Abstract: A direct-current motor includes a yoke having six magnetic poles, an iron core having nine teeth, first and second coils wound about each tooth in directions different from each other, a commutator for being rotated integrally with the iron core and having eighteen commutator pieces, and three pairs of brushes. The brush having the positive pole electrically connected to the first coil is different from the brush having the positive pole electrically connected to the second coil, the brush having the negative pole electrically connected to the first coil is different from the brush having the negative pole electrically connected to the second coil, or the brush having the positive pole and the brush having the negative pole that are electrically connected to the first coil are respectively different from the brush having the positive pole and the brush having the negative pole that are electrically connected to the second coil.

Abstract: A method of assembling a hand held electrically powered drilling and/or hammering tool having a tool housing and a drilling and/or hammering spindle mounted within the housing. The spindle has a forward end at which a tool or bit may be mounted. The method of assembly includes the steps of making a motor sub-assembly including a motor and a radial fan, the fan has a plurality of blades located on one side of the fan and non-rotatably mounting the fan on an end of the armature shaft of the motor at a first end of the motor with the blades facing away from the armature of the motor. The method further including balancing the motor sub-assembly, and mounting the sub-assembly within the housing, with the longitudinal axis of the motor armature shaft at an angle, preferably perpendicular to the longitudinal axis of the spindle and with the first end of the motor closest to the spindle axis.

Abstract: A method of preparing a plurality of bar-wound stator conductors for electrical interconnection includes inserting the plurality of conductors into a stator, twisting a conductor such that a first conductor of a first row is adjacent to a second conductor of a second row; trimming the adjacent first and second conductors to a common length using a trimming device; and grinding the trimmed first and second conductors to a pre-determined surface profile using a rotary cutting tool.

Abstract: A stator coil producing method and a stator coil production machine. The stator coil is used in an electric rotating machine. The stator coil production machine includes a rotary retainer which retains and moves shaping press pairs along a looped path to press or shape portions of a conductor wire into in-slot portions to be disposed in slots of a stator core and coil-end portions which extend outside the slots. The method comprises a coil-end portion shaping step of bringing press members of each of the shaping press pairs close to each other in sequence to shape the coil-end portions and an in-slot portion shaping step of advancing the shaping press pairs on the looped path in contact with the cam mechanism and also moving selected ones of the shaping press pairs in sequence in a direction perpendicular to the path to shape the in-slot portions.

Abstract: A method of manufacturing a commutator. A connector plate is formed with a plurality of connectors arranged circumferentially about a central opening and interconnected by links, with each connector having a terminal portion, a segment portion and a number of anchors, with adjacent segment portions being separated circumferentially by slits. A conductive layer is fixed onto a first face of the segment portions to form a brush contacting surface. The connectors are separated by severing the links. The base is fixed to a second face of the connectors. Then the conductive layer is separated into circumferentially arranged segment parts by cutting radial slots through the conductive layer aligned with the slits, the width of the slots being narrower that the width of the slits to avoid cutting the connectors.

Abstract: A method for forming a secondary for a motor, for instance a linear drive motor, includes providing a sheet of highly magnetic permeable material with a plurality of slots extending through the sheet spaced along a length of the sheet. The slots define a plurality of teeth in the sheet and enable the sheet to be conformable to a mounting surface when forming the secondary of the motor. The top surface of the sheet has a plurality of pockets formed adjacent the plurality of slots. The pockets extend parallel to the width and are spaced along the length of the sheet. The pockets form a sensor operatively connected to a control of the motor. The sensor may be an encoder, and/or operatively connected to a control for controlling commutation of the motor, and/or setting positional limits, absolute positional information, and/or providing information about the sheet.

Abstract: A method of forming a flux regulated machine includes winding stator windings into slots in an outer core. The outer core is formed to have a plurality of radially inwardly extending tooth pieces that are circumferentially spaced, and which define the slots. Further, control coils are wound around an inner core. Then, the inner core is inserted within the outer core such that the tooth pieces contact the inner core, and such that the control coils close off the slots at a radially innermost position. A flux regulated permanent magnet machine generally made according to this method is also disclosed.

