Denso Corporation

Tetsuya Gorohata

Youichi Kamakura

Hitoshi Hirano

Atsuo Ishizuka

Akito Akimoto

Takashi Kumakura

Masahiro Seguchi

Shinji Kouda

Keigo Moriguchi

Masaru Sugiyama

Masahiro Takada

Masaomi Dobashi

Shuzo Muraki

Kanehisa Urano

A stator includes a hollow cylindrical stator core and a stator coil formed of a plurality of electric conductor segments. Each of the electric conductor segments includes, at least, an in-slot portion received in a corresponding slot of the stator core and a protruding portion that protrudes from the in-slot portion outside of the corresponding slot. Each of the electric conductor segments also has an insulating coat covering its outer surface. For each intersecting pair of the protruding portions of the electric conductor segments, at least one of the two protruding portions of the intersecting pair has an indentation formed in a side face thereof radially facing the other protruding portion at the intersection of the two protruding portions. Further, a thickness of the insulating coats at the indentations is substantially equal to a thickness of the insulating coats at the in-slot portions of the electric conductor segments.

Stator for rotating electric machine and method of manufacturing the same

At one ends of a pair of coil wires, a pair of turn portionsare crossed. Further, the other ends of the coil wiresare held such that an angle &#x3b8; between the axes of the coil wiresfalls in a predetermined range (e.g., greater than or equal to 10&#xb0; and less than or equal to 90&#xb0;). Then, the coil wiresare rotated respectively about their axes in the same direction, so that corresponding pairs of turn portionsof the coil wiresare sequentially crossed from the one ends to the other ends, thereby interlacing the coil wires

Method of manufacturing coil assembly for electric rotating machine

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 coil assembly of a rotary electric machine is disclosed wherein first and second coil wire segments are located on an axis direction in opposition to each other to allow first turn portions of the first and second coil wire segments to intersect with each other (in locating step). Engaging movement, composed of a forward transferring movement, a rotating movement and a translating movement, is conducted on the second coil wire segment with respect to the first coil wire segment to allow the first turn portion of the second coil wire segment to engage a second turn portion of the first coil wire segment (first engaging step). Conducting the engaging movement allows to engage a third turn portion of the first coil wire segment (second engaging step).

Method of manufacturing coil assembly

A stator for a dynamoelectric machine includes a stator core and a stator coil. The stator coil is made up of wave-shaped electric wires mounted on the stator core. Each of the electric wires has in-slot portions, each of which is received in one of slots of the stator core, and connecting portions each of which is located outside of the slots to connect one adjacent pair of the in-slot portions. Each of the connecting portions includes an apex part that is located axially furthest in the connecting portion from the stator core and includes an oblique section extending obliquely with respect to the radial direction of the stator core. Further, the oblique sections of the electric wires on one side of the stator core in the axial direction of the stator core are oblique in the same direction as those on the other side of the stator core.

Stator for dynamoelectric machine and method of manufacturing same

During sending the combined bodyto the core member, the pre-orientation membersare respectively inserted into a plurality of the consecutive clearancesof a plurality of the clearancesformed between the adjacent straight overlap sectionsof the combined body. By the pre-orientation members, the overlap of the straight portionsin the straight overlap sectionand the pitch between the straight overlap sectionsare aligned in advance.

A weaving machine for an rotary electric machine coil assembly is disclosed including a rotating and driving section having timing belts causing rotary pulleys to rotate about their axes under the same attitudes while causing the rotary pulleys to rotate about an axis of a stationary pulley, movable members placed on the rotary pulleys to be movable in X- and Y-directions, coil feed magazines inclined such that coil wire segments have one ends slidably supported on the movable members and axes of the coil wire segments cross on a rotating axis of the rotary table, an orbit specifying member for specifying an orbit, in which the coil feed magazines are caused to rotate, in a rectangular shape, a rotating and driving member for permitting the coil feed magazines to perform synchronized rotating movements, and a coil transfer device operative to grip the coil wire segment for transfer.

