Denso Corporation

Youichi Kamakura

Tetsuya Gorohata

Masaru Sugiyama

Makoto Takahashi

Hitoshi Hirano

Kazutaka Maeda

Atsuo Ishizuka

Akito Akimoto

Masaomi Dobashi

Nobuo Suko

Masahiro Seguchi

Shinji Kouda

Masahiro Takada

Kimiharu Kayukawa

Keigo Moriguchi

Kazuki Maesoba

Yoshio Naka

Hideji Shimaoka

Shuzo Muraki

Kanehisa Urano

A method of manufacturing a stator coil includes the steps of: (1) forming substantially planar electric wires each including in-slot portions to be received in slots of a stator core and turn portions to be located outside of the slots to connect the in-slot portions; (2) rolling each of the planar electric wires into a spiral shape by plastically deforming the turn portions; and (3) assembling the rolled electric wires through relative axial movements therebetween, each of the relative axial movements being made by axially moving first and second components relative to each other with both the first and second components radially elastically deformed and with each of the first and second components circumferentially positioned by at least one positioning member, each of the first and second components being one of the rolled electric wires or an electric wire sub-assembly comprised of a plurality of the rolled electric wires.

Method of manufacturing stator coil for electric rotating machine

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

An apparatus for shaping coil ends of a generator's stator having a plurality of sets of U-shaped large and small conductor segments. The apparatus includes four twister cylinders holding connection ends of the large and small conductor segments in four radial layers at an axial end of the stator, a rotating mechanism rotating the twister cylinders alternately in opposite directions, an elevating mechanism moving the twister cylinders in the axial direction of the stator, and a controller synchronously controlling the rotating mechanism and elevating mechanism.

Apparatus for manufacturing rotary-electric-machine stator

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

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.

Production method of a sequentially joined-segment stator coil of a rotary electrical machine

A stator coil has a plurality of segments serially connected with each other to construct one turn in a phase coil. Each of the segments has a pair of slot conductor portions, a head portion which is projected toward an end of the stator core, and a pair of projected end portions which project from another end of the stator core. The head portion has head tip portion, a pair of head oblique portions, and a pair of projected end portions, each of which is stretched obliquely along the circumferential and axial directions of the stator core. A pair of end tip portions, formed at a tip of the corresponding end oblique portion, is joined with an end tip of the other end tip portion. The head oblique portions or the end oblique portions are made circular-arch-shaped around an axis of said stator core.

A tail side coil end includes a plurality of tail conductor pairs sequentially disposed with predetermined radial gaps. The radial gaps between the conductor pairs are widened in the vicinity of their tail joint portions compared with those in the vicinity of the end surface of a stator core. This arrangement effectively prevents adjacent tail joint portions or adjacent slanting portions from undesirably contacting with each other, thereby adequately maintaining electric insulation between the tail conductor pairs and also improving the space factor of the slot.

Stator coil including sequentially-connected conductor segments for an electric rotary machine and manufacturing method thereof

A swerved portion is provided on a tail slanting portion of a large-turning conductor segment or on a tail slanting portion of the small-turning conductor segment. The swerved portion is located in the vicinity of a tail joint portion so as to define a radial clearanced between the tail slanting portions.

Stator coil including sequentially-connected conductor segments for an electric rotary machine

A sequentially joined-segment coil for a rotary electric machine such an electric motor is provided. The coil has an end portion which is made up of heads of conductor segments and projects from an end of a core. The heads of conductor segments have turns or bulges. The bulges are lapped over one another in various forms or shifted in location in an axis direction of the core, thereby permitting the core to be decreased in diameter, which provides for decreases in size and weight of the rotary electrical machine.

Sequentially joined-segment coil for rotary electrical machine with high degree of electrical insulation

A method for manufacturing a stator of a rotary electric machine includes: a step of forming a plurality of conductor segments each having at least a straight leg; a step of inserting the plurality of conductor segments into each of the slots in a plurality of radially aligned layers so that the straight legs can extend outside an end of the stator core; a step of stratifying the straight legs in radially aligned layers to correspond to the layers in the slots; a step of holding each of the stratified portions at grip portions; a step of circumferentially shifting each of the grip portions in a prescribed circumferential direction of the stator core; and a step of axially shifting each of the grip portions separately from another in an axial direction of the stator core to locate those of the grip portions to be connected adjacent to each other.

Method and apparatus for manufacturing stator of rotary electric machine

In a method of manufacturing a stator of a vehicle AC generator, U-shaped conductor segments having a turn portion and a pair of forked in-slot portions are formed so that the radial width of each conductor segment can be larger than the radial depth of each slot of a stator core. The in-slot portions of the conductor segments are compressed from radially outside and inserted into each slot in an axial direction of the stator core so that the conductor segments can provide a spring-back force in the slots. Then, the U-shaped conductor segments are welded at ends of the in-slot portions in a prescribed pattern.

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Anjo, Japan

Youichi Kamakura