Abstract: A method for forming an armature for an electric motor includes: securing a lamination stack having slots therein on an armature shaft, securing a commutator on one end of the armature shaft, winding magnet wires in the slots in the lamination stack and securing ends of the magnet wires to the commutator, the magnet wires having armature lead wires that extend from the slots to the commutator; and molding plastic over the magnet wires to encase at least the armature lead wires in plastic. Alternatively and/or additionally, plastic is molded over the magnet wires to retain them in the slots and to support the armature lead wires and prevent them from vibrating when the armature rotates during operation.

Abstract: Electric motor components are formed of a conductive loaded resin-based, material. The conductive loaded resin-based material comprises micron conductive powder(s), conductive fiber(s), or a combination of conductive powder and conductive fibers in a base resin host. The percentage by weight of the conductive powder(s), conductive fiber(s), or a combination thereof is between about 20% and 50% of the weight of the conductive loaded resin-based material. The micron conductive powders are metals or conductive non-metals or metal plated non-metals. The micron conductive fibers may be metal fiber or metal plated fiber. Further, the metal plated fiber may be formed by plating metal onto a metal fiber or by plating metal onto a non-metal fiber. Any platable fiber may be used as the core for a non-metal fiber. Superconductor metals may also be used as micron conductive fibers and/or as metal plating onto fibers in the present invention.

Abstract: A commutator includes a first body and a second body which are separately made of electrically insulating material, a plurality of commutator segments fixed on an outer surface of the first body and a plurality of commutator terminals. The first body is a hollow cylinder with two opposite ends. Each terminal has a contact area for contacting a corresponding one of the commutator segments. The second body has a base and a ring wall extending from the base, and one end of the first body is received in a space defined by the base and the ring wall, with the contact area of each terminal being in tight contact with the corresponding commutator segment at the inner side of the ring wall.

Abstract: A method for making a wound stator of an automotive generator is provided for replacing the conventional winding technique. The method includes: forming a stator ring provided with a plurality of annularly arranged radial through slots; cutting a copper wire into a plurality of wire units each having a rectangular cross section; inserting the wire units into the through slots in an interlacing manner; and soldering wire ends of the wire units sequentially so as to form a connected loop.

Abstract: The invention relates to a method and device for producing an electric machine, an electric machine with a commutator, having commutator hooks for fixing electric wire windings with solder arranged between the commutator hooks and the wire winding and two electrodes arranged adjacent to each other which are pressed against the commutator hooks. An electric current is passed through the commutator hooks by means of electrodes such that the solder melts and forms a connection to the wire winding.

Abstract: A BLDC electric motor assembly (24) includes a rotor (42) having a plurality of magnet segments (50) securely retained thereabout by an annular ring (68) which is shrunk in situ in an electromagnetic forming operation. The magnet segments (50) are formed with tongues (62, 64) on their upper and lower ends (56, 58). One tongue (64) seats in a retaining pocket (48) molded on the rotor shaft (40), whereas the other tongue (62) provides a ledge into which the ring (68) seats. After the magnet forming operation, wherein the ring (68) is shrunk, the outer surface of the ring (68) is flush with the outer surfaces (54) of the magnet segments (50).

Abstract: Methods for fabricating a balance ring for a vehicular electric machine are provided. In one embodiment, the method includes the steps of providing a first metal layer having a first planar surface, providing a second metal layer having a second planar surface, cladding the second planar surface to the first planar surface to form a composite structure, and removing a portion of the composite structure to form an annular ring.

Abstract: A flat commutator having a support body, carbon segments, and conductor segments, wherein the support body is formed on the carbon ring disk, which is later separated into carbon segments that are insulated from one another, the support body sitting against the carbon ring disk radially outward, radially inward, and against the end face of the carbon ring disk, said end face lying opposite the brush contact surface. The conductor segments are subsequently applied individually such that a contact pin of each segment penetrates a cavity that extends from the support body surface lying opposite the brush contact surface to the surface of the segments or of the carbon ring disks, said surface lying opposite the brush contact surface; and the free end of said contact pin contacts the surface of the segments or of the carbon ring disk, said surface lying opposite the brush contact surface.

