Denso Corporation

Toyota Jidosha Kabushiki Kaisha

Aisin Aw Co., Ltd.

Hiroaki Takeda

Yasuyuki Hirao

Daisuke Mizushima

Ken Shirai

Ryosuke Maruyama

Toshiro Nakamura

Yasunori Kitakado

Masashi Kawai

Hiroki Fujita

Kazushi Onda

Sho Yasuda

Hirohiko Yanagawa

Masashi Matsumoto

Mitsuru Kato

Akihiro Ueda

Motohiro Murahashi

Yasushi Nishikuma

Masaomi Dobashi

Yu Maeda

Yasuhiro Makido

Keigo Moriguchi

Yoshinori Nakamura

Shimpei Fujiwara

Kazuo Yoshikawa

Tadashi Fujiyoshi

Takeshi Kurosawa

Junichi Shimoya

Toshimitsu Shiga

Syo Hasegawa

Koji Hayashida

Hideki Mukaizaka

Yuiki Goto

Kazuhiko Fukuda

A conveyer equipped with rotating discs rotatable around axes thereof relative to a mounting base. Each of the rotating discs has grooves in which rectangular wires are receivable. When an upstream and a downstream one of the rotating disc are arranged in a given angular relation to each other, one of the grooves of the upstream rotating disc is aligned with that of the downstream rotating disc to pass the rectangular wire from the upstream rotating disc to the downstream rotating disc. Upon such passing of the rectangular wire, the grooves of the upstream and downstream rotating discs hold or clamp all side surfaces of the rectangular wire, thereby ensuring the stability in retaining the rectangular wire when passed from one to another of the rotating discs, which enables the conveyer to carry the rectangular wires at high speeds.

Conveyer

A stator has a stator core composed of teeth and slots. Segment coils are inserted into the corresponding slots. The segment coil projecting from the slot has an exposed conductor part and a covered conductor part covered with an electrical insulation film. The exposed conductor part is arranged at the distal end side from the covered conductor part of the segment coil. The segment coils are connected together through the exposed conductor parts thereof projecting from the slots. The exposed conductor part has a thickness Tthinner than a thickness Tof the covered conductor part. A step part is formed at a position of the stator core side, adjacent to the exposed conductor part of the segment coil. The step part and the covered conductor part are covered with the electrical insulation film continuously from the stator core side of the covered conductor part.

Stator and method of producing the same

An aligning apparatus, which is provided for aligning coil segments to form an aligned coil, includes a cylindrical jig and a hook jig. The cylindrical jig has an outer cylinder to surround a radially outer periphery of the aligned coil and an inner cylinder to be surrounded by a radially inner periphery of the aligned coil. The hook jig has hooks arranged in a radial fashion and is rotatable relative to the cylindrical jig in a radial direction. The cylindrical jig further has an inner entrance provided in the inner cylinder, an outer entrance provided in the outer cylinder, and at least one of an inner guide wall extending from a front opening edge of the inner entrance radially inward and backward in the rotational direction and an outer guide wall extending from a front opening edge of the outer entrance radially outward and backward in the rotational direction.

Aligning apparatus and method of manufacturing aligned coil

An apparatus for manufacturing a stator includes a supporting member configured to support a stator core, at least one processing jig having a cylindrical part and a plurality of protruding parts, and an operating unit. The operating unit is configured to perform, in a state where each of coil protruding parts is inserted between one circumferentially-adjacent pair of the protruding parts of the processing jig and an axial end face of the stator core is located close to the protruding parts of the processing jig, a first operation and a second operation either simultaneously or alternately. The first operation is an operation of relatively rotating the stator core and the processing jig in a circumferential direction of the stator core. The second operation is an operation of relatively moving the stator core and the processing jig away from each other in an axial direction of the stator core.

Method for manufacturing a stator

A method of removing an insulating coating layer of coil wiring includes: a fragmentation step in which a line-shaped region of the insulating coating layer, which separates a removal-planned portion and a remain-planned portion of the insulating coating layer, is removed; a laser irradiation step in which laser light which transmits through the insulating coating layer but which is absorbed by a coil wiring is irradiated from a side of an outer surface of the removal-planned portion toward a boundary of the coil wiring with the insulating coating layer, to carbonize a boundary portion between the insulating coating layer and the coil wiring of the removal-planned portion by generation of heat of the coil wiring; and a coating turn-over step in which air is blown onto the removal-planned portion to turn over and blow off the removal-planned portion.

Method of removing coating layer of coil wiring

An aligning apparatus is provided for aligning coil segments in an annular shape to form an aligned coil. Each of the coil segments has a pair of first and second leg portions. The aligning apparatus includes an outer jig and an inner jig. The outer jig has partitioning members arranged in a radial fashion. The partitioning members are spaced at such intervals as to allow each of the first leg portions of the coil segments to be inserted between one circumferentially-adjacent pair of the partitioning members. The inner jig has hole-forming members arranged radially inside the partitioning members of the outer jig. Each of the hole-forming members has formed therein a hole in which one of the second leg portions of the coil segments is to be inserted. Moreover, the hole-forming members are configured to be rotatable relative to the outer jig in a circumferential direction and radially movable.

