Denso Corporation

Nippondenso Co., Ltd.

Masahiro Takada

Atsuo Ishizuka

Akito Akimoto

Hideki Ichikawa

Shinji Kouda

Hiroaki Kajiura

Hideji Shimaoka

Masami Niimi

Masahiro Katoh

Tetsuya Gorohata

Youichi Kamakura

Akifumi Hosoya

Masaomi Dobashi

Keigo Moriguchi

Toshiaki Oohara

Masashi Yoshida

Kuniharu Teshima

Kenichi Shibayama

Koji Katahira

Kouji Katahira

Shuzo Muraki

Yasuhiro Hideshima

Yuujirou Kuwamura

Koji Shiga

Keniti Shibayama

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 coil forming method, a coil forming die assembly and a coil manufactured by the coil forming method are disclosed. The coil forming method comprises conducting preliminary forming work on a coil under a linear state before conducting bending work on the coil. The preliminary forming work including conducting compression work on the coil under the linear state to compress the coil in a region covering a rounded corner portion formed when bending work is conducted to decrease a dimension of the coil in a widthwise direction. The dimension of the coil is decreased in the widthwise direction by the nearly same dimension as that of the coil bulged in the widthwise direction when bending work is conducted in the absence of the preliminary forming work. This prevents the occurrence of bulging of the coil during bending work with an increase in lamination factor.

Coil forming method, coil forming die assembly and coil manufactured thereby

The wireforming the stator windingincludes the in-slot portionsto be disposed in the slotsandof the stator coreand the turned portionsconnecting the in-slot portionsdisposed in the circumferentially different slotsand. The turned portionsformed on axial opposite end sides of the stator core. The crank portionwhich does not twist is formed at substantially the center of the turned portion. Steps are formed at sections of the turned portionwhich protrude outside the stator corefrom the slotsand. Further, the turned portionof the wirealso has two stepsformed between the substantially central crank portionand each of the stepsformed at the protruding sections of the turned portion

Stator for rotary electric machine and rotary electric machine using same

There is disclosed a method of manufacturing a stator for a dynamoelectric machine. The method includes a step of mounting a hollow cylindrical electric wire assembly, which includes a plurality of straight stacked portions of shaped electric wires, to a hollow cylindrical stator core that includes a plurality of slots formed in the radially inner surface thereof. The mounting step includes: (1) placing the electric wire assembly radially inside of the stator core so that each of the straight stacked portions of the electric wire assembly is radially aligned with a corresponding one of the slots of the stator core; and (2) radially expanding the electric wire assembly to insert the straight stacked portions of the electric wire assembly into the corresponding slots of the stator core.

Method of manufacturing stator for dynamoelectric machine

A method is provided for manufacturing a stator coil for a rotary electric machine, which is formed by winding up a plurality of phase wires. The method includes a shaping step for shaping a plurality of shaped wire members from electrically conductive wires, an integrating step for integrating the plurality of shaped wire members with each other to form an integrated body, and a winding-up step for winding the integrated body about a core member to form a wound body. At the winding-up step, curve forming is performed by plastically deforming turn portions of the integrated body into a curved shape, during conveyance of feeding the integrated body to the core member.

Method of manufacturing coil for stator incorporated in rotary electric machine

A first tool set holds a wire covered with an insulation film at a bending point of the wire to protrude the wire from the first tool set. A second tool set holds the protruded portion of the wire. The second tool set is rotated about the first tool set to bend the wire along a wall of the first tool set and to form a boundary corner in the wire at the same radius of curvature as the wall. The wire is released from the second tool set and is moved to place the first tool set at another bending point while protruding from the first tool set. The second tool set is placed at the protruded portion of the wire. When the wire is bent at a predetermined number of bending points and is rounded, a stator coil formed in a corrugated shape is manufactured.

Method for manufacturing a stator coil formed in a corrugated shape

A method of fabricating an annular component part is disclosed wherein press forming is carried out to prepare an annular body having a cylindrical wall, having a root portion and a distal end, and an annular flange portion. The fabricating method comprises expanding an inner circumferential periphery of the cylindrical wall to an inner diameter corresponding to an inner diametric concave portion formed on the inner circumferential periphery and squeezing the cylindrical wall in a tapered profile such that the inner diameter of the cylindrical wall gradually decreases. During inner diametric expanding operation, an annular shoulder is formed on the inner circumferential periphery of the cylindrical wall and plays a role as an undercut of the annular component.

Annular component fabricating method, die for use in such fabricating method and annular component fabricated thereby

A method of manufacturing a yoke includes a step of cutting a steel plate into a rectangular sheet having a plurality of first dovetail convexities at one end thereof and a plurality of second dovetail convexities at the other end, a step of rolling the rectangular sheet into a cylinder to fit the first dove tails and the second dove tails to each other and a step of punching border portions of the first dove tails and the second dove tails. The second dovetail convexities are formed to be the same in shape as the first dovetail convexities so that they can fit to the first dovetail convexities. A smooth-faced yoke can be manufacture without using an expensive welder.

Method of manufacturing yoke of rotary electric machine

An armature for an electric rotating machine has a plurality of outer coil elements and a plurality of inner coil elements. Each of the coil elements has end protrusions extending axially outwardly from an axial side of an armature. The end protrusions facing each other in a radial direction is joined by an arc welding. In one method, the end protrusion of the outer coil element is formed a projection at an axially inside of an axial end of the protrusion. The end protrusions are held spaced apart from each other in the radial direction while contacting only through the projection. The axial ends of the protrusions are welded by swinging the welding arc. In another method, a ring-shaped brazing material is interposed between the end protrusions. The brazing material is melted by the welding arc to weld the end protrusions, while cutting out the brazing material existing between two adjacent pairs of the end protrusions.

Method for manufacturing armature of rotating electric machine

A rotor for an electric rotary machine having an armature core, upper layer coil elements and lower layer coil elements is provided. Each coil element has a straight coil side and a pair of coil ends extending radially at a right angle from the coil side. Each coil end is inclined by a predetermined angle with respect to the coil side in a circumferential direction of the armature core. The lower layer coil side and the upper layer coil side are inserted into corresponding slots in a radial direction. A connector comprising a tip of the coil end of the upper layer coil element and a connector comprising a tip of the coil end of the lower layer coil element are welded together.

Growing community of inventors

Okazaki, Japan

Masahiro Takada