Patents by Inventor Yasuyuki Hirao

Yasuyuki Hirao has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10879776
    Abstract: A joining method for coil ends includes: pressing a pair of tapered portions such that a pair of first pressing jigs provided with a pair of detent portions is brought closer to the coil ends along an axial direction of the stator core, the pair of detent portions being fitted to the tapered portions; fixing axial positions of the pair of tapered portions such that the pair of detent portions is fitted to the pair of tapered portions so that the pair of tapered portions is sandwiched in a circumferential direction; fixing radial positions of the pair of tapered portions such that the pair of tapered portions is sandwiched by a pair of second pressing jigs so that the tapered portions of the pair of tapered portions make contact with each other; and welding a contacting portion where the tapered portions make contact with each other.
    Type: Grant
    Filed: May 8, 2019
    Date of Patent: December 29, 2020
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke Mizushima, Yasuyuki Hirao
  • Publication number: 20200204028
    Abstract: A coil includes a plurality of segment coils. Ends of two corresponding segment coils are electrically connected together via a coupling member or by being fitted together. Each of the plurality of segment coils includes a conductor-exposed portion located close to a connection portion between the corresponding segment coils and to be brought into contact with a probe of a resistance measurement apparatus. When the coil is manufactured, the ends of the plurality of segment coils are electrically connected to the ends of other corresponding segment coils, and electric resistances of connection portions between the ends are measured for each layer of the ends of the segment coils.
    Type: Application
    Filed: December 20, 2019
    Publication date: June 25, 2020
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke Mizushima, Yasuyuki Hirao
  • Patent number: 10637336
    Abstract: A stator coil forming method includes a bending step of bending portions of a linear lead wire so as to form bent portions; a cutting step of cutting curve parts of the bent portions thus formed, along a perpendicular plane that is approximately perpendicular to an extending direction of the lead wire so as to form coil segments; a U-shape forming step of bending the coil segments in a U-shape; an assembling step of assembling the coil segments to respective slots of a stator core; a tilting step of tilting both distal ends of the coil segments in a circumferential direction of the stator core so that cut surfaces of the distal ends are oriented toward a central-axis direction of the stator core; and a joining step of joining the distal ends of the coil segments adjacent to each other in a radial direction of the stator core.
    Type: Grant
    Filed: October 6, 2016
    Date of Patent: April 28, 2020
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Yasuyuki Hirao
  • Publication number: 20200112238
    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.
    Type: Application
    Filed: August 26, 2019
    Publication date: April 9, 2020
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yasushi Nishikuma, Daisuke Mizushima, Yasuyuki Hirao
  • Publication number: 20200112236
    Abstract: A laser welding method for a stator coil forms an abutting surface by abutting a side face of a first lead portion of a first rectangular wire to a side face of a second lead portion of a second rectangular wire. A laser beam is focused on a position more inward than a surface of an upper end of the abutting face between the first lead portion and the second lead portion, and the laser beam is moved in a helical loop on the upper end of the abutting face between the first lead portion and the second portion so as to melt the conductor wires to form a molten pool. The molten pool is then moved along the abutting face while the molten pool is continuously formed.
    Type: Application
    Filed: October 3, 2019
    Publication date: April 9, 2020
    Applicants: Toyota Jidosha Kabushiki Kaisha, Denso Corporation
    Inventors: Yasuyuki Hirao, Yoshiki Yamauchi, Hiroaki Takeda, Masaya Nakamura
  • Publication number: 20200106347
    Abstract: A method of removing an insulating coating layer of coil wiring includes: a fragmentation step in which a line-shaped region of the insulating coating layer, which separates a removal-planned portion and a remain-planned portion of the insulating coating layer, is removed; a laser irradiation step in which laser light which transmits through the insulating coating layer but which is absorbed by a coil wiring is irradiated from a side of an outer surface of the removal-planned portion toward a boundary of the coil wiring with the insulating coating layer, to carbonize a boundary portion between the insulating coating layer and the coil wiring of the removal-planned portion by generation of heat of the coil wiring; and a coating turn-over step in which air is blown onto the removal-planned portion to turn over and blow off the removal-planned portion.