Abstract: Apparatus including a monolithic, motor/generator phase insulation article having a manufactured state and a ready-to-use state. The insulation article has longitudinally-spaced-apart first and second tabs and flexible, transversely-spaced-apart first and second legs each having a first end monolithically joined to the first tab and a second end monolithically joined to the second tab. The first and second tabs are disposed longitudinally closer together in the manufactured state than in the ready-to-use state. In the manufactured state the first and second legs each have a more serpentine shape, and in the ready-to-use state the first and second legs each have a less serpentine shape. A method for manufacturing the insulation article is also described which cuts a monolithic, substantially-rectangular sheet of motor/generator phase insulation to create the insulation article.

Abstract: An electric motor has a stator in which an armature is disposed. The armature has a lamination stack having slots in which magnet wires are wound. An armature shaft extends coaxially through the lamination stack and a commutator is disposed on the armature shaft to which ends of the magnet wires are electrically coupled. The magnet wires are at least partially encased in thermally conductive plastic. When the thermally conductive plastic is molded, a balancing feature is formed of the thermally conductive plastic. In aspects, the balancing feature can include a layer of the plastic from which plastic can be removed during balancing; one or more balancing rings adjacent axial sides of the lamination stack from which plastic can be removed to balance the armature; or one or more balancing rings having one or more pockets therein in which one or more weights are disposed to balance the armature.

Abstract: A method for making and magnetizing an un-magnetized mechanically keyed permanent magnet rotor that can be magnetized in a magnetization fixture, without regard to the angular position of the rotor in the magnetizing fixture, and nevertheless result in a permanent magnetic field angularly synchronized to said keyed rotor comprises the steps of providing an annular permanent magnet or annular permanent magnet rotor body; a mechanically keyed rotor shaft; means for aligning and assembling the un-magnetized permanent magnet or permanent magnet rotor body and the mechanically keyed rotor shaft during assembly to form an assembled rotor; and magnetization thereof.

Abstract: A short-circuiting member for preventing a commutator from being elongated in the axial direction without increasing the types of different components. Each component includes outer circumference terminals arranged along an outer circumference, inner circumference terminals arranged along an inner circumference, and connection portions connecting corresponding outer and inner circumference terminals that are separated from each other by a predetermined angle in a circumferential direction. The outer and inner circumference terminals are substantially formed along the same plane. The components are laminated in a state in which the connection portions of one of the components are reversed to the connection portions of another one of the components.

Abstract: A stator core including at least two or more stator core-continuous bodies each formed by coupling at least two or more unit cores to each other, each unit core consisting of a tooth portion having a coupling slot and a coupling projection formed along both ends thereof and connected to adjacent unit core by means of a connection portion formed at each of both end portions of the tooth portion, wherein the at least two or more stator core-continuous bodies are fitting-connected to each other by means of the coupling slots formed at one side ends thereof and the coupling projections formed at the other side ends thereof to form the stator core having a round shape.

Abstract: A method of manufacturing a molded commutator for a vacuum cleaner motor, includes providing a cylindrical molding ring; arranging commutator segments in a circle along an inner periphery of the cylindrical molding ring such that grooves are formed between adjacent pairs of the commutator segments and the grooves are extended orthogonal to the rotating direction; press-fitting cylindrical varistors between the commutator segments, with a press-fitting load for each of the varistors ranging from 2 kN to 5 kN; and resin-molding the commutator segments and the varistors together with a molding material so as to maintain integral engagement of the commutator segments and the varistors; wherein the commutator segments are of copper alloy containing silver, and the varistors are of zinc oxide compounds; wherein side surfaces of the varistors contact with the adjacent pairs of commutator segments; and flexible metal is printed on the contacting side surfaces of the varistors.