An insulation film peeling method which radiates laser light onto a front end portion of an insulation film-coated conducting wire including a conducting wire and an insulation film in a longitudinal direction, and which peels a part of the insulation film up to a peeling boundary of a predetermined regulated peeling length, includes performing a rectilinear scan of a first region, in which a radiation position of the laser light moves from one side toward the other side and then moves from the other side toward the one side upon reaching the other side, and performing a unidirectional scan of a second region, in which the radiation of the laser light is performed from one side toward the other side and then the radiation position returns to the one side in a state in which the radiation of the laser light stops upon reaching the other side.

Insulation film peeling method

A coil bending machine is a machine that, in a stator core including a yoke and multiple teeth and having a slot formed between circumferentially adjacent teeth, while lead portions of a segment coil which is a U-shaped lead wire including a bent portion K and two lead portions R extending from the bent portion are inserted into two slots, push-bends end portions of the lead portions protruding from an axial end face of the stator core toward the stator core. The coil bending machine includes a coil bending member that push-bends the end portions of the lead portions protruding from the axial end face of the stator core toward the stator core, and a coil pressing mechanism that press-fixes a segment coil inside the slot toward the yoke, from the radially inner side of the stator core.

Coil bending machine

To effectively cover a coil end with a resin layer. A method for manufacturing a stator includes a first resin layer forming step (ii) of forming a first thermoset resin layer by impregnating the tip end side of a coil end with first thermoset resin, the coil end protruding from the core of the stator, the first thermoset resin having liquidity; a second resin layer forming step (iii) of forming a second thermoset resin layer on the first thermoset resin layer by dropping second thermoset resin from the core side of the coil end toward the tip end side; and a curing step of curing the first thermoset resin and the second thermoset resin.

A manufacturing method for an electric motor stator includes an injecting step in which thermosetting resin is injected into a forming die, a dipping step in which a coil end portion is dipped into the thermosetting resin injected into the forming die, a heating step in which the thermosetting resin inside the forming die is heated so as to form a molded portion, and a mold release step in which the molded portion is released from the forming die when at least either shear force of the thermosetting resin or adhesive strength between the coil end portion and the thermosetting resin becomes greater than previously-determined mold release force.

Manufacturing method for electric motor stator

Provided is a stator manufacturing method including: inserting a plurality of segment coils into a plurality of slots formed in a stator core; bending arms of the segment coils that protrude from the stator core, in a circumferential direction of the stator core; before or after bending the segment coils in the circumferential direction, directing parallel to each other leading end portions of the segment coils that are adjacent to each other in a radial direction of the stator core; and welding together the leading end portions of the segment coils with the leading end portions directed parallel to each other.

Stator manufacturing method

A bending-forming jig used in bending and forming a protruding portion of a leg portion of a U-shaped conductor toward a circumferential direction, the protruding portion protruding from an axial end surface of a stator core, the bending-forming jig including a ring portion and a claw portion, the claw portion including a first abutting surface that rises from an axial end surface of the ring portion with the surface directed in the circumferential direction and abuts against a tip portion of the protruding portion from the circumferential direction, and a projecting portion that projects, at a tip end of the claw portion, in the circumferential direction from the abutting surface and abuts against the tip portion of the protruding portion from the axial direction toward the axial end surface of the ring portion.

Bending-forming jig

Manufacture of a stator clamps an intersection of two legs that are protruded from different slots provided in a stator core, that are adjacent to each other in a radial direction, and that intersect with each other without any other leading end located in a circumferential direction between their respective leading ends when being viewed in the radial direction. The manufacture then bends a leading end of an inner leg located on an inner side in the radial direction out of the clamped two legs, toward an outer circumferential side of the stator core, while bending a leading end of an outer leg located on an outer side in the radial direction, toward a shaft center side of the stator core.

Manufacturing method of stator, stator, and bending process machine

An image creation device is provided with an image acquisition unit acquiring multiple captured images of a peripheral area, a detection unit detecting a three-dimensional object present in the peripheral area, a first conversion unit converting the multiple captured images into multiple individual overhead images to create a first conversion image by means of an overall overhead image, a second conversion unit creating a second conversion image in which an image captured from a virtual camera is converted in accordance with the conversion rule, the virtual camera being virtually arranged at a virtual position set on the vehicle such that a virtual optical axis direction faces the direction of the three-dimensional object, and a synthesis unit synthesizes the second conversion image on the first conversion image to create a synthesis image.

Image creation device

A method of producing a rotating electric machine stator includes an insertion step, bending step, and pressing step. In the insertion step, two leg portions of each U-shaped coil wire of a stator coil are inserted into different slots, such that protruding portions as distal end portions of the leg portions protrude in parallel with an axial direction of the stator core. In the bending step, the protruding portion of a first leg portion is bent in a first circumferential direction of the stator core, at a proximal end portion of the protruding portion as a bending start point, from a condition where the protruding portion protrudes from the slot in parallel with the axial direction of the stator core. In the pressing step, a distal end of the protruding portion bent in the first circumferential direction is pressed toward its proximal end in a second circumferential direction.

Growing community of inventors

Kariya, Japan

Hiroaki Takeda