    Type: Application
    Filed: September 24, 2019
    Publication date: April 2, 2020
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, DENSO CORPORATION
    Inventors: Ken SHIRAI, Yasuyuki HIRAO, Masashi MATSUMOTO, Hiroaki TAKEDA, Ryosuke MARUYAMA
  • Publication number: 20200099266
    Abstract: Provided is a stator manufacturing method including: inserting a plurality of segment coils into a plurality of slots formed in a stator core; bending arms of the segment coils that protrude from the stator core, in a circumferential direction of the stator core; before or after bending the segment coils in the circumferential direction, directing parallel to each other leading end portions of the segment coils that are adjacent to each other in a radial direction of the stator core; and welding together the leading end portions of the segment coils with the leading end portions directed parallel to each other.
    Type: Application
    Filed: July 19, 2019
    Publication date: March 26, 2020
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, DENSO CORPORATION
    Inventors: Yasuyuki HIRAO, Daisuke MIZUSHIMA, Hiroaki TAKEDA, Sho YASUDA
  • Publication number: 20200091800
    Abstract: A bending-forming jig used in bending and forming a protruding portion of a leg portion of a U-shaped conductor toward a circumferential direction, the protruding portion protruding from an axial end surface of a stator core, the bending-forming jig including a ring portion and a claw portion, the claw portion including a first abutting surface that rises from an axial end surface of the ring portion with the surface directed in the circumferential direction and abuts against a tip portion of the protruding portion from the circumferential direction, and a projecting portion that projects, at a tip end of the claw portion, in the circumferential direction from the abutting surface and abuts against the tip portion of the protruding portion from the axial direction toward the axial end surface of the ring portion.
    Type: Application
    Filed: September 10, 2019
    Publication date: March 19, 2020
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, DENSO CORPORATION
    Inventors: Yuiki GOTO, Daisuke MIZUSHIMA, Yasuyuki HIRAO, Hiroaki TAKEDA, Sho YASUDA
  • Publication number: 20200083787
    Abstract: A laser welding method for coil wires includes welding two coil wires by irradiating a laser beam to an upper end edge of butted surfaces of side surfaces of tip end portions of the two coil wires. At this time, a molten pool is formed at the center of a welding portion on the upper end edge by scanning the laser beam in a plurality of continuous loop shapes from one or both welding end portions, and welding is performed to make the molten pool at the center portion of the welding portion greater in welding depth than other molten pools by controlling at least one among a movement pitch, a loop area, a laser scanning speed, and a laser power of loops of the laser beam.
    Type: Application
    Filed: September 10, 2019
    Publication date: March 12, 2020
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, DENSO CORPORATION
    Inventors: Tadashi FUJIYOSHI, Yasuyuki HIRAO, Yoshiki YAMAUCHI, Hiroaki TAKEDA, Masaya NAKAMURA
  • Publication number: 20190312494
    Abstract: A method of producing a rotating electric machine stator includes an insertion step, bending step, and pressing step. In the insertion step, two leg portions of each U-shaped coil wire of a stator coil are inserted into different slots, such that protruding portions as distal end portions of the leg portions protrude in parallel with an axial direction of the stator core. In the bending step, the protruding portion of a first leg portion is bent in a first circumferential direction of the stator core, at a proximal end portion of the protruding portion as a bending start point, from a condition where the protruding portion protrudes from the slot in parallel with the axial direction of the stator core. In the pressing step, a distal end of the protruding portion bent in the first circumferential direction is pressed toward its proximal end in a second circumferential direction.
