Abstract: An intermediate holding member is inserted between a second free end and a third free end from an inner circumferential side in a radial direction, a first radial restraining member presses against a free end at an innermost circumference from radially inside, and a second radial restraining member presses against a free end at an outermost circumference from radially outside. Next, a voltage is supplied between a torch and the members, an inert gas is supplied to the torch, and an arc discharge is generated between the torch and the free ends, welding the radially-adjacent free ends.

Abstract: A manufacturing method includes a step of setting prescribed dimensions L and p, a wire feeding step of feeding a wire on a turning base surface by the dimension L, a turning step of turning the wire on the turning base surface to thereby form a first turning portion, a straight first portion, a second turning portion and a straight second portion, and a pushing step of pushing the straight first portion or the straight second portion so that it goes away from the turning base surface by the dimension p. A manufacturing apparatus that executes the above steps is also disclosed.

Abstract: A stator core is constructed by laminating and integrating first and second core divisions with the press punch directions thereof facing each other, each core division being constructed by winding a single strip of magnetic steel sheet into a helical shape with the press punch direction thereof aligned.

Abstract: A method of joining terminals by soldering is provided which allows control of increasing gas supply even in soldering performed in a gas atmosphere within a gas chamber. Utilizing a springback phenomenon occurring at a flat portion of a terminal, a solder joint of the terminal is immersed in molten solder. Then, laser soldering is performed using a gas chamber made of a material which transmits a laser beam at least in part.

Abstract: The present invention provides a dynamoelectric stator and a method for the manufacture thereof enabling electrical insulation properties to be improved by forming slot-housed portions with a racetrack-shaped cross section to suppress damage to an electrically-insulating coating arising during mounting of a stator winding to a stator core. The construction is such that the slot-housed portions of the stator winding are formed with the racetrack-shaped cross section, and are housed inside slots so as to line up in single columns in a radial direction with a longitudinal direction of the cross section of the slot-housed portions aligned in a circumferential direction.

Abstract: After respective one ends of lead wires are fixed to a printed circuit board, the lead wires are bent, the printed circuit board is brought into a case and the other ends of the lead wires are bonded to terminals of the case. Since the lead wires are processed before the substrate is brought into the case, this eliminates the necessity to perform formation of the bent portions of the lead wires and fixing of the lead wires to the substrate in a narrow space of the case and allows simplification of bonding operation. Thus provided is a lead wire bonding method for bonding lead wires with bent portions to the substrate, which simplifies a bonding operation.

Abstract: A stator winding is provided with three distributed winding phase portions each constructed by installing a conductor wire in every third slot. Slot-housed portions of the conductor wires are formed with a rectangular cross section and coil end portions are formed with a circular cross section.

Abstract: The present invention provides a rotor for a rotary electric machine that suppresses the occurrence of winding disturbances in the process of winding a coil wire and has a coil field having a uniform outside diameter that is less likely to collapse. A coil field of a rotor coil is constructed by winding a coil wire having a circular cross section onto an outer circumference of a drum portion of a bobbin in multiple layers so as to make columns in each of the layers equal in number in an axial direction.

Abstract: A manufacturing method includes a step of setting prescribed dimensions L and p, a wire feeding step of feeding a wire on a turning base surface by the dimension L, a turning step of turning the wire on the turning base surface to thereby form a first turning portion, a straight first portion, a second turning portion and a straight second portion, and a pushing step of pushing the straight first portion or the straight second portion so that it goes away from the turning base surface by the dimension p. A manufacturing apparatus that executes the above steps is also disclosed.

Abstract: A stator winding is prepared by inserting U-shaped conductor segments into pairs of slots from a first end surface end of a stator core and welding together end portions of the conductor segments projecting outward at a second end surface end of the stator core. Joint portions between the end portions of the conductor segments are arranged into two rows in an annular shape in a circumferential direction at the second end surface end of the stator core. A first electrically-insulating layer is formed by applying an epoxy resin so as to cover each of the joint portions and to bridge radially-adjacent pairs of the joint portions. A second electrically-insulating layer is formed by applying a silicone resin so as to cover the first electrically-insulating layer and to extend to an electrically-insulating coating on the conductor segments.

