Electrical machine, method of producing the same and device for producing the same

• US 20040263018A1
• Filed: 06/22/2004
• Published: 12/30/2004
• Est. Priority Date: 06/30/2003
• Status: Active Grant

• Current Assignee: Seg Automotive Germany GMBH
• Original Assignee: Robert Bosch GmbH
• Inventors: Seidel, Maik, Blenkle, Lars, Bunzel, Mirko, Werthmann, Christian, Arendes, Dieter
• Granted Patent: US 7,194,794 B2
• Time in Patent Office: Days
• US Class Current: 310/214
• CPC Class Codes: H02K 15/06 Embedding prefabricated windings in machines
• CPC Class Codes: H02K 3/48 in slots
• 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 29/49073 by assembling coil and core

Abstract

An electrical machine has a base body provided with conductors fixed in grooves of the base body by a material which limits a groove slot at both sides, and the conductors in the grooves are deformed by a stamping punch introducible through the groove slot into the corresponding groove so that a conductor cross-section is adjusted to a groove cross-section in a region of the corresponding conductor.

Claims

1. An electrical machine, comprising a base body having a periphery which limits a working air gap and is provided with a plurality of grooves having an elongated cross-section and a groove slot adapted to face the working air gap;

at least one electrical conductor extending in said groove slot over a length of said groove and fixed in said groove by a material of said base body which limits said groove slot at both sides, said at least one conductor in a respective one of said grooves being deformed over a whole length by a stamping punch inserted through said groove slot into said groove, so that a conductor cross-section is adjusted to a groove cross-section in a region of said at least one conductor.

2. An electrical machine as defined in claim 1, wherein said base body is formed as a drum-shaped armature packet of metal sheets which is arranged on a machine shaft and having said grooves in which a plurality of said conductors extend parallel to one another, wherein a total conductor cross-section of all said conductors in one of said grooves being adjusted by the stamping punch to a total groove cross-section.

3. An electrical machine as defined in claim 2, wherein in said grooves two of said conductors are arranged so that they extend axially and radially over one another, and a conductor cross-section of said conductors being adjusted by the stamping punch to said groove cross-section in a region of a respective one of said conductors.

4. An electrical machine as defined in claim 1, wherein said grooves have side walls and a width increasing between said side walls toward said groove slot.

5. A method of producing electrical machines, comprising the steps of providing a base body having a periphery which limits a working air gap and has a plurality of grooves with an elongated cross-section and with a groove slot adapted to face the working air gap;

introducing at least one electrical conductor in each of said grooves so that said at least one electrical conductor extends over a length of the groove and is fixed in said grooves by a material of the base body which limits the groove slot at both sides; and

after insertion of the electrical conductors in the grooves of the base body, introducing a stamping punch into the open groove slot of the grooves and deforming the at least one conductor with the stamping punch over a whole groove length so that its conductor cross-section is adjusted to a groove cross-section in the region of the conductor.

6. A method as defined in claim 5;

and further comprising inserting a plurality of the conductors into the grooves parallel to one another; and

adjusting a total conductor cross-section of all conductors of one groove by the stamping punch to a total groove cross-section.

7. A method as defined in claim 6;

and further comprising inserting two conductors which extend axially parallel to one another and are located radially over one another into the grooves, so that an upper one of the conductors is located in an open groove slot and partially extends above the grove; and

adjusting a conductor cross-section of the upper conductor by the stamping punch to a groove cross-section in a region of the corresponding conductor.

8. A method as defined in claim 5;

and further comprising after the stamping of the conductor of one groove, pressing and deforming a material of the base body at both sides of the groove slot in a further stamping step against the conductor for fixing the conductor in the groove, so that the groove slot is at least partially closed.

9. A method as defined in claim 8;

and further comprising moving back the stamping punch from the groove slot for deforming the at least one conductor of one groove, after the further stamping step for deforming the material on the groove slot.

10. A method as defined in claim 5;

and further comprising performing a stamping process on an element selected from the group consisting of the groove slot, the at least one conductor of one groove, and both, in steps from one nut to another nut.

11. A method as defined in claim 5;

and further comprising performing a stamping process on an element selected from the group consisting of a groove slot, at least one conductor of one nut, and both, simultaneously on oppositely located grooves of the base body.

12. A method as defined in claim 5;

and further comprising performing a stamping process on an element selected from the group consisting of a groove slot, at least one conductor of one nut, and both, simultaneously on all grooves of the base body.

13. An apparatus for producing an electrical machine having a base body with a periphery adapted to limit a working air gap and having a plurality of grooves with an elongated cross-section and a groove slot adapted to face the working air gap, and at least one electrical conductor extending in each of the grooves over the length of the groove and fixed by a material of the base body which limits the groove slot at both sides, the apparatus comprising a stamping punch operative for deforming a conductor cross-section and being a part of a stamping tool, wherein said stamping tool being provided with two pressing punches arranged at both sides of said stamping punch for deforming of edges which limit the groove slot at both sides, said pressing punches being axially set back relative to said stamping punch opposite to a stamping direction.

14. An apparatus as defined in claim 13, wherein said two pressing punches are axially displaceable in the stamping direction independently from one another.

15. An apparatus as defined in claim 13, wherein said two pressing punches are formed as pressing shoulders which are arranged at both sides of said stamping punch and set back relative to an end surface of said stamping punch.