In an oil cooled alternator (10) having a plurality of commonly connected, relatively inflexible stator coils (14) with distal ends (16) for providing electrical output power from the alternator (10), the improvement being a terminal assembly (18) for making electrical connection with each of said distal ends (16) which flexible conductor (20) with a pair of ends (22) on opposite sides of an elongate body having a flexibility substantially greater than that of coils (14) and a connector (24) with a first relatively rigid portion adapted for attachment to distal end (16) of coil (14) and second portion (28) adapted for fixed electrical connection with one of pair of ends (22) of flexible conductor (20) and relatively rigid post assembly (30) having elongate body portion (32) extending between two ends (34) and having assembly 36 carried at one of said two ends (34) for electrical connection with the other of the pair of ends (22) of flexible conductor (20). The invention includes a method of installing a terminal post (30) to stator coil (14) of an oil cooled alternator which includes preassembling a flexible cable (20) assembly having an elongate body of substantially greater flexibility than that of stator coil (14) by fixedly attaching a pair of connectors (24) to opposite ends of the elongate body (20), respectively and welding one of the pair of connectors (24) to one end (34) of an elongate terminal connector post (32) and welding another one of the pair of connectors (24) to a free end (16) of stator coil (14). A kit assembly (48) is also provided.
Reductions in cost and manufacturing processes are achieved by interposing a single metallic terminal between a lead wire of a stator and a three-phase output terminal. A rotor 3 is fixed onto a rotating shaft 2 disposed rotatably in a housing 1, and a stator core 5 is disposed opposite to the rotor 3. A stator winding 6 is wound around the stator core 5 and a lead wire 10 of the stator winding 6 is connected to a head portion 8a of a three-phase output terminal 8 through a single metallic terminal by a screw 12.
A centralized power distribution unit for a vehicular thin brushless motor includes a plurality of bus bars, a resin insulation layer that covers the bus bars, and an insulating holder having a plurality of holding grooves that hold the bus bars. The bus bars are pre-bent in a thickness direction to be formed into a substantially annular shape. Each of the bus bars is provided correspondingly with a phase of the motor. The holding grooves are formed in parallel extending along a circumferential direction of the centralized power distribution unit. The bus bars are respectively inserted into the holding grooves, and are thus stacked in a radial direction of the centralized power distribution unit. The insulating holder and the bus bars are covered by the resin insulation layer.
A centralized power distribution unit for a vehicular thin brushless motor includes a plurality of bus bars and a resin insulating layer that covers the bus bars. The bus bars are disposed correspondingly with phases of the motor. Each of the bus bars has a terminal portion to be connected to a battery and one or more tabs to be connected respectively to one or more windings of a stator. Each of the bus bars is shaped into a substantially annular shape by bending a molded material in a thickness direction. The molded material is obtained by stamping out a conductive metal plate into a strip-like shape. Diameters of the annular shapes of the bus bars are set to be different from one another depending on the corresponding phase of the motor. The bus bars are stacked in a radial direction of the centralized power distribution unit, mutually separated by a predetermined gap.