Abstract: A relay terminal bolt is mounted to a positive-side heat sink such that a head portion thereof is in a state of close surface contact with a first surface of the positive-side heat sink and an external screw thread portion projects outward from a second surface of the positive-side heat sink. An output terminal is secured by placing a mounting portion in a state of surface contact with a flange portion and fastening it with a nut screwed onto the external screw thread portion. In addition, a wiring harness terminal is securely fastened to a coupling seat in a state of surface contact with a nut screwed onto the external screw thread portion.

Abstract: A stator winding is configured into a polyphase alternating-current winding by joining together end portions of a plurality of winding sub-portions in a vicinity of each of axial ends of coil end groups within a predetermined circumferential range. Covers are fitted onto each of ancillary connection portions constituted by joint portions between the end portions of the plurality of winding sub-portions so as to closely fit onto an inner circumferential surface, an axial end surface, and an outer circumferential surface of each of the ancillary connection portions, the covers each being filled with a first electrically-insulating resin.

Abstract: In case of manufacturing a winding member, it has been necessary to first strip off a coating of an electric wire, and thereafter to perform machining so that an end portion of the electric wire is tapered. Hence, the manufacturing process is complicated and manufacturing cost is high. In the invention, a part of an electric wire 150 that includes a first conductor 112 and a coating 116 is extended to form a second conductor 120. The coating 116 is stripped off by itself due to this extension step. Thereafter, the extended second conductor is cut in the middle thereby forming an electric wire for a winding member 100. This electric wire is formed into a predetermined shape such as U-shape to obtain the winding member 100. As a result, stripping off the coating can be omitted, thus improving working efficiency and enabling reduction in cost.

Abstract: Output wires are all led out of Address 1 in slots and vibration-absorbing bent portions are formed on all of the output wires between a leader portion led out from a rear-end coil end group and a tip portion of the output wire.

Abstract: Joint terminal 21 has segue tubular hole 22, the entire surface of joint terminal 20 is provided with tinning, of which melting temperature is the carbonization temperature of an insulating coating of lead conductors 19d or less, lead conductors 19d are inserted in hole 22, and lead conductors 19d are welded to joint terminal 21 via tin 28 as an jointing ancillary agent, whereby a rotary electric machine and a method for producing the rotary electric machine, in which the jointed portion between the lead conductors and the joint terminal is not deteriorated by temperature, vibration and rust, the insulation is good, reliability of the jointed portion is excellent, are obtainable.

Abstract: An object of the present invention is to provide an automotive alternator achieving high output by overlapping a laminated core of a stator and yoke portions of a field rotor in an axial direction, and enabling high-speed and low-speed electromagnetic noise to be reduced by prescribing dimensional relationships in the stator and the field rotor. In this automotive alternator, a ratio (R2/R1) between an outer radius R2 of a cylindrical portion of a Lundell-type core and an outer radius R1 of the Lundell-type core is set to a range from 0.50 to 0.54, and a ratio (Lc/Lp) between an axial length Lc of the laminated core and an axial length Lp of the Lundell-type core is set to a range from 0.55 to 0.70.

Abstract: In a stator core having a plurality of teeth, which elongate in an inner radial direction and slots, which are configured among the teeth, powder is caused to adhere to the stator core, the powder adhering to an inner peripheral face of the stator core is removed, and the stator core is heated to melt and harden the powder.

Abstract: Coil members are obtained by forming width-reduced portions in a wire material over a predetermined longitudinal range generally centered on cutting positions, then removing an insulation coating from the width-reduced portions, and thereafter cutting the wire material at the width-reduced portions. Coil segments are prepared by bending the coil members into a general U shape. Then the coil segments are inserted into the slots in a stator core, and a stator is obtained by welding together the free end portions of the projecting coil segments.

Abstract: In a stator core having a plurality of teeth, which elongate in an inner radial direction and slots, which are configured among the teeth, powder is caused to adhere to the stator core, the powder adhering to an inner peripheral face of the stator core is removed, and the stator core is heated to melt and harden the powder.

Abstract: A rotary electric machine for being mounted on an internal combustion engine of a vehicle or the like. The rotary electric machine includes a rotation shaft rotatably supported by a bracket; a rotor fixed to the rotation shaft; a stator which has a stator core disposed opposite to the outer periphery of the rotor and a stator winding mounted onto the stator core, and which is supported by the bracket; and a pulley engaged with an end of the rotation shaft to rotate integrally with the rotation shaft. The pulley and the rotation shaft are mutually engaged to form an engagement portion. The engagement portion includes a regulation means for regulating-sliding movement between the rotation shaft and the pulley in their peripheral direction.