Electric rotary machine, armature, method of manufacturing electric rotary machine and machine for forming armature
First Claim
Patent Images
1. An electric rotary machine comprising:
- a yoke carrying thereon a plurality of permanent magnets;
an armature core, fixedly supported on an armature shaft and rotatably disposed in the yoke, which has an outer periphery formed with a plurality of slots;
a plurality of insulator-coated armature coils, wound in the slots of the armature core in multiple layers, each of which includes a flat type wire formed in lower and upper layer coils disposed in each of the slots in lower and upper layers; and
a commutator fixedly supported on the armature shaft at one end thereof and having a plurality of conductor segments equidistantly disposed on an outer periphery of the armature shaft in a circumferential direction thereof, the conductor segments including risers, respectively, to each of which the lower and upper layer coils are electrically connected;
wherein the lower and upper layer coils include a lower layer coil extension and an upper layer coil extension extracted from each of the slots of the armature core, respectively, and at least one of the lower and upper layer coil extensions includes a contour deformation part, formed in an area at an intersecting region where the lower layer coil extension and the upper layer coil extension intersect with each other, to create an insulating distance between the lower layer coil extension and the upper layer coil extension at the intersecting region thereof.
1 Assignment
0 Petitions
Accused Products
Abstract
An electric rotary machine, an armature for use in the electric machine, a method of forming an electric rotary machine and a forming machine for an armature of an electric rotary machine are disclosed wherein insulator-coated coils are wound in slots of an armature core from which lower and upper layer coil extensions extend and are connected to a commutator. The upper layer coil extension has a contour deformation part at an intersecting region where the lower and upper layer coil extensions intersect with each other to have an insulating distance between the lower and upper layer coil extensions. The forming machine includes a work holder holding the armature, and a forming jig forming a curvature portion on the upper layer coil extension.
4 Citations
32 Claims
-
1. An electric rotary machine comprising:
-
a yoke carrying thereon a plurality of permanent magnets;
an armature core, fixedly supported on an armature shaft and rotatably disposed in the yoke, which has an outer periphery formed with a plurality of slots;
a plurality of insulator-coated armature coils, wound in the slots of the armature core in multiple layers, each of which includes a flat type wire formed in lower and upper layer coils disposed in each of the slots in lower and upper layers; and
a commutator fixedly supported on the armature shaft at one end thereof and having a plurality of conductor segments equidistantly disposed on an outer periphery of the armature shaft in a circumferential direction thereof, the conductor segments including risers, respectively, to each of which the lower and upper layer coils are electrically connected;
wherein the lower and upper layer coils include a lower layer coil extension and an upper layer coil extension extracted from each of the slots of the armature core, respectively, and at least one of the lower and upper layer coil extensions includes a contour deformation part, formed in an area at an intersecting region where the lower layer coil extension and the upper layer coil extension intersect with each other, to create an insulating distance between the lower layer coil extension and the upper layer coil extension at the intersecting region thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
-
-
9. An armature for an electric rotary machine, comprising:
-
an armature shaft;
an armature core, fixedly supported on the armature shaft and adapted to be rotatable within the electric rotary machine, which has an outer periphery formed with a plurality of slots;
a plurality of insulator-coated armature coils, wound in the slots of the armature core in multiple layers, each of which includes a flat type wire formed in lower and upper layer coils disposed in each of the slots in lower and upper layers; and
a commutator fixedly supported on the armature shaft at one end thereof and having a plurality of conductor segments equidistantly disposed on an outer periphery of the armature shaft in a circumferential direction thereof, the conductor segments including risers, respectively, to each of which the lower and upper layer coils are electrically connected;
wherein the lower and upper layer coils include a lower layer coil extension and an upper layer coil extension extracted from each of the slots of the armature core, respectively, and at least one of the lower and upper layer coil extensions includes a contour deformation part, formed in an area at an intersecting region where the lower layer coil extension and the upper layer coil extension intersect with each other, to create an insulating distance between the lower layer coil extension and the upper layer coil extension at the intersecting region thereof. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
-
-
17. A method of manufacturing an electric rotary machine, comprising:
-
preparing an armature core, fixedly supported on an armature shaft and having an outer periphery formed with a plurality of slots, and a commutator carried on the armature shaft in face-to-face relationship with the armature core, the commutator including a plurality of conductor segments, circumferentially placed in equidistantly spaced positions, which have risers, respectively;
winding a plurality of upper and lower insulator-coated coils in the slots of the armature core in multiple layers such that the upper and lower insulator-coated coils are disposed in each of the slots in upper and lower layers;
extracting the upper and lower insulator-coated coils from the slots of the armature core as upper and lower layer coil extensions, respectively;
forming a contour deformation part in at least one of the lower and upper layer coil extensions in an area at an intersecting region where the lower layer coil extension and the upper layer coil extension intersect with each other to create an insulating distance between the lower layer coil extension and the upper layer coil extension; and
electrically connecting distal ends of the lower and upper layer coil extensions to each of the rises of the conductor segments of the commutator. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24)
-
-
25. A forming machine for an armature of an electric rotary machine, which armature has an armature shaft, an armature core fixedly supported on the armature shaft and rotatably disposed in the electric rotary machine while having an outer periphery formed with a plurality of slots, a plurality of insulator-coated armature coils wound in the slots of the armature core in multiple layers with each including a flat type wire formed in lower and upper layer coils disposed in each of the slots in lower and upper layers, and a commutator fixedly supported on the armature shaft at one end thereof and having a plurality of conductor segments equidistantly disposed on an outer periphery of the armature shaft in a circumferential direction thereof, the conductor segments including risers, respectively, to each of which the lower and upper layer coils are electrically connected, wherein the lower and upper layer coils include a lower layer coil extension and an upper layer coil extension extracted from each of the slots of the armature core, respectively, and at least one of the lower and upper layer coil extensions includes a contour deformation part, formed in an area at an intersecting region where the lower layer coil extension and the upper layer coil extension intersect with each other, to create an insulating distance between the lower layer coil extension and the upper layer coil extension at the intersecting region thereof;
- the forming machine comprising;
a work holder mechanism operative to hold the armature core in a given position;
a coil restraint ring operative to be placed on the outer periphery of the armature core to restrain an outer periphery of the upper layer coil extension on a stage immediately extracted from the slot of the armature core;
a forming jig operative to be inserted to a clearance between the upper and lower layer coil extensions axially extracted from the slot of the armature core and including a forming portion to form the contour deformation part on at least one of the lower and upper layer coil extensions; and
a press punch operative to press an outer periphery of at least one of the lower and upper layer coil extensions against the forming portion. - View Dependent Claims (26, 27, 28, 29, 30, 31, 32)
- the forming machine comprising;
Specification
-
- Resources
Litigation Campaign Assessment
Thank you for your request. You will receive a custom alert email when the Litigation Campaign Assessment is available.
×
-
Current AssigneeDENSO Corporation
-
Original AssigneeDENSO Corporation
-
InventorsKitou, Kazuyuki, Sakai, Eiji, Inoue, Katsunobu, Fukui, Minoru, Itoh, Akiyasu
-
Granted Patent
-
Time in Patent OfficeDays
-
Field of Search
-
US Class Current335/78
-
CPC Class CodesH02K 13/04 Connections between commuta...H02K 15/0037 Shaping or compacting windi...H02K 3/12 arranged in slots