Abstract: An armature for an electric motor has a lamination stack on a shaft with a commutator mounted on one end of the shaft. Magnet wires wound in slots in the lamination stack, the commutator and armature shaft are at least partially encapsulated in thermoset. The commutator has a commutator ring divided into a plurality of segments with slots between the segments that are filled with a second plastic when the commutator is made by molding a core of the second plastic, such as phenolic, in the commutator ring before the commutator ring is mounted on the armature shaft. Prior to molding the thermoset, the commutator ring is sealed. The seal prevents the thermoset from flowing into the slots between the commutator ring segments or over the commutator ring.

Abstract: A rotor attachment apparatus for attaching a rotor of a motor coaxially to a crankshaft by inserting the rotor into a rotor housing that is attached to an engine, including: a rotor support member; rotor positioning members that engage some of a plurality of bolt insertion holes provided in the rotor, to thereby position the rotor; a temporary fixation bolt that temporarily fixes the rotor on the rotor support member; a drive shaft a tip portion of which is engaged with a shaft end portion of the crankshaft, and which supports the rotor support member movably in an axis direction via a screw mechanism; a base member that moves the rotor support member toward and away from the rotor while rotatably supporting a base end of the drive shaft; base positioning members that engage the rotor housing; and a fastening mechanism which engages a head of a coupling bolt inserted into at least one of the bolt insertion holes, and which is supported by the rotor support member so as to bias the coupling bolt toward the rot

Abstract: An electric motor is described in which a first magnet wire forms a first pole of the coil, is disposed across two terminals of a fuse, and terminates at a first end on a power switch. The portion of the first magnet wire between the terminals of the fuse is severed such that all current of the motor must travel through the conductor of the fuse. The second end of the first magnet wire terminates at dual tang terminal disposed on the brush housing.

Abstract: A process for manufacturing an outer stator for an electric motor whereby the stator comprises stator poles surrounded by coils. A laminar body of ferromagnetic material is prepared, with elongated form and provided with laminar protrusions. A coil of conductive material is then inserted around each of the laminar protrusions. The terminal zones of the laminar protrusions are then cut or separated and deformed in order to assume an outwardly curved form. Then, the laminar body is closed such that the laminar protrusions are in an internal position and adapted to serve as stator poles.

Abstract: A method for producing a ring core having a plurality of separate core plates with lobes defined on an inner circumferential surface thereof, the separate core plates being arranged and stacked in a ring-shaped pattern. The method includes the steps of supporting the separate core plates with either one of an inner guide member being disposed radially inwardly of the separate core plates stacked in the ring-shaped pattern and an outer guide member disposed radially outwardly of the separate core plates, and applying a pressure from the other of the inner guide member and the outer guide member, wherein the inner guide member has recesses corresponding to the lobes for positioning and supporting the lobes, and stacking the separate core plates in the ring-shaped pattern to form the ring core, while rotating the separate core plates in unison through a predetermined angle with the inner and outer guide members.

Abstract: There is provided a method of manufacturing an electric motor. To begin with, a stator is provided by fixing a stator winding on a stator core. The stator winding has a coil end projecting from one end face of the stator core. Subsequently, a lead wire is drawn out from the coil end radially outward thereof. A connecting terminal is fixedly mounted to a distal end of the lead wire. A terminal block is provided such that the terminal block is held at a position to be finally fixed relative to the stator. The lead wire is bent toward the terminal block. The connecting terminal is electrically connected to the terminal block. An insulator is coated on the lead wire and the coil end by impregnating the lead wire and the coil end with liquid insulating material.

Abstract: Methods for fabricating a balance ring for a vehicular electric machine are provided. In one embodiment, the method includes the steps of providing a first metal layer having a first planar surface, providing a second metal layer having a second planar surface, cladding the second planar surface to the first planar surface to form a composite structure, and removing a portion of the composite structure to form an annular ring.

Abstract: A method for forming a loop winding having a plurality of meandering parts and disposed in a stator of a motor which includes: disposing the loop winding between a first die unit having a plurality of first dies and a second die unit having a plurality of second dies; and press forming the loop winding between the first dies and the second dies by relatively moving the first die unit and the second die unit toward each other, wherein the press forming step is so performed as to provide the loop winding with a plurality of meandering parts and, simultaneously, to reduce the loop winding in the radial direction.

