part is thinner than the other-type part in the end cover in order to reduce the variation of thermal expansion in each part of the end cover. This configuration increases anti-thermal fatigue of the end cover.

Abstract: In an alternating-current generator, an end wall of a frame is provided with a plurality of fin supports separately arranged on the outer surface of the end wall. The cooling fin is mounted on the plurality of fin supports. The end wall is provided with a plurality of reinforcements each arranged between a corresponding one of the plurality of fin supports and another one thereof and each configured to reinforce a rigidity of a portion of the end wall. The corresponding one of the plurality of fin supports and another one thereof are adjacent to each other in a circumferential direction of the axis of the rotor. The rigidity-reinforced portion of the end wall is located between the corresponding one of the plurality of fin supports and another one thereof.

Abstract: A vehicle alternator is disclosed having a stator, a rotor, a frame surrounding the stator and the rotor, a bowl-shaped end cover mounted on the frame and defining an electric component-part compartment, a brush unit held in sliding contact with slip rings of a rotary shaft, and a rectifier unit. The rectifier unit includes a terminal block embedded with A.C. conductive segments for multi-phase windings of a stator coil. The end cover includes a base wall portion and protective partitioned compartments axially protruding from a base wall portion of the end cover toward the frame at circumferentially spaced positions for the multi-phase windings, respectively, for surrounding at least one circumference of a connecting portion between an exposed end portion of each A.C. conductive segment and a diode lead and a connecting portion between the exposed end portion of each A.C. conductive segment and a stator lead.

Abstract: A vehicle alternator is disclosed having a stator, a rotor, a frame surrounding the stator and the rotor, a bowl-shaped end cover mounted on the frame and defining an electric component-part compartment, a brush unit held in sliding contact with slip rings of a rotary shaft, and a rectifier unit. The rectifier unit includes an insulating terminal block radially extending in face-to-face relation to the one end face of the frame, a positive-side cooling fin carried on one surface of the insulating terminal block, and a negative-side cooling fin carried on the other surface of the insulating terminal block. At least one of the insulating terminal block and the end cover has a heat shield plate member laterally extending through a radial space between the cooling fins and the brush unit in a direction substantially parallel to the axis of the rotary shaft.

Abstract: In a vehicular alternator having a permanent magnet protection mechanism, each magnet holder of a non-magnetic characteristic if a rectangle prism shape accommodates each permanent magnet disposed between adjacent claw poles. The magnet holders are connected in a ring shape along a circumferential direction of the alternator by using each connecting plate part which extends from each magnet holder in approximate circumferential direction toward an inner side of and at a front tip part of each claw pole. The connecting plate parts and the magnet holders are made from a non-magnetic plate by cutting and bending. Making the surfaces and the connecting plate part of each magnet holder from the non-magnetic plate by cutting and bending provides a high accuracy magnet position in the alternator with low manufacturing cost.

Abstract: The present invention provides an aluminum alloy for die castings that has superior castability and corrosion resistance. The amounts of Mn, Fe and Cu contained in the aluminum alloy components for die castings were determined to have a considerable effect on the corrosion resistance of the aluminum alloy. Therefore, the aluminum alloy for die castings of the present invention contains 9.0 to 12.0% by weight of Si, 0.20 to 0.80% by weight of Mg, and 0.7 to 1.1% by weight of Mn+Fe, the Mn/Fe ratio is 1.5 or more, the amount of Cu as impurity is controlled to 0.5% by weight or less, and the remainder is composed of aluminum and unavoidable impurities.

Abstract: A vehicle alternator is disclosed having a stator, a rotor, a frame surrounding the stator and the rotor, a bowl-shaped end cover mounted on the frame and defining an electric component-part compartment, a brush unit held in sliding contact with slip rings of a rotary shaft, and a rectifier unit. The rectifier unit includes an insulating terminal block radially extending in face-to-face relation to the one end face of the frame, a positive-side cooling fin carried on one surface of the insulating terminal block, and a negative-side cooling fin carried on the other surface of the insulating terminal block. At least one of the insulating terminal block and the end cover has a heat shield plate member laterally extending through a radial space between the cooling fins and the brush unit in a direction substantially parallel to the axis of the rotary shaft.

Abstract: In an alternating-current generator, an end wall of a frame is provided with a plurality of fin supports separately arranged on the outer surface of the end wall. The cooling fin is mounted on the plurality of fin supports. The end wall is provided with a plurality of reinforcements each arranged between a corresponding one of the plurality of fin supports and another one thereof and each configured to reinforce a rigidity of a portion of the end wall. The corresponding one of the plurality of fin supports and another one thereof are adjacent to each other in a circumferential direction of the axis of the rotor. The rigidity-reinforced portion of the end wall is located between the corresponding one of the plurality of fin supports and another one thereof.

Abstract: An alternator for a vehicle is provided which is equipped with a rectifier. The rectifier includes a positive-side radiator fin in which a positive rectifying device is installed. An output terminal through which dc voltage is outputted has a rectangular head and is fit in a through hole formed in the positive-side radiator fin. Ribs are formed on the positive-side radiator fin across the through hole. The rectangular head of the output terminal is shaped to have two sides and a diagonal line. The diagonal line is longer than an interval between the ribs. The sides are located at a distance away from each other which is smaller than the interval between the ribs. Specifically, the ribs serve as stoppers on which corners of the head hits when excessive torque acts on the output terminal, thereby minimizing deformation of the positive-side radiator fin and undesirable rotation of the output terminal.

