Method of forming coils of a stator of a rotary electric machine

• US 20070294876A1
• Filed: 08/02/2007
• Published: 12/27/2007
• Est. Priority Date: 01/30/2004
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Sawada, Yukinori
• Granted Patent: US 7,530,157 B2
• Time in Patent Office: Days
• US Class Current: 29/596
• CPC Class Codes: H02K 15/0428 characterised by the method or apparatus for simultaneously twisting a plurality of hairpins for simultaneously twisting a plurality of hairpins open ends after insertion into the machine H02K15/0087
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/5137 including assembling or disassembling station
• CPC Class Codes: Y10T 29/5141 and means to stake electric wire to commutator or armature in assembling of electric motor or generator
• CPC Class Codes: Y10T 29/53143 Motor or generator

Abstract

A method of manufacturing coils that includes forming a predetermined number of U-shaped conductor segments. The U-shaped conductor segments are twisted using first twisting formation jig composed of a first inside ring and a first outside ring and a second twisting formation jig composed of a second inside ring and a second outside ring. The U-shaped conductor segments that are twist formed in radially inward directions are radially compressed. The U-shaped conductor segments are twist formed by holding one of each pair of straight portions by holding slots that are circumferentially formed in each of a first and second inside rings and first and second outside rings. Next, first and second inside rings and the first and second outside rings are coaxially rotated.

Claims

1. A method of manufacturing coils of a rotary electric machine to be mounted in a stator thereof having a predetermined number of stator slots comprising the steps of:

forming a predetermined number of pairs of U-shaped conductor segments disposed radially inside and outside in the stator slots, each of the U-shaped conductor segments having a pair of parallelly extending radially inside and outside straight portions and a turn portion connecting the inside and outside straight portion;

twist-forming the U-shaped conductor segments by using an inside twisting formation jig composed of a first inside ring and a first outside ring and an outside twisting formation jig composed of a second inside ring and a second outside ring; and

radially compressing the U-shaped conductor segments that are twist-formed in radially inward directions, wherein;

the twist-forming comprises a step of holding one of each pair of straight portions by one of holding slots that are circumferentially formed in each of the first and second inside rings and first and second outside rings; and

coaxially rotating the first and second inside rings and the first and second outside rings to shift relative circumferential position between the inside rings and the outside rings by a predetermined angle.

2. A method as in claim 1, wherein the compressing comprises:

setting a diameter of an inscribed circle of the conductor segments by a metal core having a cylindrical outer periphery;

forming guide spaces by a plurality of guiding arrow members respectively disposed in radial directions at equal intervals between the guiding arrow members; and

compressing the conductor members in radially inner directions when straight portions of the conductor segments are disposed in the guide spaces by a plurality of thrusting arrow members respectively disposed in the guide spaces.