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: 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: 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: An on-vehicle AC generator that comprises a rotor; and a stator including a cylindrical stator iron core in which a plurality of slots extending in axial direction of a shaft are formed to be circumferentially aligned, and which is fitted to and supported in a case to contain the rotor therein, and a stator winding wound about the slot of the stator iron core, and which possesses a high rigidity to secure no deformation by force applied at the time of being fitted to the case. An insulating resin having adhesive properties is applied to an entire surface of the coil end portions. A corner portion formed by outer circumferential surface of the bottom of the coil end portions and an end face in axial direction of the stator iron core is also filled with the adhesive insulating resin.

Abstract: A varnish is applied to crossover portions of coil ends of a stator winding such that a space factor of conductor wires and the varnish relative to a cross-sectional area of the crossover portions in a cross section of the crossover portions relative to a plane including an axial center of a stator core is seventy percent (70%) or more, and a ratio occupied by exposed portions of the conductor wires relative to an outer circumference of the crossover portions in the cross section of the crossover portions is fifty percent (50%) or more.

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: A stator winding is constituted by first and second three-phase alternating-current windings. An output-wire lead wire of winding phase portions led out of Address 6 of a slot is bent so as to extend axially outward at a coil-end apex portion, and a neutral-point connection lead wire of the winding phase portions led out of Address 5 of the slots is bent so as to extend axially outward at a coil-end apex portion. The bent portions of the output-wire lead wires and the neutral-point connection lead wires extending axially outward are gathered together and a tube is mounted thereto.

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 method for manufacturing an alternator includes preparing a winding assembly formed by bending strands of wire so as to have straight portions which fit into slots, forming a base core by laminating plate-shaped magnetic members formed with the slots, stacking the winding assembly on the base core and pressing the winding assembly such that the straight portions enter the slots, and forming the stator core by bending the base core into a cylindrical shape and abutting end surfaces of the base core.

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: An automotive alternator is provided wherein surface area of a heat dissipating plate of a rectifier is enlarged, cooling characteristics of the rectifier and brush are improved, and performance and durability may be improved. The automotive alternator including a case 3 having a plurality of intake holes E, G and provided with a rotor 6, a stator 8, a rectifier 12, a regulator 14, a brush 10 and a connector 22, cooling air drawn in from intake holes E, G by operation of a fan cooling the rectifier 12 and further ventilating coil ends 19, wherein, the regulator 14 and the brush 10 are disposed so as to overlap in an axial direction, and center lines of the regulator 14, the brush 10, and the connector 22 are disposed on an approximately same plane extending in a radial direction, the rectifier 12 is disposed approximately line symmetrical to the same plane, and the plurality of intake holes E, G are formed in the case 3 at a position corresponding to the rectifier 12.

Abstract: A method includes the steps of forming a substantially U-shaped insulator having outwardly bent portions formed by bending the side portions thereof at bent parts so as to be apart from each other, forming winding assemblies including strands of wire wound in a predetermined wound state, mounting the insulator in each slot in a manner such that the outwardly bent portions of the insulator protrude from an opening of the slot, and inserting the winding assemblies in each insulator from an open side of the slot by being guided by the outwardly bent portions and pushing the winding assemblies together with the insulator into each slot.

Abstract: During molding of a brush holder which is a resin-molded part in an alternator, a capacitor component is molded integrally with a capacitor positive electrode terminal and a capacitor negative electrode terminal joined by crimping to a positive terminal and a negative terminal, respectively. The capacitor component is thereby embedded in a first resin portion.

Abstract: In a connection portion of a stator winding, conductor wires extending outward from a slot pair separated by a predetermined number of slots are joined such that end portions of conductor wires extending outward from addresses of the slot pair separated by three or more addresses are joined together (a distant-address joint portion), and end portions of conductor wires in the slot pair separated by two or less addresses are joined together (a near-address joint portion). The distant-address joint portion is offset in a circumferential direction relative to the near-address joint portion.

Abstract: An automotive alternator includes a rotor fixed to a shaft rotatably supported in a case, and a stator provided with a cylindrical stator core supported in the case so as to envelop the rotor, slots extending axially being formed in the stator core so as to line up in a circumferential direction at a ratio of two per phase per pole, and a stator winding constructed by installing a conductor wire coated with an electrical insulator in the stator core, a relationship between a radial dimension (d) of the conductor wire coated with the electrical insulator and a circumferential width dimension (L) of the slots being 2d<L.

Abstract: A stator winding is formed by inserting two conductor segments each from a first end surface of a stator core into a pair of slots separated by six slots and joining together end portions of the conductor segments extending outward from a second end surface of the stator core, slot-housed portions of the conductor segments being formed with a rectangular cross section and linking portions constituting coil ends being formed with a circular cross section.

Abstract: In an alternator of this invention, a ratio (t1/t2) between a radial thickness (t1) of a tip and a radial thickness (t2) of a root portion is within a range equal to or greater than 0.10 and equal to or less than 0.25, with a ratio (A/B) between a dimension (A) of overlap between a stator core and disk portions when viewed from a radial direction and an axial dimension (B) of the disk portions being within a range equal to or greater than 0.2 and equal to or less than 1.0, and a ratio (Lp/Lc) between an axial length (Lp) of claw-shaped magnetic poles overlapping the stator core when viewed from a radial direction and an axial length (Lc) of the stator core being within a range equal to or greater than 0.7 and equal to or less than 0.9.

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: 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 portion of a field rotor in an axial direction, and enabling electromagnetic noise to be reduced by prescribing dimensional relationships in 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 (Tr/Tp) between an axial overlap length Tr between the laminated core of the stator and the yoke portions of the Lundell-type core and an axial length Tp of the yoke portions is set to a range greater than or equal to 0.2.

Abstract: Tooth portions of a stator core are formed such that a radial length ht and a width bt thereof satisfy an expression <bt/ht<0.4.