Abstract: A mover assembly of a reciprocating motor includes: a mover body disposed at a gap between an inner stator and an outer stator; permanent magnets fixed at an outer circumferential surface of the mover body and reciprocally moved together with the mover body in a direction of an induction magnetic field between the inner stator and the outer stator; and a mixed member made of a fiber and a resin to cover and fix the permanent magnets. The permanent magnets are arranged at an outer circumferential face of the mover body, covered with the mixed member obtained by mixing a fiber and a resin, and hardened to be fixed. Therefore, the permanent magnets can be firmly and easily fixed at the mover body. In addition, by molding the mover body with a non magnetic and non-conductive material, leakage of the magnetic force of the permanent magnets can be prevented.

Abstract: This process for assembling conductive segments (16) of a rotor or stator winding of a rotary electrical machine comprises the stages consisting in inserting the conductive segments (16) in slots arranged in a core (12) of the rotor or of the stator in such a way that the conductive segments project beyond the latter by their free ends, and in welding the conductive segments in pairs by their projecting free ends to form a winding (14) around the rotor or the stator. The conductive segments each being formed by a wire of electrically conductive material covered with a layer of electrically insulating material, the layer of electrically insulating material is eliminated, in the zone in which the conductive segments are welded, by the means used to weld the latter. Application to the assembly of conductive segments of a rotor or stator winding of a motor-vehicle alternator.

Abstract: A production method of a polyphase sequentially joined-segment coil of a rotary electric machine and a product produced by the same are provided. A production machine includes pairs of tines working to catch heads of conductor segments when they are twisted using rings. The tines are designed to be rotatable about an axis of the rings following rotation of the rings to absorb stress acting on insulating coating on the heads of the segments to minimize rubbing of the insulating coatings, thereby ensuring a desired degree of electrical insulation of the stator coil.

Abstract: A stator winding includes a plurality of winding sub-portions in each of which a strand of wire formed from a continuous wire is wound so as to alternately occupy an inner layer and an outer layer in a slot depth direction within slots at intervals of a predetermined number of slots and form a lap winding having two turns in each lap, the strands of wire folding over outside the slots at end surfaces of a stator core, four of the strands of wire constituting the winding sub-portions being housed so as to line up in each of the slots in a slot depth direction, turn portions formed by folding the strands of wire over outside the slots at a first end surface of the stator core being disposed circumferentially to form two rows in a radial direction, and turn portions formed by folding the strands of wire over outside the slots at a second end surface of the stator core being disposed circumferentially to form two layers in an axial direction.

Abstract: A method of making composite electric machine components. Magnetic segments and non-magnetic segments are separately formed to green strength, and then arranged adjacent to each other in a desired magnetic pattern. A small amount of powder material is added in-between the segments, and the whole assembly is then sintered to form a sinterbonded composite component of high structural integrity.

Abstract: A turret-like insertion head having at least one twisting device for mounting electrical components. The insertion head has a stator, a rotor and an optical measuring device. A plurality of circularly distributed grippers are mounted on the rotor such that the grippers can rotate about a mounting axis. The optical measuring device detects the position of the components held on the grippers, and as a result, a component can be twisted into its approximate mounting position during forward movement of the gripper before making a final position measurement, thereby saving time.

Abstract: A yoke in a motor includes a cylindrical yoke housing having a closed end and two magnets that is located in the yoke housing. The magnets are fixed to the yoke housing with adhesive. The adhesive is applied a at least to each adhering area of the yoke housing that is to be adhered to the corresponding magnet or to an adhering area of the each magnet that is to be adhered to the yoke housing. The adhesive is spread to the adhering areas of the yoke housing and each magnet by sliding the adhering areas on each other. Therefore, the magnets are firmly fixed to the yoke housing with a small amount of adhesive.

Abstract: Coil members are obtained by forming width-reduced portions in a wire material over a predetermined longitudinal range generally centered on cutting positions, then removing an insulation coating from the width-reduced portions, and thereafter cutting the wire material at the width-reduced portions. Coil segments are prepared by bending the coil members into a general U shape. Then the coil segments are inserted into the slots in a stator core, and a stator is obtained by welding together the free end portions of the projecting coil segments.

