Minebea Company, Limited

Naohiko Aoyama

Taiichi Miya

Hiroyuki Kujirai

Tsuneo Tetsuka

A stator stack and stator jig assembly provide a consistent amount of slack in stator coil wires without increasing the complexity of coil-winding machines or adding production steps, and prevent crossing of the stator coil wires in the slack areas. A stator stack having magnetic pole teeth is mounted in a stator installation jig, and the ends of slack forming plates having grooves are made to project above the top surface of the stator stack to thrust stator coil wires upwardly. The coil-winding machine winds stator coil wires around the magnetic pole teeth, and after the stator coil wires are wound, the ends of the stator coil wires are passed through grooves in the ends of the plates to output pins. The coil-winding machine wraps the ends of the stator coil wires around the output pins. On removing the stator from the stator installation jig, the parts of the stator coil wires which where thrust upward become slack areas.

Coil-winding machine stator installation jig

An iron core winding is such that a winding of a given polarity is coiled in series so that the beginning of each coiling and the ending of each coiling cross on a magnetic pole that is positioned in the direction of a circumference of the iron core. When the winding of the magnetic core with the given polarity is completed, the winding direction is reversed and the remainder of the winding, which has the opposite polarity, is coiled in series so that the beginning of each coiling and the ending of each coiling cross in the reversed direction. A variable reluctance angle detector uses the iron core winding. The number of windings of the output winding is the same for each pole, and an induced voltage output of a sine wave is obtained.

Iron core winding, method of winding an iron core, and variable reluctance angle detector

A lead-wire-fixing attachment for fixing a lead wire is provided in a lead-wire-fixed portion arranged in a stator core, and a lead wire is connected to a stator-winding mounting board by way of a through-hole provided at the upper end of the lead-wire-fixing attachment. The through-hole is formed by notches provided at a location where the first attachment and second attachment contact each other. An inlet passage through which a potting material is poured, outlet passages through which the potting material runs out, base portions which are inscribed in the inside wall of the lead-wire-fixed portion are formed in the upper portion of the lead-wire-fixing attachment. The lead wire is made to pass through the through-hole and the lead-wire-fixing attachment is inserted in the lead-wire-fixed portion, and then they are fixed by using a potting material.

Lead terminal structure of resolver

A slack-forming mechanism for stator coils that is able to impart slack of appropriate size to the stator coil without imposing an excessively heavy burden on the coiling machine. The slack-forming mechanism includes a coiling machine attachment jig having a protruding member that passes through a clearance formed between a stator body and connector, and has a top edge positioned higher than a clearance pass-through part of a stator coil. As it is possible to form slack in the stator coil without changing the configuration of the coiling machine, deficiencies in prior art slack-forming mechanisms are overcome such as the difficulty of maintaining uniform slack amounts, and unreliability. Moreover, since design-related restrictions are few, an adequately large slack is imparted to the stator coil to adequately suppress breakage of the stator coil induced by temperature change.

Slack-forming mechanism for stator coil

A stator device which prevents the formation of varnish accumulations on jumper wires, thereby preventing jumper wire breakage due to temperature variations. A gap is created between the jumper wire and the stud located on the stator body. When varnish is applied to the stud and the jumper wires, excess varnish flows through the gap and pools underneath. Moreover, when there is a significant accumulation of varnish in the gap, the varnish will flow off from the edge of the stator body.

Growing community of inventors

Tokyo, Japan

Naohiko Aoyama