Abstract: A stator for a rotary electric machine includes a stator coil configured such that a tip end of a conductor segment bent in a stator circumferential direction is joined to a tip end of another conductor segment in the same phase. A conductive material is exposed from the tip ends of the conductor segments, and a distance between the tip ends in different phases and adjacent to each other in the stator circumferential direction is larger than a distance between the tip ends in the same phase and adjacent to each other in the stator circumferential direction.

Abstract: To effectively cover a coil end with a resin layer. A method for manufacturing a stator includes a first resin layer forming step (ii) of forming a first thermoset resin layer by impregnating the tip end side of a coil end with first thermoset resin, the coil end protruding from the core of the stator, the first thermoset resin having liquidity; a second resin layer forming step (iii) of forming a second thermoset resin layer on the first thermoset resin layer by dropping second thermoset resin from the core side of the coil end toward the tip end side; and a curing step of curing the first thermoset resin and the second thermoset resin.

Abstract: Provided is a manufacturing method for a stator coil in which end portions of one-side conductor segments inserted into slots from the side of one end in an axial direction of a stator core and end portions of other-side conductor segments are connected to each other through coupling members inside the slots. The method includes: pressing in the one-side conductor segment or the other-side conductor segment in an insertion direction in a state where the end portion of the one-side conductor segment or the end portion of the other-side conductor segment, or an end portion of the coupling member has been moved toward the inner circumferential side of the stator core; connecting the end portion of the one-side conductor segment and the end portion of the other-side conductor segment to each other; and executing the pressing in and the connecting sequentially from the outer circumferential side of the stator core.

Abstract: A stator for a rotary electric machine includes a stator coil configured such that a tip end of a conductor segment bent in a stator circumferential direction is joined to a tip end of another conductor segment in the same phase. A conductive material is exposed from the tip ends of the conductor segments, and a distance between the tip ends in different phases and adjacent to each other in the stator circumferential direction is larger than a distance between the tip ends in the same phase and adjacent to each other in the stator circumferential direction.

Abstract: Provided is a manufacturing method for a stator coil in which end portions of one-side conductor segments inserted into slots from the side of one end in an axial direction of a stator core and end portions of other-side conductor segments are connected to each other through coupling members inside the slots. The method includes: pressing in the one-side conductor segment or the other-side conductor segment in an insertion direction in a state where the end portion of the one-side conductor segment or the end portion of the other-side conductor segment, or an end portion of the coupling member has been moved toward the inner circumferential side of the stator core; connecting the end portion of the one-side conductor segment and the end portion of the other-side conductor segment to each other; and executing the pressing in and the connecting sequentially from the outer circumferential side of the stator core.

Abstract: To effectively cover a coil end with a resin layer. A method for manufacturing a stator includes a first resin layer forming step (ii) of forming a first thermoset resin layer by impregnating the tip end side of a coil end with first thermoset resin, the coil end protruding from the core of the stator, the first thermoset resin having liquidity; a second resin layer forming step (iii) of forming a second thermoset resin layer on the first thermoset resin layer by dropping second thermoset resin from the core side of the coil end toward the tip end side; and a curing step of curing the first thermoset resin and the second thermoset resin.

Abstract: A stator for a rotary electric machine includes a stator coil configured such that a tip end of a conductor segment bent in a stator circumferential direction is joined to a tip end of another conductor segment in the same phase. A conductive material is exposed from the tip ends of the conductor segments, and a distance between the tip ends in different phases and adjacent to each other in the stator circumferential direction is larger than a distance between the tip ends in the same phase and adjacent to each other in the stator circumferential direction.

Abstract: A purpose is to provide a rotor manufacturing method including a magnet assembly formed of divided permanent magnet pieces to enhance insulation and advance cost reduction. The rotor manufacturing method includes forming permanent magnet pieces by dividing a permanent magnet, arranging and resin-molding the permanent magnet pieces to form a magnet assembly, and placing the magnet assembly in a rotor. The method includes placing the permanent magnet pieces all together in a molding die for use in resin-molding, and moving the permanent magnet pieces by a moving device provided in the molding die to move the permanent magnet pieces within the molding die, thereby forming the magnet assembly.

Abstract: A method for cleaving a plate-shaped workpiece formed with two or more linear recesses into three or more parts includes: a first positioning step of holding the workpiece by a positioning unit in place to position a first linear recess; a first clamping step of clamping one side of the first linear recess by a fixing clamp and the other side by a rotating clamp; a first cleaving step of moving back the positioning unit and rotationally separating the rotating clamp; a second positioning step of releasing the clamps and causing the positioning unit to position a second linear recess; a second clamping step of clamping one side of the second linear recess by the fixing clamp and the other side by the rotating clamp, and a second cleaving step of moving back the positioning unit and rotationally separating the rotating clamp.

Abstract: A stator structure for a rotary electric machine includes a stator core having a cylindrical shape in which slots and pole pieces are formed on an inner peripheral side and alternately arranged in a circumferential direction, a conductor segment which is a conducting wire having a rectangular cross section inserted in one of the slots through an insulator being connected with a conductor segment similarly inserted in another slot to form a coil. Each insulator has a shape including a pair of opposite side surface portions connected with an intermediate portion along a wall surface defining the slot. Each insulator includes end protrusions facing each other at free ends of the side surface portions to position the conductor segments. The insulators are made of an insulating and elastic material.