Abstract: Punchings for stator core laminations of a generator stator frame are disposed on a rotary table to form annular arrays of punching, with each layer staggered relative to adjacent layers. A mandrel is disposed at the center of the table and has fingers projecting radially for receiving the slots of the punchings to facilitate location of the punchings on the table and relative to one another. An annular cover is provided and disposed over the uppermost layer of punchings and clamped to the superposed sets of annular layers of punchings. The cover and punchings can then be removed from the table for disposition in the generator stator frame. The fingers on the mandrel are displaced vertically relative to the table as the height of the punchings on the table increases.

Abstract: A conductor segment constituting a stator coil has a head conductor portion protruding from slots of a stator core for constituting a head side coil end. The head conductor portion of the conductor segment consists of a V-angled portion and straight portions extending straight in the axial direction from both ends of the V-angled portion, so as to form, as a whole, a pentagonal shape.

Abstract: A method of inserting coils in slots of a stator is provided. The method includes interleaving a first set of first phase windings and a first set of second phase windings on an insertion tool. The method also includes activating the insertion tool to radially insert the first set of first phase windings and the first set of second phase windings in the slots of the stator. In one embodiment, interleaving the first set of first phase windings and the first set of second phase windings on the insertion tool includes forming the first set of first phase windings in first phase openings defined in the insertion tool, and forming the first set of second phase windings in second phase openings defined in the insertion tool.

Abstract: The method makes it possible to form a stator of an electric motor by means of a multiple-slide press (21, 22, 23). The starting point is a bundle consisting of rectilinear segments of sheets obtained by stamping and welded. The stator is formed by means of four successive operations carried out by four groups of slides of a multiple-slide press and corresponding dies. The cylinder formed is subsequently welded along its joining generatrix and is calibrated in a hydraulic press.

Abstract: A device and a process for mounting the rotor of a hermetic compressor, said device comprising a pulling rod (40), which is loosely and coaxially provided through the rotor (30) of the electric motor of the compressor, in order to have a first end coupled to an end of the crankshaft (10) located adjacent to an end face of the rotor (30), and a second opposite end to be seated against an opposite end face of the rotor (30) and to which a driving means (DM) is engaged to move the pulling rod (40), in order to provoke a relative axial displacement of the crankshaft (10), sufficient to fit, by mechanical interference, the extension (11) of the crankshaft (10) inside the rotor (30).

Abstract: A tool for aligning a stator with respect to a crankshaft of a hybrid vehicle is provided. The tool comprises a central hub, a plurality of alignment members, and an actuating device. The central hub has a mating surface configured to secure the central hub to the crankshaft. The alignment members are configured to engage the stator and are slideably mated with the central hub for movement between a first position and a second position. The actuating device moves the plurality of alignment members between the first and second positions. The second position is further away from the crankshaft than the first position. The stator is moved to an aligned position with respect to the crankshaft when the aligning members are at the second position.

Abstract: An object of the invention is to provide a method of assembling a disc which can reduce an unbalance of a rotating portion.

Abstract: A method and apparatus in which wave windings, cut from a continuously formed wave winding band, are brought with a defined number of waves essentially tangentially to a rotor or stator lamination packet or a rotorlike transfer tool having radially outwardly open slots. During a rotary motion of the lamination packet or transfer tool and a substantially tangential relative motion, at a speed corresponding to the circumferential speed of the rotary motion, the straight portions of the bandlike wave windings are pressed into the slots.

Abstract: A stator winding wound on a cylindrical stator core of a rotary electric machine such as an alternator for use in an automobile vehicle is formed in the following manner. Plural U-shaped conductor segments are inserted into slots formed in the stator core. Pairs segment ends to be electrically connected are aligned along two or more coaxial circumferences and correctly positioned by individually restricting each pair of segment ends. Correctly positioned plural pairs are continuously welded one by one by rotating the stator core.

Abstract: The invention relates to a fixing unit comprises a multi-part, electrically conductive base body provided with connections for the electric power supply of the electrically conductive basebody and additional connections for the electric motor and which is arranged in an electrically non-conductive support comprising at least two fixing holes. The multi-part, electrically conductive base body and the electrically non-conductive support are provided with a common recess.

