Abstract: An electric rotary machine, an armature for use in the electric machine, a method of forming an electric rotary machine and a forming machine for an armature of an electric rotary machine are disclosed wherein insulator-coated coils are wound in slots of an armature core from which lower and upper layer coil extensions extend and are connected to a commutator. The upper layer coil extension has a contour deformation part at an intersecting region where the lower and upper layer coil extensions intersect with each other to have an insulating distance between the lower and upper layer coil extensions. The forming machine includes a work holder holding the armature, and a forming jig forming a curvature portion on the upper layer coil extension.

Abstract: A method of manufacturing a yoke of an electric rotary machine is disclosed. The manufacturing method includes providing a cutout steel plate having one end formed with a plurality of concave portions and the other end formed with a plurality of protrusions, rolling the cutout steel plate into a cylindrical shape until a distal end of each protrusion faces the inlet of each concave portion, inserting the protrusions into the concave portions, respectively, in a circumferential direction, and conducting punch-caulking press on each protrusion at near-wall areas on both sides thereof in close proximity to indents of each concave portion to form localized expanding portions at the near-wall areas on both sides of each protrusion while causing the localized expanding portions to flow axially outward to be fitted into the indents of each concave portion, respectively.

Abstract: An electric rotary machine, an armature for use in the electric machine, a method of forming an electric rotary machine and a forming machine for an armature of an electric rotary machine are disclosed wherein insulator-coated coils are wound in slots of an armature core from which lower and upper layer coil extensions extend and are connected to a commutator. The upper layer coil extension has a contour deformation part at an intersecting region where the lower and upper layer coil extensions intersect with each other to have an insulating distance between the lower and upper layer coil extensions. The forming machine includes a work holder holding the armature, and a forming jig forming a curvature portion on the upper layer coil extension.

Abstract: A yoke 1 and method of manufacturing a yoke are disclosed. A cutout steel plate 6 is prepared and rolled into a cylindrical shape to allow protrusions 7 to be inserted to concave portions 8, after which punch caulking P is carried out on near-wall areas of respective sidewalls of one of each protrusion and each concave portion. This causes localized expanding portions 10, 10A, formed on the relevant sidewalls, to be filled in associated indents 9, 9A formed on the other one of each protrusion and each concave portion, mechanically jointing the protrusions and the concave portions to form the yoke 1.