Toyota Jidosha Kabushiki Kaisha

Fujio Ando

Atsushi Watanabe

Masayoshi Haga

Manabu Kitamura

Hirotsugu Iwamoto

A method for manufacturing a stator operatively associated with an inner and outer circumferential jigs including sequentially ordered steps of inserting segment coils, each constituting of a pair of straight portions connected with a connecting portion in a U-like shape, in slots of a stator core, rotating a twisting ring while distal end parts of the pairs of straight portions protruding on an opposite side to the connecting portions are engaged with ring grooves of the twisting ring to twist and shape in one direction the distal end parts located in odd-numbered positions from an outer circumferential side or an inner circumferential side in a radial direction and twist and shape the distal end parts located in even-numbered positions in an opposite direction to the one direction, and welding the distal end parts twisted in the one direction and the distal end parts twisted in the opposite direction.

Method of manufacturing a stator operatively associated with inner and outer circumferential jigs

A stator includes a stator core and a distributed winding type multi-phase coil. This coil includes unit coils made by winding a flat conductor wire in plural turns. The unit coils are mounted in slots of the stator core and connected with each other. Each unit coil includes an outer-layer coil and an inner-layer coil each being concentrically wound. Those two layer coils are made of a single continuous flat conductor wire. A winding start portion of the outer-layer coil and a winding end portion of the inner-layer coil form first and second connection end portions of the unit coil respectively. The first and second connection end portions are located separately on both edges of the unit coil above an upper end face of the stator core. The first connection end portion is placed close to an inner circumference of the stator core and the second connection end portion is placed close to an outer circumference of the stator core. The first connection end portions of the adjacent unit coils constituting the same phase are connected with each other. The second connection end portions of the adjacent unit coils constituting the same phase are connected with each other.

Stator and method of manufacturing unit coil to be used therein

To provide a stator capable of achieving downsizing and high output power and a stator manufacturing method, a stator comprises a split stator core and slots formed between the teeth, and protrusion-formed coils each being made of a flat rectangular conductor and placed in the slots. Each protrusion-formed coil has a shape including, in a coil end portion, a lead-side protrusion or a non-lead-side protrusion formed to protrude upward in an axial direction of the stator core from a first oblique side portion, a second oblique side portion, a third oblique side portion, and a fourth oblique side portion, and a first oblique side portion, a second oblique side portion, a third oblique side portion, and a fourth oblique side portion. The lead-side protrusion or the non-lead-side protrusion is designed with a height to avoid interference between the protrusion-formed coils placed in the stator core.

Growing community of inventors

Nagoya, Japan

Fujio Ando