Denso Corporation

Nippondenso Co., Ltd.

Masanori Oomi

Tsutomu Shiga

Masami Niimi

Nobuhiko Uryu

Shozou Ikezima

An armature of a rotary electric machine composed of an armature core, an armature winding and a shaft is manufactured in the following manner. A conductor bar including plural conductors connected in line is formed, and each conductor is cut out from the conductor bar. The conductor in a straight shape is inserted into each slot of the armature core, and then both side portions of the conductor are bent at substantially right angle so that the side portions are positioned along axial end surfaces of the armature core. The side portions are further skewed and electrically connected to form the armature winding. An outer surface of the side portions circularly arranged on the axial end surface of the armature core is used as a commutator surface.

Method of manufacturing armature of rotary electric machine

A starter for cranking an internal combustion engine is composed of an electric motor, an output shaft driven by the motor, a pinion gear coupled to the output shaft, and a magnetic switch. Electric power is supplied to the motor from an on-board battery through a switch, a movable contact of which is driven by the magnetic switch. The movable contact is connected to a brush lead wire via a connection formed by soft-soldering. The connection formed by the soft-soldering is positioned close to the commutator and covered with an end cover, so that the temperature of the connection becomes higher than other places in the starter. The connection easily melts away to thereby shut off power supply to the motor when its temperature becomes unusually high, and thereby the starter is protected from overheating.

Starter having structure for preventing overheating

An overrunning clutch which exhibits improved resistance to wear owing to grease filled thereinto which exhibits resistance to thermal oxidation even at increased temperatures due to overrunning. The overrunning clutch has a plurality of cam cases formed between its outer and inner members and also has a plurality of rollers arranged one by one in the cases. The cases are filled with a grease containing a first extreme pressure additive which is liquid and a second extreme pressure additive which is solid and yet melts at a prescribed temperature. Below the prescribed temperature, only the first extreme pressure additive functions as a lubricant, so that the rollers permit the engagement of the outer and inner members for the transmission of turning force from one member to the other. When the prescribed temperature is reached in the overrunning state, the second extreme pressure additive melts to function as a lubricant, thereby preventing the rollers from wearing. The second extreme pressure additive is halogen-based and decomposes below the ignition point of grease, thereby exhibiting flame retardance. Therefore, it also protects grease from thermal oxidation when the grease is heated to a temperature close to its ignition point.

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Anjo, Japan

Masanori Oomi