Abstract: The apparatus of the present invention provides a stator for an electric motor. The apparatus includes a plurality of stator components assembled together to form a generally annular stator core. A wire is wrapped around at least a portion of the stator core to form a stator winding. A first generally annular end plate and a second generally annular end plate are mounted to axially opposite sides of the stator core such that the stator core is axially trapped and retained therebetween. A fastener applies a clamping load to the first and second end plates such that the stator core is compressed therebetween. The clamping load from the fastener is applied directly to the first and second end plates which distribute the clamping load to the stator core such that the plurality of components are held together without the fastener directly applying the clamping load to the stator core. A corresponding method for providing a stator is similarly provided.

Abstract: Some embodiments of the present disclosure provide a method of making a rotor of an electric brushless motor configured to be light weight and prevent vibrations generated during an operation of the motor to be transferred to the shaft of the rotor. The method includes providing a shaft elongated in a rotational axis, providing a single body magnet comprising alternately magnetized portions, and providing a vibration absorption portion interposed between the shaft and single body magnet. The vibration absorption portion absorbs vibrations generated during the operation of the motor and may include an elastic or a non-elastic material. The method further includes providing a non-elastic portion configured to inhibit the expansion of the vibration absorption portion when the vibration portion is elastic.

Abstract: A carbon commutator, for an electric motor, has a plurality of segments forming a brush contact surface and a hub supporting the segments. Each segment has a connector having a terminal for connection of a lead wire, a carbon layer forming the brush contact surface, and a connecting layer fixed to the carbon layer and electrically connecting the carbon layer to the connector. A plurality of micro structures is formed at the interface between the connecting layer and the carbon layer.

Abstract: A slip ring module (76) for a rotor (40) of an electrical machine (10), in particular, an alternator is disclosed, comprising at least one first slip ring (79) with at least one first connecting conductor (103) held in sections of an insulation material (101) for the slip ring module (76), in electrically conducting connection with at least one first slip ring (79) and with an end (115) of the connection conductor (103), facing away from the first slip ring (79), provided for connection to an excitation coil (61). The invention is characterised in that the slip ring module (76) has a further formed conductor (139) forming a direct electrical connection from the first connection conductor (103) to a surface (142) of the slip ring module (76). An electric machine is also provided, in particular, an alternator for motor vehicles, comprising a rotor (40), supporting an excitation coil (61), said slip ring module (76) providing the power supply to the excitation coil (61).

Abstract: An armature for an electric motor has a lamination stack on a shaft with a commutator mounted on one end of the shaft. Magnet wires wound in slots in the lamination stack, the commutator and armature shaft are at least partially encapsulated in thermoset. The commutator has a commutator ring divided into a plurality of segments with slots between the segments that are filled with a second plastic when the commutator is made by molding a core of the second plastic, such as phenolic, in the commutator ring before the commutator ring is mounted on the armature shaft. Prior to molding the thermoset, the commutator ring is sealed. The seal prevents the thermoset from flowing into the slots between the commutator ring segments or over the commutator ring.

Abstract: In a motor, an insulator covering an armature core has a lid covering an end surface of the armature core. The lid has an inner ring disposed radially inside slots of the armature core and an outer ring disposed radially outside the slots. Each of a plurality of slot insulators inserted into the slots has a blocking portion at a position in the inner ring.

Abstract: The present invention relates to a method for manufacturing a shaft-hub component (1) having a shaft (2), a hub component (3; 10; 11; 12) and a shaft-hub connection for an armature of an electrical machine, comprising the steps: hardening of the shaft (2) at least on the outer lateral surface (6) of said shaft (2), shaping of the hardened shaft (2) such that a partial region (L1; L2; L3; L4) of said shaft (2) is shaped in such a manner that at least one radially projecting section (4) and one radially indented section (5) are produced and joining of said shaped shaft (2) and the hub component (3, 10, 11, 12) to the shaft-hub component so that said shaft-hub connection includes an interference fit at the projecting section (4), a hardness of said hub component (3; 10; 11; 12) being less than a surface layer hardness of said shaft (2). The invention further relates to a shaft-hub component for an armature of an electrical machine.