Abstract: A three dimensional amorphous metal mass suitable for milling is formed wrapping amorphous metal ribbon into a three dimensional shape and then applying adhesive to the three dimensional shape. The adhesive permeates the three dimensional shape. The adhesive is then cured. The three dimensional shape is mechanically contained in three dimensions. If the amorphous metal mass is made as a toroid, then it could be processed into a stator. The stator would then be suitable for use in very high frequency electric motors.

Abstract: A technique for making a stator for an electric motor or similar machine includes disposing a plurality of concentric coils in a stator core such that leads exit both ends of the stator core. The coils are disposed in accordance with a winding pattern that is particularly suited for making four-pole, three-phase machines. Certain of the coils are disposed singularly within core slots, while other coils share slots with coils of other winding groups. The coils may be inserted by machine, and in several layers by rotating the stator core between each layer insertion.

Abstract: A method of forming a stator core assembly for an electric machine includes providing a stator core having a plurality of radially extending slots, forming a flat wire pack having a plurality of continuous electrical wires, shaping the flat wire pack into a substantially cylindrical shape, and engaging the substantially cylindrically shaped flat wire pack with the stator core such that the continuous electrical wires are interlaced within the slots of the stator core.

Abstract: The invention relates to a method for producing a shaft (22), and an apparatus containing such a shaft (22), in particular an armature shaft (22) of an electric motor-driven drive (12) that is brought to a nominal dimension (44). The shaft (22) is reshaped by means of material displacement (46) at least one point until the nominal dimension (44) is reached.

Abstract: A motor assembling apparatus is adapted to magnetize permanent magnets for the field and mount a stator 2 and an armature 3 in the same apparatus. The apparatus comprises a magnetizing unit 24 having an outer magnetizing coil 29 and an inner magnetizing coil 30, a vertically movable stator support 23 for supporting the lower end of the stator 2, an armature holder 25 to the outside of which the stator support 23 can be fitted and a stator keeping jig 22 arranged above the stator support 23. The stator 2 is placed on the stator support 23 and pinched between the stator keeping jig 22 and the stator support 23 to move it vertically and magnetize it by means of the magnetizing unit 24. After magnetizing the permanent magnets, the stator 2 is raised immediately by means of the stator support 23 and fitted to the armature 3.

Abstract: In a watertight brushless fan motor of the present invention, a first pad 33 is disposed in a first space between a stator 1 and a circuit substrate 3. A second pad 35 is disposed in a second space between the circuit substrate 3 and a plate-like section 7c of a case 7. Spaces between the plate-like section 7c of the case 7 and a bearing supporting cylindrical section 7a are formed with an insulating resin in such a manner that the stator 1 and the circuit substrate 3 are included inside, thereby forming a molded part 31. With this arrangement, the watertight brushless fan motor is provided that can prevent occurrence of a crack in the outer surface of the molded part due to the so-called molding shrinkage of the insulating resin or expansion and shrinkage of the insulating resin caused by a change in ambient temperature.

Abstract: A motor and a method for manufacturing thereof use a rotor having permanent magnets and stators. The highest revolving speed of a motor is adjusted by using end plates of different thickness. The end plates are made of a magnetic material and disposed at the end faces of the rotor. The end plates made of a magnetic material provide part of the magnetic flux generated from the permanent magnets with short circuits within the inside of the rotor. The magnetic flux that links with the coil can be adjusted by using end plates of different thickness. Therefore, the highest revolving speed of a motor can be finely adjusted with ease.

Abstract: It is an object of the present invention to provide a method of manufacturing a rotor for an electric motor, in which displacement of the center of gravity is prevented. According to a feature of the present invention, a rotor for an electric motor comprises an inner core fixed to a rotating shaft of the rotor and multiple coil units respectively fixed to the inner core, wherein the coil unit has an outer core, a bobbin and a winding wound on the bobbin, and wherein weight of outer cores as well as winding units (the bobbin and the winding wound thereon) is respectively measured and stratified into several groups, necessary number of the outer cores and winding units are respectively picked out from the same stratified group and then such outer cores and winding units are assembled to the inner core.

