Nippondenso Co., Ltd.

Kenji Kanayama

Hidekuni Sugi

Shuzo Kinkori

Masatoshi Suzuki

Kouzi Kawasumi

Saburo Ito

An armature coil assembly for magnet-type rotary electric machines such as alternators or motors, which comprises flat conductor pieces or segments with large-area sides thereof arranged parallel to the direction of the magnetic fluxes of a permanent magnet, and a ferromagnetic member inserted between the conductor pieces. The ferromagnetic member inserted provides a magnetic anisotropy in the armature coil along the axis of coil rotation, thus the flow of magnetic fluxes from the magnet through the armature coil to the machine core is facilitated thereby to reduce leakage magnetic fluxes. A stator coil assembly is also made up by using like coil conductor segments.

Rotary electric machine coil assemblies

A flat type rotary electric machine has a flat stator armature coil and two rotors having magnets disposed in opposite relationship to the coil. The flat coil is formed by an annular carrier member of an insulating material and windings carried thereby. The windings are formed by a plurality of layers of annular rows of generally radially extending and axially thin conductor segments each having radially inner and outer end sections and an intermediate effective section axially aligned with magnets on an associated rotor during rotation thereof. The axial thickness of the effective section of each of the conductor segments of the outermost layers is smaller than the axial thickness of the effective section of each of the conductor segments of inner layers.

Flat type rotary electric machine

An electric rotary machine including a stationary armature coil, and a rotor for generating a rotary magnetic field, wherein the armature coil is formed with slits arranged radially and each located between segments of the coil which are arranged radially, and the armature coil is supported with radial gaps at outer and inner peripheral edges of the armature coil, so that thermal strain in the coil can be released through the slits, gaps, and a resilient insulator, and thermal stresses can be prevented from developing. By utilizing the rotation of the rotor, air is introduced from outside to a central portion of the armature coil, from which it is allowed to flow radially outwardly along the armature coil, to thereby suppress a rise in the temperature of the armature coil.

Heat insulation and heat dissipation construction for flat electric

There is provided a three-phase flat coil having a disclike outer periphery of an insulating plate and an electrical conductor positioned radially on front and back sides of said insulating plate and having bent-over portions on outer and inner peripheries thereof. Said electrical conductors are the three-phase coil windings including a-phase, b-phase and c-phase windings each wound in a wave form in the same direction and terminating at output terminals on the outer periphery of said plate. The output terminals are located at substantially one point on the outer periphery of said plate. The ends of the b-phase winding at said output terminals are different in polarity from the ends of the a-phase and c-phase windings. Intersections of the said three-phase coil windings are collectively positioned at substantially one point on the outer periphery of said insulating plate. Said intersections are provided for in a bridging wiring member which three-dimensionally connects the respective a-phase, b-phase and c-phase coil windings. The bridging wiring member having the intersections is provided at substantially one point of the outer periphery of the insulating plate thereby rendering the manufacture and wiring arrangement much easier. Stacking said flat coils together is easily accomplished by removing the bridging wiring member from one coil and placing that coil on top of another coil with an insulating plate in between. The output terminals of the bottom coil can be directly connected to the correct winding in the coil above. All connections are located at the outer periphery of the disc coils.

Three-phase flat coils

A flat coil for use in a rotary electric machine has an annular row of generally radially extending and circumferentially spaced electrically conductive segments (1) on each annular end face of an electrically insulating base member (2). Each segment has a non-effective section disposed adjacent to the radially inner end of the segment and having a mean thickness greater than that of the remaining sections of the segment to improve the cooling ability of the coil. The segments are formed by punching a blank of thin copper sheet to form therein an annular row of radially extending and circumferentially spaced slits to thereby form an annular row of radially extending and circumferentially spaced segments. Before or after the blank is punched, the blank is subjected to forging, electrolytic plating, electrolyzing treatment or mechanical treatment so that the non-effective section of each segment has a thickness greater than that of the remaining sections. Thereafter, the annular row of segments is secured to an annular end face of the annular base member. A similar another annular row of segments is prepared and secured to the other end face of the annular base member. The segments of the two annular rows are then welded at their radially inner and outer ends to form three separate windings of coil around the base member. The annular rows of the segments are then severed along the outer and inner peripheral edges of the rows to separate the segments from the blanks to thereby complete the flat coil.

Flat coil for an electric machine

An AC generator includes a pair of cup-shaped housings to accomodate a stationary armature coil and a rotor. The armature coil includes a multiphase windings formed in a flat annular shape having flat surfaces perpendicular to the axis of a rotating shaft of the AC generator, and the flat annular-shaped armature coil is mounted on the pair of cup-shaped housings with the outer peripheral portion of the armature coil fixed between the pair of housings. The rotor includes a pair of discs of magnetic material fixed to the rotating shaft spaced from and opposed to each other interposed therebetween by the flat annular-shaped armature coil. Each of the discs has a plurality of permanent magnets arranged concentrically with the rotating shaft in alternate magnetic polarities on one surface of the disc facing the armature coil, so that magnetic fluxes which rotate with the discs and which link with the stationary armature coil are produced between opposed permanent magnets of the pair of discs. The longitudinal size of the AC generator is reduced to achieve a compact AC generator.

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Kariya, Japan

Kenji Kanayama