Toyota Jidosha Kabushiki Kaisha

Ryuji Toh

Yasutomo Kawabata

Eiji Yamada

Tetsuya Miura

Takao Miyatani

Yoshiaki Taga, Deceased

Shigeo Taga, Heir

Yutaka Taga

Hiroaki Urano

Norihiko Akao

Shigetaka Nagamatsu

Akio Fukui

Akihiko Kanamori

Satoshi Koide

Shigeru Matsuhashi

Ryouji Mizutani

Masaru Hirako

Tomohiro Oda

Shinji Kogure

Takiko Taga, Heiress

Tomoyo Taga, Heir

Takiko Taga, Heir

Yoshiaki (deceased) Taga

A stator core for a motor in which a member with rounded edges is used to prevent the electrical breakdown of the winding of a coil which may occur at a slot edge therein. End plates 18 are disposed on ends of the stator core 10 formed of laminated magnetic steel plates 12. Each of the end plates 18 has substantially the same pattern as each magnetic steel plate 1, viewed from the axis of the motor. The elongate surface 18a of the end plate 18 continues smoothly from the inner surface 16a of each of slots 16 to the rounded edge surface 18b. The rounded edge surface extends smoothly from the elongate surface 18a to the end surface 18c of the end plate 18. This structure can eliminate sharp edges from the fringe of the slot 16, thus preventing the electrical breakdown of a coated conductor 22 in the coil which may occur at the edges.

Stator for electric motor

A power output apparatus of the invention includes a clutch motor (30) and an assist motor (40) that allow energy output from an engine (50) driven at a driving point of high efficiency to be converted to energy expressed as the product of a revolving speed and a torque of a drive shaft (22) and to be output to the drive shaft (22). In case that a large torque is required, for example, when the vehicle starts on a rising slope or runs at a low speed, the engine (50) is driven at a high-energy driving point having a large torque and a high efficiency. This structure causes large electric power to be generated by excess energy greater than the energy generally consumed and enables a battery (94) to be charged with the large electric power. The power output apparatus of the invention further has functions of predicting the process of charging the battery (94) with the large electric power based on a driving state of the vehicle and topographical information and lowering the remaining charge of the battery (94) in advance according to the requirements. This process effectively prevents the battery (94) from being damaged with excess charging.

Power output apparatus and method of controlling the same

In a method for manufacturing a stator of a motor, when an angular line is used to increase the occupancy rate of line members for coil pieces inserted into slots, not-slot-inserted parts project from a stator core. This results in enlarging the size of a stator, and damaging coatings via interference between a coil piece and other parts. In order to solve these problems, an angular line is first wound a predetermined times. Then, slot-inserted parts (a coil side) are separately clamped, and one of them is rotated by 180 degrees in a direction perpendicular to the winding direction, so that twisted parts are formed on coil ends. The coil sides are sequentially inserted into predetermined slots while maintaining respective twisted parts substantially parallel to each other, until a stator is completed.

Manufacturing method for stator of motor

A power output apparatus (20) of the present invention includes a clutch motor (30), an assist motor (40), and a controller (80) for controlling the clutch motor (30) and the assist motor (40). The clutch motor (30) includes an outer rotor (32) linked with a crankshaft (56) of a gasoline engine (50) and an inner rotor (34) connecting with a drive shaft (22). The assist motor (40) includes a rotor (42) connecting with the drive shaft (22). A control CPU (90) of the controller (80) controls a first driving circuit (91) to make the clutch motor (30) carry out power operation, so that the drive shaft (22) is rotated at a revolving speed higher than that of the crankshaft (56). The control CPU (90) also controls a second driving circuit (92) to make the assist motor (40) carry out regenerative operation. The electric power regenerated by the assist motor (40) is supplied to the clutch motor (30) to cover the electric power consumed by the clutch motor (30). The power output apparatus (20) of the invention transmits or utilizes the power generated by the gasoline engine (50) at a high efficiency and enables the drive shaft (22) to rotate at a revolving speed higher than that of the crankshaft (56).

A power output apparatus 20 includes an engine 50, a clutch motor 30 having rotors 31 and 33 respectively linked with a crankshaft 56 and a drive shaft 22, an assist motor 40 attached to a rotor-rotating shaft 38, a first clutch 45 for connecting and disconnecting the rotor-rotating shaft 38 to and from the crankshaft 56, a second clutch 46 for connecting and disconnecting the rotor-rotating shaft 38 to and from the drive shaft 22, and a controller 80 for controlling the motors 30 and 40. The controller 80 operates the clutches 45 and 46 according to the states of the engine 50 and the drive shaft 22 and changes the connection of the rotor-rotating shaft 38, so as to enable power output from the engine 50 to be efficiently converted by the motors 30 and 40 and output to the drive shaft 22.

In a power output apparatus (20) of the present invention, a controller (80) controls a clutch motor (30) and an assist motor (40), thereby converting energy output from an engine (50) and expressed by the product of the revolving speed and the torque of a crankshaft (56) of the engine (50) to energy expressed by the product of the revolving speed and the torque of a drive shaft (22) and outputting the converted energy to the drive shaft (22). When the remaining charge of a battery (94) is less than a predetermined range, the battery (94) is charged with electric power, which is regenerated from part of the energy output from the engine (50) by either the clutch motor (30) and the assist motor (40). When the remaining charge of the battery (94) exceeds the predetermined range, on the other hand, part of electric power consumed by either the clutch motor (30) or the assist motor (40) is supplied by electric power released from the battery (94). These procedures enable the remaining charge of the battery (94) to be kept within the predetermined range.

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Toyota, Japan

Ryuji Toh