Abstract: A stator core (20) and manufacturing frame (40) combination, a stator core plate punching member (30), and methods of rolling a core body (22) without risk of significant damage to the core body (22) are provided. The combination preferably includes a stator core (20) having a substantially cylindrical and elongate core body (22). The core body (22) preferably includes a plurality of plate punching members (30). Each of the plurality of plate punching members (30) has a substantially smooth outer surface (32). The combination also preferably includes a manufacturing frame (40) positioned to substantially underlie the core body (22). The frame (40) preferably includes a plurality of spaced-apart rollers (45) each positioned to contact the substantially smooth outer surface (32) of each of the plurality of place punching members (30).

Abstract: Hollow cylindrical dynamo-electric machine stator cores may be made by superimposing at least two strips of core material to produce a composite strip. One or more of the strips may be run through a pressure roller structure prior to super-positioning of the strips. The composite strip is coiled helically to produce the hollow cylindrical stator core. By pressure rolling at least one strip, the internal diameter of the stator core can be adjusted to reduce irregularities. By superimposing strips prior to coiling, thinner strips can be used without requiring the stator forming machine to operate longer or faster to produce stator cores of a given size. The pressure rolling aspects of the invention are also applicable to coiling apparatus that uses only a single strip. Stator cores may also be made by coaxially assembling and joining two coils with a hollow annular lamination disposed between the two axially spaced coils.

Abstract: A segment 33 of electric conductors having insulating coats 37 on surfaces thereof is received in each of slots 35 formed in a stator core 32 along its circumferential direction so as to form coil ends by protruding portions of the electric conductors from an end surface of the stator core. A first copying surface curved along a bending direction is formed in a slot opening forming cut of each slot arranged on the end surface of the stator core. A second copying surface curved along the bending direction is formed on a bending member 208 inserted into an area between two groups of coil ends of the two adjacent slots for each pair of slots. Each electric conductor is bent along a successively-curved shape formed out of the first copying surface and the second copying surface.

Abstract: A motor includes a permanent magnet unit at a circumference for providing a plurality of magnetic poles and a rotor disposed inside the circumference to be coaxial with the permanent magnet unit. Such a rotor is constituted of a center core, a plurality of coil cores disposed at the peripheral portions of the rotor and a plurality of concentrated coils respectively mounted on the coil cores. Each coil core is fitted to the center core by sliding along an axial direction of the center core.

Abstract: An armature coil winder for winding coils at high density while restricting coil ends within a restricted space in an armature core assembly having a plurality of slots in an outer circumference thereof and a series of continuous coils, the coil winder including a fixed former for guiding one of the continuous coils into two of the slots, and a movable former for restricting a position of a coil end of one of the continuous coils between the two slots by moving in the fixed former along both end surfaces of the armature core assembly toward a center of the core assembly; a former slider including a flyer for winding one of the continuous coils around the fixed former; and a coil shaping mechanism including coil shaping blades for shaping one of the continuous coils in the slots relative to the armature core assembly. The use of such a winder to form coils of an armature core assembly is also described.

Abstract: Apparatus and methods for winding wire around the poles and partly within the slots of dynamoelectric machine components, such as stators. Some stators are designed with poles having pole tips that extend relatively far in a peripheral direction, perhaps reaching nearly half way across the stator core. When the pole tips reach so far around the stator core and thus leave little room between opposing pole tips, it may be difficult to use winding technologies with needles that need to move between opposing pole tips. Therefore, stators may be divided into segments for the winding of each pole, and then reassembled to form a complete stator. The segments are wound by rotating the segment and a wire guide structure about an axis, while providing wire to the rotating apparatus from a wire source.

Abstract: An assembly method and fixture for assembling a supporting disk of a motor rotor according to the invention is based on an “adjusting, and fixing” concept. A functional axis fixture and an adjusting axis fixture, which can match with each other for holding the supporting disk and the rotor, are first prepared. The functional axis of the supporting disk is aligned with the geometric axis of the functional axis fixture, and the geometric axis of the rotor is aligned with the geometric axis of the adjusting axis fixture. By engaging the functional axis fixture and the adjusting axis fixture, the functional axis of the supporting disk is aligned with the geometric axis of the rotor. Therefore, the bias and concentricity can be precisely controlled and improved.

Abstract: A resin fixture that is inserted into a stator for an electric motor for a pump for the purpose of insulating the stator with resin. The resin fixture includes a rubber cover that is inflated. The fixture thereby prevents the stator bore from filling with resin.

