Denso Corporation

Akito Akimoto

Atsuo Ishizuka

Masaomi Dobashi

Makoto Taniguchi

Tetsuya Gorohata

Masahiro Takada

Masayuki Takiguchi

Shin Kusase

Takeo Maekawa

Keiji Kondou

Youichi Kamakura

Akira Fukushima

Keigo Moriguchi

Kazuhiro Nobata

Yoshinobu Yanagisawa

Noboru Taniguchi

Shuzo Muraki

Seiji Hayashi

Shinichi Ogawa

Keisuke Suga

Toshiaki Oohara

Seiji Tachibana

Keiji Kondo

Takuji Harada

Yuya Mizuma

Mitsuyuki Hayashi

Hideji Shimaoka

Noriyuki Fukui

Takeshi Kurosawa

Akio Mori

Aki Itakura

Shinichi Awano

Kentaro Mitsuki

Seiji Yamaguchi

Katsuhiko Kanoh

A stator includes a stator core having slots arranged in a circumferential direction and a stator coil formed by wave-winding continuous coil wires on the stator core. Each of the continuous coil wires has in-slot portions received in the slots and turn portions each of which connects, on the outside of the slots, one pair of the in-slot portions. The stator coil is formed, by spirally rolling a band-shaped coil wire bundle that is formed by bundling the continuous coil wires, into a cylindrical shape. In the coil wire bundle, the continuous coil wires are transposed at a plurality of locations. Moreover, in a range where the continuous coil wires extend in the circumferential direction of the stator core by one complete turn, at least one interval between adjacent transposition locations in the coil wire bundle is greater than or equal to the circumferential length of one turn portion.

Stator of rotating electric machine

A stator includes a stator core having a plurality of slots arranged in a circumferential direction and a stator coil formed by wave-winding continuous coil wires on the stator core. Each of the continuous coil wires has in-slot portions received in the slots and turn portions each of which connects, on the outside of the slots, one pair of the in-slot portions. Each of the continuous coil wires has, at root parts of the turn portions respectively connected with ends of the in-slot portions, first crank portions that are radially bent. An amount of radial bending of the first crank portions is set to be half of a radial width of the in-slot portions.

A stator includes an annular stator core having a plurality of slots arranged in the circumferential direction at predetermined intervals and a stator coil formed of a plurality of electric conductor wires mounted on the stator core. Each of the electric conductor wires has a plurality of in-slot portions received in the slots of the stator core and a plurality of turn portions that connect, on the outside of the slots, adjacent pairs of the in-slot portions. The stator coil has first and second coil end parts and that respectively protrude axially outward from a pair of axial end faces of the stator core. At each of the coil end parts, the turn portions of the electric conductor wires are stacked in a radial direction of the stator core, and the axial heights hof the turn portions are set so as to gradually increase from the radially inside to the radially outside.

Disclosed is an apparatus for rolling a substantially planar electric wire by more than one turn into a spiral shape. The apparatus includes an inner pressing member having an outer surface, an intermediate pressing member having radially inner and outer surfaces, and an outer pressing member having an inner surface. The inner and intermediate pressing members together press a first part of the electric wire between the outer surface of the inner pressing member and the inner surface of the intermediate pressing member, thereby plastically deforming the first part to extend along the outer surface of the inner pressing member. The intermediate and outer pressing members together press a second part of the electric wire between the outer surface of the intermediate pressing member and the inner surface of the outer pressing member, thereby plastically deforming the second part to extend along the outer surface of the intermediate pressing member.

Method and apparatus for rolling electric wire for stator coil of electric rotating machine

At one ends of a pair of coil wires, a pair of turn portionsare crossed. Further, the other ends of the coil wiresare held such that an angle &#x3b8; between the axes of the coil wiresfalls in a predetermined range (e.g., greater than or equal to 10&#xb0; and less than or equal to 90&#xb0;). Then, the coil wiresare rotated respectively about their axes in the same direction, so that corresponding pairs of turn portionsof the coil wiresare sequentially crossed from the one ends to the other ends, thereby interlacing the coil wires

Method of manufacturing coil assembly for electric rotating machine

A method of manufacturing a stator coil for an electric rotating machine includes the steps of: (1) forming substantially planar electric wires each of which includes in-slot portions to be received in slots of a stator core and turn portions to be located outside the slots to connect adjacent pairs of the in-slot portions; (2) rolling each of the planar electric wires through plastic deformation into a spiral or circular-arc shape; and (3) assembling the rolled electric wires together to form the stator coil. Further, in the rolling step, each of the planar electric wires is rolled by deforming each of the turn portions of the electric wire while restricting movement of at least one of the in-slot portions of the electric wire which is located closer to a rolling start end of the electric wire than the turn portion is.

Method and apparatus for manufacturing stator coil for electric rotating machine

A turn part of a lead wire includes a projection part, a slope part and a second bent part. The projection part projects from a first slot to a direction parallel to an axial direction of the stator core. The slope part is diagonally extended at an angle of less than 90 degrees aiming to a Kth slot. The Kth slot is separated from the first slot at a specific interval via a first bent part that is bent in a circumferential direction from a tip of the projection part. The second bent part is connected with the slot accommodation part accommodated in the Kth slot, and is bent to the direction parallel to the axial direction of the stator core from a tip of the slope part.

