Denso Corporation

Denso Corpora Tion

Tadahiro Kurasawa

Kazuhiro Andoh

Yamato Utsunomiya

Tsutomu Shiga

Masami Niimi

Kensuke Hirai

Tomoyuki Okamura

Shinji Usami

Masanori Ohmi

Takashi Hirabayashi

Yasuyuki Wakahara

Tomohiro Teramachi

In an armature, a busbar unit includes at least first-, second-, and third-phase busbars electrically connected to respective first-, second-, and third-phase armature windings. The first-phase busbar serves as a lowermost busbar in the axial direction, the second-phase busbar serves as an intermediate busbar stacked over the lowermost busbar in the axial direction, and the third-phase busbar serves as an uppermost busbar stacked over the intermediate busbar in the axial direction. A resin member of the busbar unit covers the lowermost busbar, intermediate busbar, and uppermost busbar stacked in the axial direction, so that the lowermost busbar, intermediate busbar, and uppermost busbar are integrated to constitute a busbar stack. A protrusion member is mounted to the intermediate busbar and protruding radially outward from the intermediate busbar. At least part of the protrusion member is located to be nonoverlapped with the uppermost busbar and the lowermost busbar.

Rotating electrical machine and method of manufacturing the same

A rotating electric machine includes a neutral busbar and a temperature sensor. The neutral busbar has a main body and a bent part that retains the temperature sensor therein. The main body has first and second parts each of which has one or more connection terminals formed therein. The bent part is formed between a circumferential end portion of the first part and a circumferential end portion of the second part. In the first part, there is formed, between the circumferential end portion of the first part and a closest connection terminal formed in the first part to the bent part, a first extending portion that extends axially or radially. Similarly, in the second part, there is formed, between the circumferential end portion of the second part and a closest connection terminal formed in the second part to the bent part, a second extending portion that extends axially or radially.

Rotating electric machine and armature

A rotating electric machine includes an armature and a busbar unit. The armature includes an annular armature core and a multi-phase armature coil wound on the armature core. The busbar unit is configured to connect winding end portions of the armature coil which are arranged apart from one another in a circumferential direction of the armature. Moreover, the busbar unit is fixed to a back yoke of the armature core by a plurality of pins.

A starter is disclosed as having a housing carrying thereon a motor, and a pinion moving body including a pinion gear, operative to mesh with a ring gear of an engine to transfer a rotational force of the motor thereto, and a pinion shielding member connected to the pinion gear at a front end thereof. The pinion shielding member has an outer circular periphery, having an outer diameter greater than the diameter of the addendum circle of the pinion gear, and a bottomed cylindrical configuration formed with a hollow portion having a front opened end and a closed rear end. Further, a clearance between an inner circumferential periphery of the nose portion and the outer circular periphery of the pinion shielding member is minimized to avoid interference between the nose portion of the housing and the pinion shielding member.

Starter with compact structure

An electromagnetic switch includes an electromagnetic coil, a fixed core, a movable core, and a diode. The electromagnetic coil is configured to form an electromagnet when energized. The fixed core is arranged to be magnetized by the electromagnet. The movable core is arranged to be attracted by the magnetized fixed core to move in a movement direction toward the fixed core. The diode is electrically connected in parallel with the electromagnetic coil. The diode includes a main body and has a pair of leads respectively extending from a pair of ends of the main body which are opposite to each other in a lead arrangement direction of the diode. The lead arrangement direction of the diode is parallel to the movement direction of the movable contact.

Electromagnetic switch

In a commutator motor, a brush holding device includes a plurality of brush holders and a substantially annular holder plate. Each of the brush holders includes a holder frame, which receives a pair of brush and spring, and a bottom plate having two opposite side portions. The holder plate is disposed around a commutator and has a major surface on which a plurality of pairs of guide walls are formed; each pair of the guide walls defines a pair of grooves. The side portions of the bottom plate of each of the brush holders are respectively fit in a corresponding pair of the grooves defined by the guide walls. Each of the brush holders has a radially outer end that abuts an inner surface of a side wall of an end frame, whereby radially outward movement of each of the brush holders is restricted by the end frame.

Commutator motor utilizing existing part to restrict radially outward movement of brush holders

An electromagnet switch has a metal contact for a switch terminal that projects from a case and is wired to one end of a coil. A male connector member surrounds an outer periphery of the metal contact. The male connector member is connected to a female connector member that is provided at a tip end of a cable used for supplying electric power to the coil. Such a penetrating hole is formed in a case that reaches the metal contact. A tester terminal can contact the metal contact through the penetrating hole for conducting conductive testing of the electromagnet switch, in a commercial field.