Abstract: An electric motor comprises a shaft to which a stator is fixedly mounted and a rotor is rotatably mounted.

Abstract: A method of manufacturing an elongate stack of interlocked laminae in a die assembly. The method includes the steps of stamping a first lamina having generally opposed first and second edges in the strip stock material, stamping at least one first interlock means for engaging another lamina in the first lamina, separating the first lamina from the strip stock material, placing the first lamina into the choke passageway, the first and second edges of the first lamina frictionally engaging the choke passageway, stamping a second lamina having first and second elongate edges in the strip stock material, stamping at least one second interlock means for engaging another lamina in the second lamina, at least partially engaging the first and second interlocking means, separating the second lamina from the strip stock material, placing the second lamina into the choke passageway, and frictionally engaging the choke passageway along the first and second elongate edges of only one of the first and second laminae.

Abstract: A stator core extends along a longitudinal axis and includes a yoke, and a plurality of radially-inwardly projecting teeth separated by intervening slots. A radially innermost portion of each tooth initially includes a pair of legs separated by a recess disposed therebetween. The conventional tooth tips are unformed in the first stage, thereby defining an increased-size slot opening for allowing the insertion of stator windings. In a second processing stage, after the core itself has been manufactured and wound with stator windings, the legs are cold-formed in order to form tooth tips, which define a reduced-size slot opening to provide a magnetic flux path and provide a wire retention function. A higher stator slot fill is provided, which allows and enables higher generator efficiencies and output for a given package size.

Abstract: A progressive stamping die assembly apparatus and method in which strip stock material advances in a first direction through the apparatus and substantially simultaneously with the strip stock movement, a transversely moveable die station moves in opposite second and third directions substantially perpendicular to the first direction to one of a plurality of predetermined positions.

Abstract: A method for manufacturing a motor has a stator in which coils are inserted into slots provided in an inner peripheral surface of a ring-shaped motor core.

Abstract: An assembling apparatus for assembling rotating electrical machines having permanent magnets and armatures cores. The apparatus holds the armature core while the permanent magnets are assembled on to it thus avoiding hand labor. At all times, the rotor is supported so that it cannot cant relative to the stator and its permanent magnets and thus, no damage to the magnets or any coating thereon or to the armature will occur.

Abstract: A rotary electric machine has a stator winding. The stator winding has a plurality of conductors wound one over another. The conductors are wound with left and right ends. Therefore, the stator winding on the stator core has an overlapped joined portion. This arrangement allows a high ratio of the conductors in the slot and is easy to manufacture.

Abstract: A shapeable lamination stack and method of manufacture. The lamination stack includes a plurality of interlocked laminations which may be stamped using a conventional progressive die. The laminations are stacked in a first stack shape wherein each of the laminations are mutually parallel and positioned perpendicular to linear axis. The laminations are relatively repositionable wherein the laminations form a second stack shape wherein at least one of the laminations is oriented non-parallel to another one of the laminations. The stack may also include spacing elements to separate a pair of laminations by a spacing volume. The spacing volume has a substantially uniform thickness when the stack is in the first stack shape and at least one of the spacing volumes has a non-uniform thickness when the stack is in the second stack shape. The spacing element may be lamination or a integral projection located on one of the laminations.

Abstract: A technique for separating the stator leads of an electric motor during the manufacturing process. The technique comprises a system having a lead gathering assembly, a lead separator, and a drive mechanism. The lead gathering assembly is adapted to gather together a plurality of stator windings extending from a stator. The lead separator having a plurality of teeth adapted to separate a stator winding from the plurality of stator windings gathered together by the lead gathering assembly. The drive mechanism is adapted to drive the lead separator into the plurality of stator windings. The lead separator has teeth to separate each of the stator windings gathered together by the lead gathering assembly.

