Abstract: A connection structure and a connection method of connecting field coils and lead wires in a vehicle alternator. The connection structure includes a rotor assembly, a rear fan, and a rotor insulator. The rotor assembly includes a rotor shaft, a spool bobbin, and rotor segments. In the connection structure, a soldering or welding process is performed on twisted parts, which are formed by twisting field coils and lead wires around each other, the twisted parts are bent in the guide pockets of the rotor insulator, epoxy is applied to the outer surfaces of the twisted parts and the inner surfaces of guide pockets, and the rear fan is coupled to the front of the rotor insulator so that the inner surfaces of the protrusion hubs of the rear fan are in close contact with the guide pockets of the rotor insulator.

Abstract: A method of manufacturing a terminal assembly of an alternator for vehicles and the terminal assembly manufactured by the method. The terminal assembly manufacturing method of the present invention includes a first step of notching and piercing a blank plate, a second step of deep-drawing notched portions of the plate to form a plurality of assembly protrusions, each of which has a pierced cylindrical shape protruding from the plate, a third step of trimming and piercing the plate to give it a predetermined shape, and a fourth step of coining and bending the plate, thus forming the terminal assembly.

Abstract: A connection structure and a connection method of connecting field coils and lead wires in a vehicle alternator. The connection structure includes a rotor assembly, a rear fan, and a rotor insulator. The rotor assembly includes a rotor shaft, a spool bobbin, and rotor segments. In the connection structure, a soldering or welding process is performed on twisted parts, which are formed by twisting field coils and lead wires around each other, the twisted parts are bent in the guide pockets of the rotor insulator, epoxy is applied to the outer surfaces of the twisted parts and the inner surfaces of guide pockets, and the rear fan is coupled to the front of the rotor insulator so that the inner surfaces of the protrusion hubs of the rear fan are in close contact with the guide pockets of the rotor insulator.

Abstract: A method of manufacturing a terminal assembly of an alternator for vehicles and the terminal assembly manufactured by the method. The terminal assembly manufacturing method of the present invention includes a first step of notching and piercing a blank plate, a second step of deep-drawing notched portions of the plate to form a plurality of assembly protrusions, each of which has a pierced cylindrical shape protruding from the plate, a third step of trimming and piercing the plate to give it a predetermined shape, and a fourth step of coining and bending the plate, thus forming the terminal assembly.