    Type: Application
    Filed: March 29, 2019
    Publication date: October 10, 2019
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, DENSO CORPORATION
    Inventors: Daisuke MIZUSHIMA, Yasuyuki HIRAO, Hiroaki TAKEDA
  • Patent number: 10439462
    Abstract: A stator coil includes a plurality of flat wire-shaped coil pieces extending in a circumferential direction of a rotary electric machine at a position on an outer side of a stator core in an axial direction of the rotary electric machine. At the position on the outer side of the stator core in the axial direction, a distal end portion of one of the coil pieces, extending in a first direction in the circumferential direction, is joined with a distal end portion of another one of the coil pieces, extending in a second direction in the circumferential direction. The second direction in the circumferential direction is reverse to the first direction in the circumferential direction. An axially outer end face of the distal end portion of each coil piece is a circular arc face that is convex toward the outer side in the axial direction.
    Type: Grant
    Filed: November 13, 2017
    Date of Patent: October 8, 2019
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Yasuyuki Hirao
  • Publication number: 20190280574
    Abstract: An insulation film peeling method which radiates laser light onto a front end portion of an insulation film-coated conducting wire including a conducting wire and an insulation film in a longitudinal direction, and which peels a part of the insulation film up to a peeling boundary of a predetermined regulated peeling length, includes performing a rectilinear scan of a first region, in which a radiation position of the laser light moves from one side toward the other side and then moves from the other side toward the one side upon reaching the other side, and performing a unidirectional scan of a second region, in which the radiation of the laser light is performed from one side toward the other side and then the radiation position returns to the one side in a state in which the radiation of the laser light stops upon reaching the other side.
    Type: Application
    Filed: February 27, 2019
    Publication date: September 12, 2019
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, DENSO CORPORATION
    Inventors: Ken SHIRAI, Akihiro UEDA, Yasuyuki HIRAO, Toshiro NAKAMURA, Hiroaki TAKEDA
  • Publication number: 20190267879
    Abstract: A joining method for coil ends includes: pressing a pair of tapered portions such that a pair of first pressing jigs provided with a pair of detent portions is brought closer to the coil ends along an axial direction of the stator core, the pair of detent portions being fitted to the tapered portions; fixing axial positions of the pair of tapered portions such that the pair of detent portions is fitted to the pair of tapered portions so that the pair of tapered portions is sandwiched in a circumferential direction; fixing radial positions of the pair of tapered portions such that the pair of tapered portions is sandwiched by a pair of second pressing jigs so that the tapered portions of the pair of tapered portions make contact with each other; and welding a contacting portion where the tapered portions make contact with each other.
    Type: Application
    Filed: May 8, 2019
    Publication date: August 29, 2019
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke MIZUSHIMA, Yasuyuki HIRAO
  • Patent number: 10361611
    Abstract: A coil end bending jig pushes down a plurality of coil ends of coil segments held by a toric stator core, the plurality of coil ends being arranged on a same circumference. The coil end bending jig includes a plurality of bending units each having a bending tooth that makes contact with a corresponding one of the coil ends, and a guide member having a plurality of guiding slits into which the plurality of bending units is inserted, respectively. The plurality of guiding slits extends from an inner peripheral side of the stator core to an outer peripheral side of the stator core so as not to intersect with each other when viewed from an axial direction of the stator core.
    Type: Grant
    Filed: October 20, 2016
    Date of Patent: July 23, 2019
    Assignee: TOYOTA JIDOSHA KABUSIKI KAISHA
    Inventor: Yasuyuki Hirao
  • Patent number: 10355567
    Abstract: A joining method for coil ends includes: pressing a pair of tapered portions such that a pair of first pressing jigs provided with a pair of detent portions is brought closer to the coil ends along an axial direction of the stator core, the pair of detent portions being fitted to the tapered portions; fixing axial positions of the pair of tapered portions such that the pair of detent portions is fitted to the pair of tapered portions so that the pair of tapered portions is sandwiched in a circumferential direction; fixing radial positions of the pair of tapered portions such that the pair of tapered portions is sandwiched by a pair of second pressing jigs so that the tapered portions of the pair of tapered portions make contact with each other; and welding a contacting portion where the tapered portions make contact with each other.