Weaving machine for coil assembly of rotary electric machine

In a stator coil of a rotary electric machine, a first crank portion radially shifts one side of a turn portion from the other side thereof by a first length. The one side extends to one of paired straight portions, and the other side extends to the other thereof. A second crank portion radially shifts one side of a turn portion from the other side thereof by a second length. The one side extends to one of the paired straight portions, and the other side extends to the other thereof. The first length is equivalent to a radial width of the turn portion of the first segment of each set. The second length allows the second crank portion of the second segment of each of the sets to substantially overlay the first crank portion of the first segment of each set.

Rotary electric machine having stator coil with U-shaped segment

In a stator of a rotary electric machine that includes a stator winding and a stator core having a plurality of slots, the stator winding is constituted of a plurality of series-connected regular U-shaped segments each of which has a pair of in-slot portions and a plurality of U-shaped irregular segments each of which has a pair of in-slot portions disposed in a pair of slots that is suitable to connect the regular segments to form the stator winding and a continuous crossover portion crossing over some of the regular segments. The irregular U-shaped segments extend to be in contact with the turn portions of the regular segments. Therefore, the regular segments are connected by the irregular segments that have least electric resistance.

Stator arrangement of a rotary electric machine having lead wires in sagging contact with the stator winding

A rotary electric apparatus, such as motor, comprises a rotor and a stator arranged to face the rotor in the radial direction. The rotor rotates together with a rotation shaft. The stator has a cylindrical stator core, a stator winding wound in the stator core to have coil-end blocks arranged to protrude respectively from both ends of the stator core in the axial direction and being arranged on both sides of the stator core in the circumferential direction, and a lead wire taken from the windings. The lead wire includes a first wire portion taken along the axial direction from one of the coil-end blocks, a second wire portion extended from the first wire portion and arranged partly along the circumferential direction to be secured with resin material on the coil-end block, and a third wire portion extended from the second wire portion and arranged outwards in the radial direction.

Rotary electric apparatus with coil-end block from which lead wires are drawn out

In manufacturing a stator coil for a rotary electric machine, a U-shaped segment is deformed at the turn portion thereof so that one of two straight portions thereof moves against the other one in a direction generally perpendicular to a borderline which connects two bordering points between the straight portions and the turn portion. The segment is twisted by moving the straight portions apart from each other. The segment is inserted into slots formed in a stator core so that the turn portion and end portions of the straight portions protrude from both axial end surfaces of the stator core. The end portions are folded in the circumferential direction of the stator core. The tips of the end portions are connected to tips of other segments.

Manufacturing method of stator coil composed of conductor segments

Provided is a method of manufacturing a sequential segment joining type stator coil for use in an electric rotating machine, capable of achieving satisfactory electrical and thermal contact between end tip portion pairs of segments and basal electrodes and of realizing suitable welding even in the alignment of a large number of end tip portion pairs. For the arc welding of the end tip portion pairs of a sequential segment joining type stator coil, a large number of end tip portion pairs adjoining each other in a radial direction are held and pressed between basal electrode blocks. At this time, a circular-arc-like auxiliary electrode is put in a radial spacing between the end tip portion pairs. This not only enables the feeding to the end tip portion pairs lying at an intermediate position in the radial direction but also stabilizes the positions of the end tip portion pairs, and even reduces the heat radiation to an insulating coat of end skewing portions extending from the proximal portions of each end tip portion pair.

Method of manufacturing a sequential segment joining type stator coil

Stator arrangement of rotary electric machine

A stator core that includes electrical insulation between a small conductor segment and large conductor segment which forms stator coils inserted into slots of the stator core of a driving motor for a automobile vehicle. The axial length of the curved head of the small conductor segment is shorter than that of the curved head of the large conductor segment. A distance between slanted portions of the curved heads is greater than the difference between an amount of contraction due to bending of the large segment and the small segment.

Stator coil made of joined conductor segments for rotary electric machinery and method for manufacturing the same

A production method of a polyphase sequentially joined-segment coil of a rotary electric machine and a product produced by the same are provided. A production machine includes pairs of tines working to catch heads of conductor segments when they are twisted using rings. The tines are designed to be rotatable about an axis of the rings following rotation of the rings to absorb stress acting on insulating coating on the heads of the segments to minimize rubbing of the insulating coatings, thereby ensuring a desired degree of electrical insulation of the stator coil.

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Anjo, Japan

Tetsuya Gorohata