Electromagnetic switch for a starter motor

A starter which may employed in starting an engine is provided. The starter includes an electromagnetic actuator and a pinion carrier. The pinion carrier includes a pinion and a holder. The holder retains a shift lever and transmits movement of the shift lever, as achieved by a magnetic attraction produced by the electromagnetic actuator, to the pinion, thereby shifting the pinion into engagement with a ring gear joined to, for example, an engine. The holder is made of material smaller in specific gravity than the pinion. Specifically, the holder is lower in mass or weight than the pinion, thereby permitting the magnetic attraction required to shift the pinion carrier through the shift lever to be decreased. This permits the electromagnetic actuator to be decreased in size.

Compact structure of starter

In a starter, a grommet attached to a yoke of a motor supports a motor terminal plate made of metal. The motor terminal plate is inserted in a penetration hole formed in the grommet. A pig-tail of a positive electrode brush is connected to one end of the M terminal plate projecting toward the inside of the yoke through the penetration hole. The other end of the M terminal plate projecting toward the outside of the yoke through the penetration hole is inserted into the inside of the resin cover through an insert groove formed in the resin cover of the electromagnetic switch. The M terminal plate is positioned in the grommet in the insert direction thereof to limit the movement of the M terminal plate toward the electromagnetic switch side and the motor side. This configuration provides a stable position of the M contact against the resin cover.

Starter

A starter includes a motor and an electromagnetic switch disposed close to and radially outward of the motor. The switch includes a contacts cover, a terminal bolt, and a conductive metal member. The contacts cover is cup-shaped. The terminal bolt is secured in the contacts cover so as to extend in the axial direction of the motor through an end wall of the contacts cover. The metal member has a first and a second end portion. The first end portion is inserted in the contacts cover through a side wall of the contacts cover. The second end portion is located outside the contacts cover and electrically connected to the motor. The switch further includes a movable contact, a first fixed contact that is electrically connected to a power source via the terminal bolt, and a second fixed contact made up of the first end portion of the metal member.

Starter having minimized electromagnetic switch

The electromagnetic switch for use in a starter includes a solenoid including an excitation coil and a plunger, and an energization terminal through which a current is supplied to the excitation coil from an external battery. The excitation coil generating, when applied with the current, a magnetic attraction force to move the plunger in order to close a main contact of the starter to thereby energize a motor of the starter. The energization terminal is constituted by a male terminal having a plate-like shape and insert-molded in the mold cover, and a female terminal fixed to a coil bobbin of the excitation coil and connected with a lead wire of the excitation coil, the female terminal being provided with a fitting section to which the male terminal is fitted so that the male and female terminals are electrically connected to each other.

Electromagnetic switch for use in starter

A starter includes a magnetic switch, a motor, and a terminal. The terminal fixed to both the magnetic switch and the motor and has two end portions in the longitudinal direction of the terminal. An end portion of the terminal confronts a movable contact within the magnetic switch. The other end portion of the terminal is connected to an electric circuitry of the motor therewithin.

Starter having connecting member electrically connecting magnetic switch and motor

An electromagnetic switch has a shaft and a movable contact member slidably supported by the shaft. The shaft is moved with a plunger when an electromagnet is formed of an electromagnetic coil receiving an electric current and attracts the plunger. The movable contact member is moved with the plunger and connects fixed contact members with each other to turn on the switch. The shaft has a shaft body and a projection projected from the shaft body. The movable contact member has a hole. The projection is inserted into the hole to pass through the hole, and the movable contact member is disposed on the shaft body. Then, the movable contact member is rotated so as to engage the projection with the movable contact member. Therefore, the projection prevents the movable contact member from coming out of the shaft.

Electromagnetic switch of starter

According to the invention, an electromagnetic switch includes a pair of fixed contacts, a movable magnetic core, a magnetic coil, and a fixed magnetic core. The movable magnetic core is configured to be moved by a magnetic attraction, thereby establishing an electrical connection between the fixed contacts. The fixed magnetic core is configured to create the magnetic attraction when the magnetic coil is energized. The fixed magnetic core has a base portion and a disc portion. The base portion is arranged to face the movable magnetic core. The disc portion is fixed to the base portion and formed of a stack of metal sheets including at least one base metal sheet and a balance metal sheet. The balance metal sheet has a thickness that is predetermined to balance a difference between a desired thickness of the disc portion and a total thickness of the at least one base metal sheet.

Electromagnetic switch with fixed magnetic core having disc portion formed of stack of base and balance metal sheets

An electromagnetic switch for use in actuating a starter for automotive vehicles is provided. The switch includes fixed contacts, a moving contact, and a plunger shaft. The moving contact is joined to a plunger shaft through an insulator. The plunger shaft is to be moved magnetically to bring the moving contact into abutment with the fixed contact to establish electric communication between the fixed contact. The switch also includes a rotation holder working to hold the moving contact and the insulator from rotating relative to each other. Use of the rotation holder results in a decrease in wear of the insulator. This eliminates the need for the insulator to have an additional thickness which would be worn down, thus permitting the insulator to be reduced in thickness to shorten the overall length of the switch.

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Chita-gun, Japan

Tadahiro Kurasawa