Stator of rotating electrical machine

A method is provided, for manufacturing a stator for a rotary electric machine by shrink-fitting an outer cylinder to a core assembly where a cage-shaped wound coil is assembled with segment cores. The assembly is inserted into the outer cylinder having a diameter increased by thermal expansion caused by the heat from a heating unit, while the outer diameter of the assembly is being reduced by permitting the assembly to pass through a tapered guide unit. The guide unit has a portion whose diameter is larger than an outer diameter of the assembly, and a portion whose diameter is larger than an inner diameter of the outer cylinder and smaller than an inner diameter of the cylinder in the thermally expanded state, and a tapered through hole vertically passing through the guide unit. Thus, the size of the assembly is radially reduced, with a uniform diameter being obtained throughout the assembly.

Method for manufacturing stators for rotary electric machines

A stator which may be employed in an electric rotating machine. The stator includes a stator winding which includes in-slot portions disposed in slots of a stator core. The in-slot portions are arrayed in each of the slots in a form of multiple layers aligned in a radial direction of the stator core. The stator winding is made up of a first winding and a second winding which are connected together through a joint. The first winding is defined by a portion of the stator winding between the joint and an end of the stator winding which is to be connected to an external. The second winding includes the in-slot portion placed within at least one of the slots as an outermost layer that is one of the layers placed most outwardly in the radial direction of the stator core. This results in a great decrease in leakage current.

Stator designed to minimize leakage current and electric rotating machine using same

An electric wire shaping apparatus includes a pair of male and female shaping dies and a pressing mechanism. Each of the male and female shaping dies has a shaping surface that includes a plurality of straight parts and a plurality of bent parts. The pressing mechanism moves one of the male and female shaping dies toward the other, thereby pressing a turn portion of an electric wire between the shaping surfaces of the male and female shaping dies in a width-wise direction of the turn portion. Furthermore, the male and female shaping dies are so configured that when they are located closest to each other, a gap Wbetween a corresponding pair of the bent parts of the shaping surfaces of the male and female shaping dies is different in size from a gap Wbetween a corresponding pair of the straight parts of the shaping surfaces.

Apparatus and method for shaping electric wire for stator coil of electric rotating machine

A method of manufacturing a stator includes the steps of: (1) forming substantially planar electric wires each of which includes in-slot portions to be received in slots of a stator core and turn portions to be located outside the slots to connect adjacent pairs of the in-slot portions; (2) rolling each of the planar electric wires by more than one turn into a spiral shape; (3) forming a stator coil by assembling the rolled electric wires through elastic deformation thereof; and (4) assembling the stator core and the stator coil to form the stator. Further, in the rolling step, each of the planar electric wires is rolled by plastically deforming the turn portions into circumferentially-extending sections each having a predetermined curvature. Furthermore, a curvature ratio of a radially-outermost one of the circumferentially-extending sections is set to be greater than that of a radially-innermost one of the same.

Method of manufacturing stator for electric rotating machine

A plurality of shaped wires, which are obtained by shaping electric wires, are assembled to form a wire assembly. The wire assemblyis then rolled around a core memberwith aligning membersbeing inserted into spacesformed between adjacent ones of straight superposed partsof the wire assembly

Method of manufacturing stator coil

A method of manufacturing a stator coil to be wound in and around a stator by bending an insulating-coating conducting wire so as to alternately have slot-held conductor sections to be held in slots of the stator and a coil-end conductor sections each mutually connecting two of the slot-held conductor sections outside the slots. The method includes arranging three or more pairs of molds at predetermined intervals along the insulating-coating conducting wire, each pair of molds having paired molds facing each other with the wire located therebetween. First, the coil-end conductor sections are formed by moving the mold pairs such that the paired molds come closer to each other. Then the slot-held conductor sections are formed by moving the molds, in parallel, in both the longitudinal direction along which the insulating-coating conducting wire extends and in a direction perpendicular to the longitudinal direction.

Method for manufacturing circumferentially deploying type of stator coil

A stator includes a stator-core having slots and teeth, and a back-yoke having convex and concave portions. The convex portions are partially inserted into the slots, and the concave portions receive the teeth. The teeth include tip portions whose circumferential widths become larger along a radial direction from the inside to the outside of the stator. The back-yoke includes convex portions whose circumferential widths become larger along the radial direction from the outside to the inside of the stator. The tip portions and the convex portions have substantially the same shape. The length of a joint portion between the tip portion and the convex portion, the circumferential width of the tooth corresponding to a tip surface of the convex portion, the width of a root portion of the tooth, and the circumferential width of the convex portion corresponding to a bottom face of the concave portion are substantially the same.

Stator for a rotating electric machine and rotating electric machine

A method is provided for shaping an electric wire for a stator coil of an electric rotating machine. The electric wire to be shaped includes a plurality of straight portions and a plurality of turn portions. Each of the turn portions includes a specific part and all of the specific parts of the turn portions are identical to each other. The method includes clamping the specific part of one of the turn portions of the electric wire in a width-wise direction thereof, holding two different sections of the specific part in a thickness-wise direction thereof, and moving one of the first and second holders relative to the other in the thickness-wise direction of the specific part, thereby shaping the specific part to form a crank-shaped portion therein.

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Kariya, Japan

Akito Akimoto