Method for assembling conductive segments of a rotor winding or stator winding in a rotary electric machine

• US 20030159269A1
• Filed: 02/05/2003
• Published: 08/28/2003
• Est. Priority Date: 02/28/2001
• Status: Active Grant

• Current Assignee: Valeo Equipements Electriques Moteur (Valeo SE)
• Original Assignee: Valeo Equipements Electriques Moteur (Valeo SE)
• Inventors: Lenoir, Romaric, Even, Denis, Hevia, Thierry, Arrighi, Sebastien
• Granted Patent: US 6,915,556 B2
• Time in Patent Office: Days
• US Class Current: 29/596
• CPC Class Codes: H02K 15/0056 Manufacturing winding connections
• CPC Class Codes: H02K 15/0081 for form-wound windings
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49011 Commutator or slip ring assembly
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/53143 Motor or generator

Abstract

The inventive method of assembling conductive segments (16) of a rotor winding or a stator winding in a rotary electric machine comprises the following stages: insertion of the conductive segments (16) into slots made in a core (12) of the rotor or stator, whereby the free ends of the conductive segments protrude beyond the latter, and welding of the free ends of the conductive segments in groups of two in order to form a winding (14) around the rotor or stator. The conductor statements are both made of wire which is electrically conductive and coated with an electrically insulating material. The coating of electrically insulating material is removed in the welding zone of the conductive segments by the means used for welding the latter. The invention can be used for conducting segments of a rotor or stator winding in an alternator in a motor vehicle.

Claims

1. Process for assembling conductive segments (16) of a rotor or stator winding of a rotary electrical machine, comprising the stages consisting in:

inserting the conductive segments (16) in slots (18) arranged in a core (12) of the rotor or of the stator in such a way that the segments project beyond the latter by their free ends,

folding the free ends of the conductive segments, and

welding the conductive segments (16) in pairs by their projecting free ends to form a winding around the rotor or the stator,

characterised in that, 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.

2. Assembly process according to claim 1, characterised in that the stage in which the layer of electrically insulating material is eliminated is carried out during the welding of the conductive segments (16).

3. Assembly process according to claim 2, characterised in that, following the welding of the conductive segments, a stage in which debris of electrically insulating material produced during welding is removed.

4. Assembly process according to claim 3, characterised in that the stage of removing debris includes a phase in which the welded zones are brushed, followed by a suction phase.

5. Assembly process according to claim 1, characterised in that the welding process is a welding process of the electron-beam type.

6. Assembly process according to claim 5, characterised in that the general axis of the electron beam is inclined by about 45°

to the axis of the rotor or of the stator.

7. Assembly process according to claim 5, characterised in that, in the course of welding, the electron beam has imparted to it a sweeping motion over the entire welding zone.

8. Assembly process according to claim 1, characterised in that the welding process is a laser-welding process.

9. Assembly process according to claim 8, characterised in that the welding means is driven in a sequential manner, the laser beam being interrupted between two welding operations.

10. Process according to claim 9, characterised in that the welding operation between [sic] the laser beam is fixed relative to the free ends (22 and 24) to be welded of the conductive segments.

11. Process according to claim 10, characterised in that the free ends (22 and 24) to be welded have a chamfer for the formation of a penetrating weld seam forming an inner triangle.