Denso Corporation

Sawafuji Electric Co., Ltd.

Denso Corpora Tion

Tomoya Imanishi

Youichi Hasegawa

Sadayoshi Kajino

Shinji Usami

Yasuo Osawa

Kazuaki Murase

Shuichi Aoki

A method of manufacturing a field coil member having first and second edgewise coils to be respectively fitted on first and second pole cores mounted on a circumferential surface of a yoke. Each of the first and second pole cores has an outer periphery, the outer periphery having at least one rounded corner. The method includes providing a rectangular wire strap having a pair of opposing major sides and a thickness therebetween substantially less than a width of the major sides and providing first and second coil forms, the first coil form having an outer periphery identical in shape to the outer periphery of the first pole core, the second coil form having an outer periphery identical in shape to the outer periphery of the second pole core.

Method of manufacturing a field coil member having first and second edgewise coils

A starter includes a motor, a pinion, a pinion carrier carrying the pinion, a ring member provided on the pinion carrier, a shifting member, and a lubricant blocking member. The ring member is rotatable relative to the pinion carrier and restricted in axial movement toward the pinion. The shifting member has a ring portion that is arranged on the pinion carrier with the ring member interposed between the ring portion and the pinion. The ring portion has an axial end face that has a recess for receiving lubricant and is covered by the ring member. The shifting member is configured to shift, by pushing the ring member with the ring portion, the pinion in the axial direction, thereby bringing the pinion into mesh with a ring gear of an engine. The lubricant blocking member blocks the lubricant from being scattered due to rotation of the pinion carrier with the pinion.

Engine starter having shift lever with lubricant-blocking wall

In a rotary electric machine, a field coil member includes a first edgewise coil composed of a plurality of coaxially layered convolutions. The coaxially layered convolutions are wound around the outer periphery of the first pole core. The field coil member includes a second edgewise coil composed of a plurality of coaxially layered convolutions. The coaxially layered convolutions are wound around the outer periphery of the second pole core. The field coil member includes a link portion connecting between the first edgewise coil and the second edgewise coil in series. One of the first and second edgewise coils has one coil end extending therefrom to cross over the link portion at a crossover portion thereof. The crossover portion between the one coil end and the link portion is arranged to be non-overlapped with the convolutions of the one of the first and second edgewise coils.

Rotary electric machine with coil member and method of manufacturing coil member

The rotational electric machine includes a cylindrical yoke and a field winding connected to an inner surface of the cylindrical yoke. The field winding is composed of plural formed coils, each coupled to a bobbin. The bobbin includes a first flange for insulating the formed coil from the inner surface of the cylindrical yoke, a second flange for insulating the formed coil from a supporting brim of a pole core and a pipe portion for insulating the formed coil from a boss portion of the pole core. The first flange is made all around the pipe portion while the second flange is formed to extend only in the lateral direction of the pipe portion. The bobbin is easily coupled to the formed coil by flexibly bending the bobbin. Alternatively, the bobbin or bobbins may be made by folding a bobbin sheet after placing the formed coils on the bobbin sheet.

Rotational electric machine having field winding formed by coupling formed coil to bobbin

A starter and a method of manufacturing the starter are disclosed wherein the starter comprises a case, a housing disposed in front of the case, a pinion moving body slidably received by the case and the housing, and a lever unit having a lever, swingably supported on a lever support member, for actuating the pinion moving body to an operative position to allow a pinion to be brought into meshing engagement with a ring gear of an engine to start up the same. The lever support member is mounted on the case via a positioning mechanism composed of positioning components, formed on the lever support member, and the positioning components, formed on the case, with which the positioning components engage, respectively.

Starter

The starter for an engine of a vehicle includes a motor generating torque for starting the engine, an output shaft configured to move in an axial direction thereof by being pressed at a pressure-receiving portion thereof, and applied with the torque to rotate, and a lever switch configured to press the pressure-receiving portion of the output shaft at a pressure-applying portion thereof in accordance with an external command so that a pinion rotatably fixed to the output shaft engages with a gear of the engine to thereby start the engine. A protection member rotatable with respect to the pressure-receiving portion is provided between the pressure-receiving portion and the pressure-applying portion. The pressure-applying portion facing the pressure-receiving portion across from the protection member is formed with a groove to be filled by lubricant.