Abstract: The invention relates to a commutator (1) comprising electrically conductive commutator segments (12), which are disposed about a rotational axis (10) in a manner free of a pressing material body, and which are electrically insulated from each other by means of an air gap (14) disposed between two adjacent commutator segments (12), characterized in that a fixing means (42) applied to the commutator (1) in a flowable phase in a form-free manner is cured after a flow process between two commutator segments (12) adjoining in the circumferential direction about the rotational axis (10), and that the position of the commutator segments (12) is fixed by the cured fixing means (42), and to a power tool having an electric motor comprising such a commutator, and to a method for the production of a commutator.

Abstract: Coils are electrically connected to a commutator, which includes commutator segments that are arranged one after another in a circumferential direction of a dielectric body along an outer peripheral surface of the dielectric body. Each commutator segment includes a slidably contacting portion, a claw portion and a bending fulcrum portion. The slidably contacting portion is provided in one axial side of the commutator segment and is slidably contactable with each brush. The claw portion is provided in the other axial side of the commutator segment and is engageable with the corresponding coil. The bending fulcrum portion is formed on a claw portion side of the slidably contacting portion and is bent upon radially inwardly pressing the claw portion by a fusing electrode.

Abstract: A method for sheathing an armature for electric machines, in which a stack of lamellae that is equipped with grooves for armature windings is mounted on an armature shaft by means of a bore and is provided with at least one groove insulation with the aid of the sheathing process. The sheathing plastic flows through ducts that extend along the bore of the stack and the armature shaft. The plastic is molded in only on a first face of the stack and flows into the grooves and through the ducts. The plastic invades the grooves also from the second face after being discharged from the ducts and converges with the plastic discharged from the first face. The method implements fixing and insulation of the grooves while the groove insulation is provided with a minimum layer thickness for such sheathings at the bottom thereof in order to allow for maximum copper fillings.

Abstract: A short-circuit member includes a short-circuit conductor and a short-circuit insulator. The short-circuit conductor includes superimposed first and second short-circuit member formation groups. Each of the short-circuit member formation groups has outer terminals, inner terminals, and linking portions. The outer terminals contact one another and the inner terminals contact one another between each of the short-circuit member formation groups. The linking portions are maintained in non-contact between each of the short-circuit member formation groups.

Abstract: A method for manufacturing an armature including securing a core to the shaft having a plurality of slots extending in the axial direction formed on the outer circumferential surface thereof, forming a coil composed of a plurality of coil portions by simultaneously winding wires a plurality of turns around a pair of slots separated by a predetermined number of slots and offsetting each of the coil portions one slot at a time in the circumferential direction of the core, securing a commutator to the shaft having a plurality of segments, adjacent coil portions having a slot along one side thereof, wherein a number of vacant slots between adjacent ones of the coil portions within each of simultaneously-wound coil portion groups is nonuniform, and electronically connecting segments which should have the same electric potential by means of equalizing connectors so that each of pairs of the coil portions that should have the same electric potential has a substantially equal electric potential.

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: A commutator includes a conductive part that has a cylindrical body and a plurality of coil latching portions at intervals circumferentially on one axial end; and an insulating part formed inside the conductive part. The conductive part includes segments that are insulated for each latching portion by cutting axially the conductive part, and latching claws that are provided in a projecting state on an inner peripheral surface of the segments and embedded in the insulating part, wherein the latching claws include axial latching claws that are long in an axial direction and project inward, and circumferential latching claws that project circumferentially.

Abstract: A commutator has an electrically non-conductive base and a plurality of commutator segments fixed to the base. Each segment comprises an electrically conductive connector and a segment part, wherein the connector has a segment portion, a terminal portion and anchors all formed as a monolithic construction. The terminal and anchors extend from the segment portion at radial ends thereof. The anchors fix the connectors to the base by being embedded therein. The segment part is a part of an annular disc forming an electrically conductive brush-contacting layer fixed to a side of the segment portion remote from the base. The segment portions are circumferentially separated by slits into which the base extends and the segment parts are separated circumferentially by slots. The slots are aligned with the slits, are narrower than the slits and extend axially into the material of the base within the slits between adjacent connectors.