    Type: Grant
    Filed: October 17, 2016
    Date of Patent: July 16, 2019
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke Mizushima, Yasuyuki Hirao
  • Publication number: 20190199183
    Abstract: A coil bending machine is a machine that, in a stator core including a yoke and multiple teeth and having a slot formed between circumferentially adjacent teeth, while lead portions of a segment coil which is a U-shaped lead wire including a bent portion K and two lead portions R extending from the bent portion are inserted into two slots, push-bends end portions of the lead portions protruding from an axial end face of the stator core toward the stator core. The coil bending machine includes a coil bending member that push-bends the end portions of the lead portions protruding from the axial end face of the stator core toward the stator core, and a coil pressing mechanism that press-fixes a segment coil inside the slot toward the yoke, from the radially inner side of the stator core.
    Type: Application
    Filed: December 20, 2018
    Publication date: June 27, 2019
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, DENSO CORPORATION
    Inventors: Daisuke MIZUSHIMA, Yasuyuki HIRAO, Hiroaki TAKEDA
  • Patent number: 10163551
    Abstract: A method of manufacturing a coated conducting wire assembly includes forming a conducting wire assembly by twist-deforming a conducting wire bundle, forming a coated conducting wire assembly by covering the conducting wire assembly with an insulation coating, and annealing the coated conducting wire assembly. The conducting wire bundle is formed by bundling a plurality of conducting wires. The conducting wire assembly includes a parallel portion, a left-wound portion, and a right-wound portion. The annealing is performed by heating and holding the coated conducting wire assembly at an annealing temperature while applying tension to the covered conducting wire assembly.
    Type: Grant
    Filed: May 16, 2016
    Date of Patent: December 25, 2018
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yasuyuki Hirao, Hideki Manabe
  • Patent number: 10128728
    Abstract: A manufacturing method for a segment coil according to the invention includes forming an assembled wire by bundling a plurality of element wires, forming a stranded wire by twisting the assembled wire, forming a rectangular conductor by rolling the stranded wire, and forming a segment coil by cutting the rectangular conductor into a given length and bending the cut rectangular conductor. Before the rectangular conductor is bent, the plurality of element wires is fastened at a position where the coil end portion of the segment coil is formed.
    Type: Grant
    Filed: July 16, 2015
    Date of Patent: November 13, 2018
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Yasuyuki Hirao
  • Publication number: 20180166939
    Abstract: A stator coil includes a plurality of flat wire-shaped coil pieces extending in a circumferential direction of a rotary electric machine at a position on an outer side of a stator core in an axial direction of the rotary electric machine. At the position on the outer side of the stator core in the axial direction, a distal end portion of one of the coil pieces, extending in a first direction in the circumferential direction, is joined with a distal end portion of another one of the coil pieces, extending in a second direction in the circumferential direction. The second direction in the circumferential direction is reverse to the first direction in the circumferential direction. An axially outer end face of the distal end portion of each coil piece is a circular arc face that is convex toward the outer side in the axial direction.
    Type: Application
    Filed: November 13, 2017
    Publication date: June 14, 2018
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Yasuyuki HIRAO
  • Patent number: 9853527
    Abstract: In a method for producing a rotor including a leak prevention hole formed in a rotor core to prevent leakage of magnetic flux from a permanent magnet; an outer-circumferential-side dovetail groove formed in an outer-circumferential-side inner wall of the leak prevention hole, an inner-circumferential-side dovetail groove formed, opposite the outer-circumferential-side dovetail groove, in an inner-circumferential-side inner wall of the leak prevention hole; and a non-magnetic bridge having both end portions engageable with the dovetail grooves, an external force is applied to bring the outer-circumferential-side inner wall close to the inner-circumferential-side inner wall, the non-magnetic bridge is inserted in the dovetail grooves while keeping the rotor core in an elastically deformed state, and, after inserting, the external force is released.
    Type: Grant
    Filed: August 7, 2015
    Date of Patent: December 26, 2017
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Ippei Hamanaka, Yasuyuki Hirao, Yasuo Kinoshita