Abstract: A vehicle alternator is disclosed having a stator, a rotor, a frame surrounding the stator and the rotor, a bowl-shaped end cover mounted on the frame and defining an electric component-part compartment, a brush unit held in sliding contact with slip rings of a rotary shaft, and a rectifier unit. The rectifier unit includes a terminal block embedded with A.C. conductive segments for multi-phase windings of a stator coil. The end cover includes a base wall portion and protective partitioned compartments axially protruding from a base wall portion of the end cover toward the frame at circumferentially spaced positions for the multi-phase windings, respectively, for surrounding at least one circumference of a connecting portion between an exposed end portion of each A.C. conductive segment and a diode lead and a connecting portion between the exposed end portion of each A.C. conductive segment and a stator lead.

Abstract: In an AC generator for a vehicle, an end cover has two types of parts, one-type part is away from a rib part in a positive cooling fin, and the other-type part is close to the rib part. The rib part projects toward the end cover side. The one-type part is thinner than the other-type part in the end cover in order to reduce the variation of thermal expansion in each part of the end cover. This configuration increases anti-thermal fatigue of the end cover.

Abstract: The vehicle AC generator includes a frame including an end wall section and a peripheral wall section, a stator core, a stator coil having rear and front coil ends projecting axially rearward and frontward respectively from the stator core, a rotor supported by the frame, and a cooling fan having centrifugal blades and fixed to the rotor. The peripheral wall section has a cooling air discharge opening adjoining the end wall section. The end wall section has a centrifugal-blade-facing portion axially facing the centrifugal blades, and a coil-end-facing portion axially facing the rear coil end. The coil-end-facing portion is bent at a predetermined curvature radius and extending from the centrifugal-blade-facing portion to the cooling air discharge opening. The inner end surface of the coil-end-facing portion is formed with a recess located axially rearwardly of a radial extension line of an inner end surface of the centrifugal-blade-facing portion.

Abstract: In a vehicular alternator having a permanent magnet protection mechanism, each magnet holder of a non-magnetic characteristic if a rectangle prism shape accommodates each permanent magnet disposed between adjacent claw poles. The magnet holders are connected in a ring shape along a circumferential direction of the alternator by using each connecting plate part which extends from each magnet holder in approximate circumferential direction toward an inner side of and at a front tip part of each claw pole. The connecting plate parts and the magnet holders are made from a non-magnetic plate by cutting and bending. Making the surfaces and the connecting plate part of each magnet holder from the non-magnetic plate by cutting and bending provides a high accuracy magnet position in the alternator with low manufacturing cost.

Abstract: The present invention provides an aluminum alloy for die castings that has superior castability and corrosion resistance. The amounts of Mn, Fe and Cu contained in the aluminum alloy components for die castings were determined to have a considerable effect on the corrosion resistance of the aluminum alloy. Therefore, the aluminum alloy for die castings of the present invention contains 9.0 to 12.0% by weight of Si, 0.20 to 0.80% by weight of Mg, and 0.7 to 1.1% by weight of Mn+Fe, the Mn/Fe ratio is 1.5 or more, the amount of Cu as impurity is controlled to 0.5% by weight or less, and the remainder is composed of aluminum and unavoidable impurities.

Abstract: A vehicle alternator has an armature coil, a rectifier, and a terminal connector. The armature coil has a substantial rectangular cross-section. The rectifier rectifies a voltage induced at the armature coil. The terminal connector includes a crimping portion and a connecting portion. The crimping portion is crimped onto a lead of the armature coil. The connecting portion is fixed to an input terminal of the rectifier with a screw. The crimping portion of the terminal connector is crimped onto the lead so that two opposed surfaces of the lead have surface contact with the terminal connector.

Abstract: A brushless-type alternator has a rotor, which comprises a pair of pole cores. The pole cores include a plurality of nail parts, respectively. The nail parts are arranged alternately in a rotating direction of the rotor. The nail parts are coupled to-each other with a non-magnetic ring. A permanent magnet is interposed between adjacent two of the nail parts, and fixedly held in position with the non-magnetic ring. The permanent magnets are located radially inside or outside the non-magnetic ring.

Abstract: A vehicle AC generator includes a rotor, a stator having a stator core and a stator winding, a pair of front and rear frames and electric components including a rectifier unit and other electrical parts disposed rear of the rear frame. The stator winding is connected to the rectifier unit by one of means of welding, soldering and clamping, and the rear frame has a stay having a fixing surface disposed rear of the electric components. Therefore, it is not necessary to provide a space for screwing a screw bolt to connect the stator winding and the rectifier unit. Because cooling air is discharged from a discharge window along the stay, heated air will not return to any of air intake window.

Abstract: A vehicle alternator has an armature coil, a rectifier, and a terminal connector. The armature coil has a substantial rectangular cross-section. The rectifier rectifies a voltage induced at the armature coil. The terminal connector includes a crimping portion and a connecting portion. The crimping portion is crimped onto a lead of the armature coil. The connecting portion is fixed to an input terminal of the rectifier with a screw. The crimping portion of the terminal connector is crimped onto the lead so that two opposed surfaces of the lead have surface contact with the terminal connector.