Abstract: The object of the invention is to provide an armature which is in good rotational balance, where the total number of the coils to be disposed in the slots of the rotary electric machine can be freely set when winding coils on the armature core. Coils are wound on an outer periphery of an armature core 3 by use of a winding device 7 which is provided with sixteen nozzles 11b movable in the axial direction to draw out the coils to thirty two slots formed on the outer periphery of the armature core 3, wherein sixteen coils 5 are simultaneously wound through a single winding operation and the winding operation with respect to the slot 3c is performed three times in such a manner that the total number of the coils 5 in the slots 3c becomes 96 (C) so that the number obtained by dividing the total number of the coils 5 C by twice the number of the slots does not become a natural number.

Abstract: Bearing bores for engine mount components must be periodically repaired. A component is disassembled and a bearing is removed from the bearing bore. An inner surface of the bearing bore is machined to remove any damage. A sizing sleeve is selected to have a press fit with the machined inner surface of the bearing bore and with the outer surface of a new bearing. The bearing is press fit into the sizing sleeve and the sizing sleeve is press fit into the bearing bore. The outer surfaces of the sizing sleeve and the bearing are swaged to assist in retaining and preventing relative movement between the bearing, sizing sleeve and engine mount component.

Abstract: A stator of a rotary electric machine having secured core slot insulators includes a multi-phase stator winding, having a plurality of slot segments that are adapted to be radially inserted into a plurality of circumferentially spaced axially-extending core slots in a surface of a cylindrically-shaped stator core. The stator winding includes the plurality of slot segments alternately connected at the first and second ends of the stator core by a plurality of end loop segments to form the winding. The plurality of core slots house an insulator to electrically isolate the slot segments from the core slots. The insulator is secured to the sides of the core slot prior to the process of radial inserting the plurality of slot segments into the plurality of core slots of the cylindrically-shaped stator core.

Abstract: The invention relates to a closed loop conductor blank for a drum commutator (T). The conductor segments are interconnected via bridge sections. One end face of the conductor segments comprises connecting projections (7) as well as inward-facing anchor ties for anchoring said conductor segments in a support element (1). The first anchor ties (9a, 9b), which are produced by the partial splitting of material on the radially inner surface of the strip in the vicinity of the conductor segments (4), form K-shaped pairs of anchor ties. In addition, second anchor ties (10a, 10b) are provided, said ties being C-shaped and arranged substantially on the end face and being produced by the inward deformation of anchoring projections arranged on the edges of the strip.

Abstract: In manufacturing of the stator unit 2 according to one preferred embodiment of the present invention, a plurality of terminal pins are arranged in an axially spaced manner from a plurality of the coils during a twining process of the wires from the coils 232 to the terminal pins 241. Then, after the wire is twined to the terminal pins, the terminal pins connected to the coils are moved along the outer side face of the sleeve housing, functioning to as a guide portion 2201 for the terminal pins. By virtue of the configuration, the terminal pins 241 may be approximated to the coils without applying the tension on wire, and the stator unit may be made thin with preventing the open circuit of the wires.

Abstract: A method of manufacturing a commutator main body which has a cylindrical insulating body, and a plurality of segments arranged in an outer circumference of the insulating body. A short-circuit member is arranged in an end in an axial direction of the insulating body. The short-circuit member has a plurality of first short-circuit pieces and a plurality of second short-circuit pieces. A tabular insulating portion covers first coupling portions of the first short-circuit pieces, and second coupling portions of the second short-circuit pieces. The insulating portion has a restriction recess, and the end in the axial direction has a restriction projection. The restriction projection is engaged with the restriction recess, whereby the movement of the short-circuit member in the circumferential direction with respect to the commutator main body is restricted. Accordingly, the assembly of the short-circuit member in the commutator main body is facilitated.