Aisin Aw Co., Ltd.

Tooru Kuroyanagi

Shingo Hashimoto

Tsuyoshi Yamaguchi

Hideaki Kimura

Yoshiyuki Kawasaki

Takahiro Kido

Takeshi Yokoyama

Nobuyuki Asaoka

A rotary electric machine-manufacturing apparatus utilized to implement a process of infiltrating varnish into wire-wound coils of a rotary electric machine, and of curing the varnish, an apparatus includes a rotatorsupporting a work S attached with the wire-wound coils Sc and rotating the work; and a high-frequency power supply device supplying electric power to the wire-wound coils. It is thus possible to support and heat up the work without having devices that surround the work S, thereby positioning a varnish dropping-infiltrating deviceappropriately. Further, there is no need to change a stage as conventional heat-up processes with an oven or a hot blast-circulating furnace did, and an entire process from pre-drying to curing can be implemented at a single stage.

Rotary electric machine-manufacturing apparatus and method of manufacturing the same

A coil forming and insertion apparatus includes plural coil winding frames, a winding jig for forming a multipole coil, plural coil receiving portions, and an inserter jig for inserting and arranging the multipole coil in slots of a stator core. The coil forming and insertion apparatus has each coil receiving portion opposed to a coil winding frame, the multipole coil is formed by connecting the monopole coils wound on the coil winding frames and the multipole coil is transferred from the winding jig to the inserter jig.

Coil forming and inserting device and coil forming and inserting method

A stator manufacturing device including a winding unit for forming a winding coil made up of a plurality of unipolar coils formed by winding wire, an insertion unit for receiving the winding coil from the winding unit and inserting the winding coil into a stator core, a shaping unit for shaping an outline of the winding coil that has been inserted into the stator core, and a transfer unit that is movable towards the insertion unit and the shaping unit, such that, in a state of holding the stator core, the transfer unit, by relatively moving to the insertion unit, moves the winding coil into a position for insertion into the stator core, and, by moving relative to the shaping unit, forms an outline of the winding coil.

Stator manufacturing device

A coil forming apparatus for forming a continuous-pole coil having a plurality of single-pole coils includes a winding jig rotatable around a center swing axis. The winding jig includes: a holder rotatable around a center axis of rotation different from center swing axis; and a plurality of coil bobbins arranged around said holder and mounted for reciprocal movement between advanced and retracted positions relative to the holder. Each individual coil bobbin has a winding axes which can be aligned with the center swing axis by turning the winding jig around the center axis of rotation. The single-pole coils having little twist can be stably formed for any coil bobbin to thereby form the continuous-pole coil.

Coil forming method and coil forming device

A plurality of single-pole coils are retained by a coil retaining device, the single-pole coils are arranged such that the coil insertion portions of each single-pole coil confront the inner circumference openings of the slots and may be generally parallel to the axial direction of the motor core, each single-pole coil is moved linearly toward the motor core such that the coil retaining device and the moving locus before the adjoining coil insertion portions in the adjoining single-pole coils are inserted into the slots are parallel or approach the more from the inner circumference side to the outer circumference side and the two coil insertion portions of each single-pole coil are moved such that they may start their movements simultaneously and at equal velocities.

Motor manufacturing process

A motor manufacturing method includes: a coil formation step of forming a unipolar coil, having coil inserting portions at two positions and coil end portions at two positions, in to a shape that changes such that a size in a height direction parallel to the coil inserting portion is larger in an inner peripheral side corresponding to a diametrical direction of a motor core along a direction of a winding axis center, than in an outer peripheral side; and a coil insertion step of disposing the unipolar coil in such a manner that the coil inserting portions in the unipolar coil respectively face toward inner peripheral opening portions of slots and are substantially parallel to an axial direction of the motor core, and inserting the coil inserting portions of the unipolar coil into the slots by moving the unipolar coil toward the motor core substantially linearly, while holding the motor core such that protrusion dimensions at both ends protruding from both end surface positions in an axial direction of the motor core are maintained substantially the same.

Motor manufacturing method

An apparatus and method of forming a resin film on a surface of a stator core including a ring-shaped yoke portion, a plurality of teeth each protruding from the yoke portion in a radial direction, and a plurality of slots formed between the teeth, including forming the resin film on a section of the stator core by molding a synthetic resin material onto a surface of the section and repeating the molding on another section of the stator core so as to form the resin film on a whole periphery of the stator core, wherein the stator core is divided into a plurality of sections with respect to an axial center thereof.

Stator core resin molding method

A three-phase motor having a stator in which the dimensions of protrusion of coil end parts in winding coils of individual phases can be equalized as much as possible and in which the overall dimension of protrusion of the coil end parts in the winding coils of the three phases can be reduced to an optimal dimension is provided. Each of unipolar coils forming the winding coils of the three phases has a pair of coil end parts protruding from end parts in the axial direction of a stator core. The winding coils of the three phases have the relationships of Cv/Cu=0.88 to 0.98 and Cw/Cv=0.88 to 0.98, where Cu, Cv, Cw represent average lengths of electric wires forming the coil end parts in the three phases of U-phase, V-phase and W-phase.

Three-phase motor

Coil forming device and coil forming method

An insulating paper piece for electric motors, capable of improving both electrical insulation between a coil and a stator core and electrical insulation between ends of coils of different phases without adversely affecting ease of coil insertion or the space taken up for the coil. A single insulating paper piece for electric motors contains at least two slot cell portions arranged in two slots of the stator core in which portions of one single pole coil are to be inserted, with two phase insulation portions arranged to connect respective ends of the two slot cell portions to form loops and disposed to face directly against coil ends of the single pole coil. The phase insulation portions comprise overlapping widthwise portions extended from both ends so that when a plurality of the insulating paper pieces for electric motors are mounted on the stator core, the respective overlapping portions of the adjacent insulating paper pieces overlap one another.

Insulating paper piece for electric motors and electric motor

A core provided with an insulating member, including the core having a plurality of slots, each slot formed between two teeth protruding from a yoke and having a side face and a bottom face that are formed in a generally flat shape; and the insulating member having a slot portion covering the slot and a core end face portion covering an end face of the core; wherein a core side face of the slot portion is formed in contact with the side face and the bottom face of one of the plurality purality of slots, a coil side face of the slot portion having two side portions and a bottom portion that are formed in a generally flat shape, and the slot portion of the insulating member has a thick portion in at least one portion that is thicker than other portions.

Growing community of inventors

Anjo, Japan

Tooru Kuroyanagi