公开(公告)号：US11114923B2

公开(公告)日：2021-09-07

申请号：US16566256

申请日：2019-09-10

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  DENSO CORPORATION

Inventor： Yuiki Goto ,  Daisuke Mizushima ,  Yasuyuki Hirao ,  Hiroaki Takeda ,  Sho Yasuda

IPC: H02K15/00 ,  B21K23/00

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.

公开(公告)号：US20210083560A1

公开(公告)日：2021-03-18

申请号：US17010160

申请日：2020-09-02

Applicant: DENSO CORPORATION ,  TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Yasunori Kitakado ,  Kazuo Yoshikawa ,  Hiroaki Takeda ,  Junichi Shimoya ,  Kazushi Onda

IPC: H02K15/085 ,  H02K15/00 ,  H02K15/04 ,  H02K15/02 ,  H02K15/06 ,  H02K3/50 ,  H02K3/28 ,  H02K3/12 ,  H02K1/16

Abstract: An apparatus for manufacturing a stator includes a supporting member configured to support a stator core, at least one processing jig having a cylindrical part and a plurality of protruding parts, and an operating unit. The operating unit is configured to perform, in a state where each of coil protruding parts is inserted between one circumferentially-adjacent pair of the protruding parts of the processing jig and an axial end face of the stator core is located close to the protruding parts of the processing jig, a first operation and a second operation either simultaneously or alternately. The first operation is an operation of relatively rotating the stator core and the processing jig in a circumferential direction of the stator core. The second operation is an operation of relatively moving the stator core and the processing jig away from each other in an axial direction of the stator core.

公开(公告)号：US11801547B2

公开(公告)日：2023-10-31

申请号：US17117162

申请日：2020-12-10

Applicant: DENSO CORPORATION ,  TOYOTA JIDOSHA KABUSHIKI KAISHA ,  AISIN AW CO., LTD.

Inventor： Takeshi Kurosawa ,  Kazuhiko Fukuda ,  Hiroaki Takeda ,  Ryosuke Maruyama ,  Toshiro Nakamura ,  Tadashi Fujiyoshi ,  Daisuke Mizushima ,  Hideki Mukaizaka

IPC: B21F23/00 ,  B65G25/02 ,  B65G47/84 ,  B65G35/00

CPC classification number: B21F23/005 ,  B65G25/02 ,  B65G35/00 ,  B65G47/846 ,  B65G2201/0217

Abstract: A conveyer equipped with rotating discs rotatable around axes thereof relative to a mounting base. Each of the rotating discs has grooves in which rectangular wires are receivable. When an upstream and a downstream one of the rotating disc are arranged in a given angular relation to each other, one of the grooves of the upstream rotating disc is aligned with that of the downstream rotating disc to pass the rectangular wire from the upstream rotating disc to the downstream rotating disc. Upon such passing of the rectangular wire, the grooves of the upstream and downstream rotating discs hold or clamp all side surfaces of the rectangular wire, thereby ensuring the stability in retaining the rectangular wire when passed from one to another of the rotating discs, which enables the conveyer to carry the rectangular wires at high speeds.

公开(公告)号：US11233443B2

公开(公告)日：2022-01-25

申请号：US16226968

申请日：2018-12-20

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  DENSO CORPORATION

Inventor： Daisuke Mizushima ,  Yasuyuki Hirao ,  Hiroaki Takeda

IPC: H02K15/04 ,  H02K15/10 ,  H02K15/02 ,  H02K15/06 ,  H02K15/00 ,  H02K3/34

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.

公开(公告)号：US11658532B2

公开(公告)日：2023-05-23

申请号：US17019464

申请日：2020-09-14

Applicant: DENSO CORPORATION ,  TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Ryosuke Maruyama ,  Hiroaki Takeda ,  Yasuhiro Makido ,  Toshiro Nakamura ,  Ken Shirai

IPC: H02K3/12 ,  H02K1/16 ,  H02K3/28 ,  H02K3/34 ,  H02K15/04 ,  H02K15/085 ,  H02K15/10 ,  H02K15/00 ,  H02K3/14 ,  B21D28/28