Abstract: A magnet splitting device includes a one-side holder for holding a plurality of pre-split magnets on one sides of respective splitting grooves, an other-side holder for holding the magnets on the other sides, and an actuating unit for causing relative movement of the other-side holder to split the magnets all at once. The other-side holder includes a plurality of other-side independent holding parts for holding the magnets independently. The actuating unit includes a plurality of independent actuating parts for moving the other-side independent holding parts independently and a simultaneous operating part for simultaneously operating the holding parts.

Abstract: In a method for manufacturing a rotor in which a plurality of cleaved magnet pieces are mounted in a rotor core with cleaved surfaces of the cleaved magnet pieces in an engaged state. In a cleaving step, a magnet workpiece having a recess in a surface thereof is cleaved at the recess as a starting point, thereby producing a first magnet piece and a second magnet piece. In a surface processing step, the cleaved surface is processed to reduce protrusions on the cleaved surface of the first magnet piece. Accordingly, the engagement between the cleaved surfaces is poor, the contact area is reduced, and the contact resistance is increased. As a result thereof, the eddy currents in the cut magnets flow less easily, and loss caused by eddy currents may be decreased.

Abstract: An apparatus for handling a magnet handles a plurality of split magnets obtained by sequentially splitting a magnet to be split from one end thereof. The apparatus for handling a magnet is equipped with a mechanism which arranges a split magnet with respect to a previously split magnet so that the magnets are put on top of one another and the corresponding irregularities of a pair of split surfaces thereof are arranged opposite each other. The apparatus for handling a magnet is also equipped with a section where the plurality of split magnets are arranged.

Abstract: A method for cleaving a plate-shaped workpiece formed with two or more linear recesses into three or more parts includes: a first positioning step of holding the workpiece by a positioning unit in place to position a first linear recess; a first clamping step of clamping one side of the first linear recess by a fixing clamp and the other side by a rotating clamp; a first cleaving step of moving back the positioning unit and rotationally separating the rotating clamp; a second positioning step of releasing the clamps and causing the positioning unit to position a second linear recess; a second clamping step of clamping one side of the second linear recess by the fixing clamp and the other side by the rotating clamp, and a second cleaving step of moving back the positioning unit and rotationally separating the rotating clamp.

Abstract: A manufacturing method of a rotating electric machine includes the steps of: preparing a plurality of split stator cores annularly arranged at intervals in a circumferential direction so that their inner end portions are aligned with an imaginary circle and a support member positioned inside the imaginary circle in a radial direction to support the inner end portions of split stator cores; mounting a fastening member on outer peripheries of split stator cores to press respective split stator cores inward in the radial direction; and displacing split stator cores pressed by fastening member inward in the radial direction while the support member is supporting split stator cores.

Abstract: A purpose is to provide a rotor manufacturing method including a magnet assembly formed of divided permanent magnet pieces to enhance insulation and advance cost reduction. The rotor manufacturing method includes forming permanent magnet pieces by dividing a permanent magnet, arranging and resin-molding the permanent magnet pieces to form a magnet assembly, and placing the magnet assembly in a rotor. The method includes placing the permanent magnet pieces all together in a molding die for use in resin-molding, and moving the permanent magnet pieces by a moving device provided in the molding die to move the permanent magnet pieces within the molding die, thereby forming the magnet assembly.

Abstract: A stator structure for a rotary electric machine includes a stator core having a cylindrical shape in which slots and pole pieces are formed on an inner peripheral side and alternately arranged in a circumferential direction, a conductor segment which is a conducting wire having a rectangular cross section inserted in one of the slots through an insulator being connected with a conductor segment similarly inserted in another slot to form a coil. Each insulator has a shape including a pair of opposite side surface portions connected with an intermediate portion along a wall surface defining the slot. Each insulator includes end protrusions facing each other at free ends of the side surface portions to position the conductor segments. The insulators are made of an insulating and elastic material.

Abstract: An apparatus for handling a magnet handles a plurality of split magnets obtained by sequentially splitting a magnet to be split from one end thereof. The apparatus for handling a magnet is equipped with a mechanism which arranges a split magnet with respect to a previously split magnet so that the magnets are put on top of one another and the corresponding irregularities of a pair of split surfaces thereof are arranged opposite each other. The apparatus for handling a magnet is also equipped with a section where the plurality of split magnets are arranged.

Abstract: A magnet splitting device includes a one-side holder for holding a plurality of pre-split magnets on one sides of respective splitting grooves, an other-side holder for holding the magnets on the other sides, and an actuating unit for causing relative movement of the other-side holder to split the magnets all at once. The other-side holder includes a plurality of other-side independent holding parts for holding the magnets independently. The actuating unit includes a plurality of independent actuating parts for moving the other-side independent holding parts independently and a simultaneous operating part for simultaneously operating the holding parts.

Abstract: A connection line has a first bent portion bent toward a coil's main body in a vicinity of a stator core's axial length limit line. Furthermore, the connection line at a portion closer to the coil's main body than the first bent portion has a second bent portion bent away from the coil's main body. Furthermore, the connection line has a third bent portion bent away from the coil's main body to have a connection portion along an end surface of the terminal member in contact therewith generally parallel thereto.