Starter for vehicle engine

An electromagnetic switch has a solenoid and an electric contact section set to a closed state in response to an attraction force of the solenoid. The contact section is covered with a contact cover fixed to the solenoid, and a terminal electrically connected with the solenoid is placed within the cover. An end of the terminal is protruded from the cover and is electrically connected with a conducting member. The member has a portion joined to the terminal and other portions separated or detachable from the terminal. In the maintenance of the switch, the portion of the member joined to the terminal is removed from the switch. After the maintenance, one of the other portions of the member is joined to the end of the terminal.

Electromagnetic switch of starter

A magnet switch which may be employed in automotive engine starters is provided. The magnet switch includes a metallic terminal which extends through a hole formed in a switch cover to have one of ends thereof protruding outside the cover. The other end of the terminal is connected to an exciting coil to energize it to establish an electric connection between contacts. The magnet switch also includes a cylindrical seal and a stopper. The seal is fit on the end of the terminal to hermetically seal a clearance between the hole and the terminal. The stopper provided on the terminal works to stop the seal from moving to the other end of the terminal, thereby ensuring the stability of installation and sealing performance of the seal in the magnet switch.

Structure of magnet switch ensuring stability of installation of seal

The starter includes a housing housing a solenoid and fixed to an engine, a center case held between a motor thereof and the housing, a clutch housed in the center case, and a pinion shaft movable in its axial direction and spline-connected to an inner periphery of an inner tube of the clutch, which is rotatably supported by a bearing. The housing has a tubular wall section through which the pinion shaft extends and to which the center case is coupled in the axial direction. The tubular wall section is formed with a through hole. The center case has a bearing holding section holding the bearing and a cylindrical projecting section projecting in the axial direction towards the housing at a position radially outwardly of the bearing holding section inside the tubular wall section. The outer periphery of the projecting section faces the through hole.

An electromagnetic switch mounted on a starter for cranking an internal combustion engine includes an excitation coil for driving a plunger upon supplying electric current to the excitation coil. A conductor member led out from the excitation coil is connected to an outside cable to supply electric current to the excitation coil. The conductor member is made of a thin plate to be easily led out from a molded contact cover and is connected to a reinforcing member made of a thick plate that is embedded in the contact cover. The outside cable is connected to the reinforcing member so that the thin conductor member is not damages by a high vibration of an engine. The outside cable is easily connected to the reinforcing member with a screw after completion of the electromagnetic switch.

Electromagnetic switch for starter

An electromagnetic switch of an engine starter includes a pair of stationary contacts connectable to a starter motor, a movable contact disposed at a first distance from the pair of stationary contacts; a rod having one end that slidably supports the movable contact via an insulating member and a stopper that restricts axial movement of said movable contact, an electromagnetic coil unit that includes a plunger, a stator core, a spring that urges the movable contact against the stopper and an exciting coil which moves the rod by the plunger a second distance when excited, and an inclination rectifying member, disposed near the stationary contacts, for providing a rectifying surface disposed at a third distance from the movable contact to abut the movable contact when one of the stationary contacts wears to a preset degree. There is the following relationship between the first, second and third distances: the second distance&#x3e;the third distance&#x3e;the first distance.

Electromagnetic switch of engine starter

In a starter, an output shaft is disposed on a same axial line with a motor shaft through a planetary gear reduction device. The output shaft has an accommodation recess at the rear end thereof and rotatably receives the top end of the motor shaft therein through a ball. The output shaft and the motor shaft have respective end surfaces opposing each other in the axial direction with a spacing therebetween under a condition that the ball is disposed between the output shaft and the motor shaft. A thrust receiving member thinner than the spacing is disposed in the spacing. The thrust receiving member limits a movement of the output shaft toward the motor due to wear of the accommodation recess.

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Kariya, Japan

Tomoya Imanishi