Abstract: In order to simplify the adjustment of an axial play of a rotor shaft (2.4) between the rotor shaft (2.4) and a stator (1) of a motor with the purpose of reducing the component expenditure and the assembly expenditure of the motor, a first clamp holder (3) and a second clamp holder (4) exert pressure on both sides of a plain bearing (5). In a first step, a rotor (2) of the motor is positioned relative to a housing (1.3) of the motor. A bearing receiver (1.1) is then fixed relative to the housing (1.3) of the motor by inserting, at an axially inner end of the bearing receiver (1.1), the second clamp holder (4); by moving the second clamp holder (4) to a second operating end position; and by fixing the second claim holder (4) at the second operating end position. Next, at an axially outer end of the bearing receiver (1.1), the plain bearing (5) and the first clamp holder (3) are axially inserted into the bearing receiver (1.1).

Abstract: The invention provides an apparatus (with a corresponding method) for manufacturing a magnetic wound core of a toroidal transformer. The apparatus in accordance with a preferred embodiment of the invention comprises a control device for controlling the apparatus based on parameters of the core material and the wound core, a supplying device for providing the core material ribbon, a cutting device for cutting the lateral edges of the core material ribbon under the control of the control device, and a winding device for receiving and winding the core material ribbon into the wound core.

Abstract: A stator stack and stator jig assembly provide a consistent amount of slack in stator coil wires without increasing the complexity of coil-winding machines or adding production steps, and prevent crossing of the stator coil wires in the slack areas. A stator stack having magnetic pole teeth is mounted in a stator installation jig, and the ends of slack forming plates having grooves are made to project above the top surface of the stator stack to thrust stator coil wires upwardly. The coil-winding machine winds stator coil wires around the magnetic pole teeth, and after the stator coil wires are wound, the ends of the stator coil wires are passed through grooves in the ends of the plates to output pins. The coil-winding machine wraps the ends of the stator coil wires around the output pins. On removing the stator from the stator installation jig, the parts of the stator coil wires which where thrust upward become slack areas.

Abstract: The present invention relates to an auxiliary tool for assembling a scrubber which includes a motor, a shaft rotatably coupled to and extending through the motor, a shaft pin detachably connected to the shaft, and a disk coupled to the shaft and having a notch located relative to the shaft pin at a predetermined angle with respect to a longitudinal axis of the shaft when properly assembled. In specific embodiments, the auxiliary tool comprises a tool body configured to at least partially receive the motor, the shaft pin, the disk, and the notch of the disk. The tool body includes a first recess configured to at least partially receive the shaft pin and a protrusion configured to be at least partially received into the notch of the disk. The first recess and the protrusion are arranged at the predetermined angle to position the notch of the disk and the shaft pin of the scrubber for proper assembly at the predetermined angle with respect to the longitudinal axis of the shaft.

Abstract: A tool for driving a stator slide under a stator wedge within a radial slot of a stator core includes a frame including a pair of elongated rail members, the frame provided with a pair of handles at respective opposite ends of the elongated rail members. A force application cart is located between the rail members, the force application cart having a drive block thereon. A drive is connected to the frame, substantially intermediate opposite ends of the frame, the drive having an on/off trigger located on one of the handles. A lead screw is threadably engaged at one end with the force application cart and connected at an opposite end to the drive such that the drive rotates the lead screw when actuate; wherein in use, rotation of the lead screw causes axial movement of the force application cart and the drive block along the elongated rail members.

Abstract: In a method of manufacturing a rotor of an electric motor to be arranged inside a stator, a permanent magnet is formed in a ring-shape, and a rotating shaft and the permanent magnet are concentrically arranged in a mold. Then, a rubber material in a fluid state is poured into a space between the permanent magnet and the rotating shaft to vulcanize and mold a cushioning member having predetermined hardness. The permanent magnet and the rotating shaft are integrally coupled through the cushioning member.

Abstract: An electrical connector assembly for a power tool, a power tool and methods for assembling a power tool. A one-piece trace or spider terminal member assembly provides points of connection for the motor components, such as the field windings, the brushes and the switch. To assemble the motor, the terminal member assembly is positioned in the motor housing. To mount the terminal member assembly, the terminal member assembly is preferably co-molded with the housing or, alternatively, may snap-fit into connectors formed on the housing. The terminal member assembly and the housing are then preferably punched or stamped at points to provide the necessary number of electrically separated contact elements to connect the components of the motor. For example, the female ends or terminals of the field windings, the brushes and the switch are connected to the electrically separated contact elements to provide a suitable complete electrical circuit for the motor.