Denso Corporation

Yoshio Naka

Masaru Sugiyama

Kazuki Maesoba

Kazutaka Maeda

Tsutomu Shiga

Shin Kusase

Atsushi Umeda

Hiroshi Ishida

Youichi Kamakura

Shinichi Matsubara

Mitsuyuki Hayashi

Katsumi Shizu

A stator core has a plurality of slots. Insulating members are formed into a cylindrical shape and are inserted into the slots. Axial ends of the insulating members are expanded respectively and deformation marks thinner than the other portion are formed respectively. Then, the insulating members are moved toward the expanded ends to position the deformation marks in the out of the slots. After that, the conductors are inserted into the slots from the expanded side of the insulating members. Therefore, insulation failure at the portions of the deformation marks is prevented.

Stator of rotary electric machine and method for making the same

A method of peeling off a coating of an elliptical cross sectional insulated conductive wire has a groove forming process of forming a groove nearly perpendicular to a longitudinal direction of the insulated conductive wire at given positions within a peeling region thereof, a first peeling process of peeling off the coating by moving a pair of first cutting edges in a longitudinal direction of the insulated conductive wire and perpendicularly to a longer diameter direction of the cross section thereof toward the groove from opposite ends of the peeling region, and a second peeling process of peeling off the coating at the peeling region by moving a pair of second cutting edges in a direction perpendicular to the longitudinal direction and in parallel with the longer diameter direction of the cross section thereof. As a result, the coating all around the outer circumference of the insulated conductive wire at the peeling region may be completely peeled off.

Method of peeling off coating of insulated conductive wires

A method of manufacturing a stator of a rotary electric machine is comprised of the following steps: providing a plurality of U-shaped basic conductor segments and a plurality of U-shaped connection conductor segments; forming the U-turn portions and straight portions into crossover portions, inserting the pair of straight portions of the basic and connection conductor segments into prescribed two slots of a stator core from one end thereof to extend from the other end, bending one of the pair of straight portions in the direction opposite to the other of the pair of extended straight portions so that the edges of straight portions extending from the prescribed slots can adjoin each other, connecting the adjoining edges to form a plurality of phase coils, and removing the U-turn portion of the connection conductor segments to form terminals of the phase coils.

Method of manufacturing rotary electric machine's stator

A method of manufacturing a U-shaped conductor segment which has a U-shaped head and a pair of legs includes setting a straight conductor wire of a prescribed length on the outer peripheries of a pair of parallel rollers, and pushing a bender against one side of the conductor wire opposite the rollers between the pair of rollers so that the conductor wire can be bent to allow the bender to pass between the pair of rollers.

Method of manufacturing conductor segments of AC generator

In a stator of an ac generator for vehicle, a plurality of insulators are disposed in the slots of the stator to insulate the stator winding from the stator core. Each of the insulators has a smooth edge at one end and a stopper portion at the other end. The stopper portions project from an axial end of the stator core from which conductor segments of the stator winding are inserted. The conductor segments can be inserted into the slots with the smooth edges being at the head and can be easily positioned in the slots by the stopper.

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Toyota, Japan

Yoshio Naka