CPC classification number: H02K3/12 ,  B21D28/28 ,  H02K1/16 ,  H02K3/14 ,  H02K3/28 ,  H02K3/345 ,  H02K15/0081 ,  H02K15/0421 ,  H02K15/085 ,  H02K15/10

Abstract: A stator has a stator core composed of teeth and slots. Segment coils are inserted into the corresponding slots. The segment coil projecting from the slot has an exposed conductor part and a covered conductor part covered with an electrical insulation film. The exposed conductor part is arranged at the distal end side from the covered conductor part of the segment coil. The segment coils are connected together through the exposed conductor parts thereof projecting from the slots. The exposed conductor part has a thickness T2 thinner than a thickness T1 of the covered conductor part. A step part is formed at a position of the stator core side, adjacent to the exposed conductor part of the segment coil. The step part and the covered conductor part are covered with the electrical insulation film continuously from the stator core side of the covered conductor part.

公开(公告)号：US11277060B2

公开(公告)日：2022-03-15

申请号：US16850435

申请日：2020-04-16

Applicant: DENSO CORPORATION

Inventor： Hiroaki Takeda ,  Hiroki Fujita

IPC: B23P19/00 ,  H02K15/04 ,  H02K15/06

Abstract: An aligning apparatus is provided for aligning coil segments in an annular shape to form an aligned coil. Each of the coil segments has a pair of first and second leg portions. The aligning apparatus includes an outer jig and an inner jig. The outer jig has partitioning members arranged in a radial fashion. The partitioning members are spaced at such intervals as to allow each of the first leg portions of the coil segments to be inserted between one circumferentially-adjacent pair of the partitioning members. The inner jig has hole-forming members arranged radially inside the partitioning members of the outer jig. Each of the hole-forming members has formed therein a hole in which one of the second leg portions of the coil segments is to be inserted. Moreover, the hole-forming members are configured to be rotatable relative to the outer jig in a circumferential direction and radially movable.

公开(公告)号：US11223259B2

公开(公告)日：2022-01-11

申请号：US16192116

申请日：2018-11-15

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  DENSO CORPORATION

Inventor： Masashi Kawai ,  Yasushi Nishikuma ,  Hiroaki Takeda

IPC: H01F7/06 ,  H02K15/00 ,  H02K15/10 ,  H02K15/12 ,  H02K5/08 ,  H02K1/04 ,  H02K15/02

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

公开(公告)号：US11196326B2

公开(公告)日：2021-12-07

申请号：US16180510

申请日：2018-11-05

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  DENSO CORPORATION

Inventor： Shimpei Fujiwara ,  Masashi Kawai ,  Hiroaki Takeda

IPC: H02K15/12 ,  H02K3/34 ,  H02K15/10 ,  B29C35/02 ,  B29C41/20 ,  B29L31/00 ,  B29K67/00 ,  B29K63/00

Abstract: A manufacturing method for an electric motor stator includes an injecting step in which thermosetting resin is injected into a forming die, a dipping step in which a coil end portion is dipped into the thermosetting resin injected into the forming die, a heating step in which the thermosetting resin inside the forming die is heated so as to form a molded portion, and a mold release step in which the molded portion is released from the forming die when at least either shear force of the thermosetting resin or adhesive strength between the coil end portion and the thermosetting resin becomes greater than previously-determined mold release force.

公开(公告)号：US11196313B2

公开(公告)日：2021-12-07

申请号：US16516678

申请日：2019-07-19

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  DENSO CORPORATION

Inventor： Yasuyuki Hirao ,  Daisuke Mizushima ,  Hiroaki Takeda ,  Sho Yasuda

IPC: H02K3/12 ,  H02K15/085 ,  H02K15/04 ,  H02K15/00

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.

公开(公告)号：US11387718B2

公开(公告)日：2022-07-12

申请号：US16580391

申请日：2019-09-24

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  DENSO CORPORATION

Inventor： Ken Shirai ,  Yasuyuki Hirao ,  Masashi Matsumoto ,  Hiroaki Takeda ,  Ryosuke Maruyama

IPC: H02K15/00 ,  H01F41/12 ,  B23K26/16 ,  B23K26/142 ,  B23K26/359 ,  B23K101/38 ,  B23K101/42 ,  H05K1/11 ,  H01F41/10

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.