METHOD OF MANUFACTURING COIL ASSEMBLY

• US 20090260217A1
• Filed: 04/17/2009
• Published: 10/22/2009
• Est. Priority Date: 04/18/2008
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: KAMAKURA, Youichi, ISHIZUKA, Atsuo, GOROHATA, Tetsuya
• Granted Patent: US 8,186,039 B2
• Time in Patent Office: Days
• US Class Current: 29/596
• CPC Class Codes: H02K 15/0478 Wave windings, undulated windings when on diagonally wound hollow coils H02K15/0492
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/49071 by winding or coiling

Abstract

A method of manufacturing a coil assembly of a rotary electric machine is disclosed wherein first and second coil wire segments are located on an axis direction in opposition to each other to allow first turn portions of the first and second coil wire segments to intersect with each other (in locating step). Engaging movement, composed of a forward transferring movement, a rotating movement and a translating movement, is conducted on the second coil wire segment with respect to the first coil wire segment to allow the first turn portion of the second coil wire segment to engage a second turn portion of the first coil wire segment (first engaging step). Conducting the engaging movement allows to engage a third turn portion of the first coil wire segment (second engaging step).

Claims

1. A method of manufacturing a coil assembly of a rotary electric machine, comprising:

a preparing step for preparing first and second coil wire segments each having a plurality of turn portions;

a locating step for locating the first and second coil wire segments on an axis direction in opposition to each other such that a first turn portion of the first coil wire segment and a first turn portion of the second coil wire segment intersect with each other;

a first engaging step for conducting an engaging movement, composed of a forward transferring movement to transfer the second coil wire segment forward to the first coil wire segment, a rotating movement to rotate the second coil wire segment about the axis direction, and a translating movement to translate the second coil wire segment for causing the first turn portion of either one of the first and second coil wire segments to engage a second turn portion of the other one of the first and second coil wire segments; and

a second engaging step for conducting the engaging movement to allow the first turn portion of the either one of the first and second coil wire segments to engage a third turn portion of the other one of the first and second coil wire segments;

whereby the first and second coil wire segments are woven to form the coil assembly.

2. The method of manufacturing the coil assembly of the rotary electric machine according to claim 1, wherein:

the first and second engaging steps allow the forward transferring movement, the rotating movement and the translating movement to be independently conducted.

3. The method of manufacturing the coil assembly of the rotary electric machine according to claim 1, wherein:

the first and second engaging steps allow the forward transferring movement, the rotating movement and the translating movement to be simultaneously conducted.

4. The method of manufacturing the coil assembly of the rotary electric machine according to claim 1, wherein:

the translating movement of the first engaging step allows the second coil wire segment to be translated from an odd-numbered turn portion to an even-numbered turn portion of the first coil wire segment; and

the translating movement of the second engaging step allows the second coil wire segment to be translated from an even-numbered turn portion to an odd-numbered turn portion of the first coil wire segment.

5. The method of manufacturing the coil assembly of the rotary electric machine according to claim 1, wherein:

the translating movement of the first engaging step allows the second coil wire segment to be translated from an odd-numbered turn portion to an even-numbered turn portion of the second coil wire segment; and

the translating movement of the second engaging step allows the second coil wire segment to be translated from an even-numbered turn portion to an odd-numbered turn portion of the second coil wire segment.

6. The method of manufacturing the coil assembly of the rotary electric machine according to claim 1, wherein:

after the second engaging step has been completed, the first and second engaging steps are similarly and repeatedly conducted to allow the first turn portion of the second coil wire segment to engage respective subsequent turn portions from a fourth turn portion of the second coil wire segment in sequence.

7. The method of manufacturing the coil assembly of the rotary electric machine according to claim 1, wherein:

each of the first and second coil wire segments includes a plurality of in-slot portions placed in slots of a stator core of the rotary electric machine, and the plurality of turn portions each connected between the in-slot portions placed in the slots circumferentially spaced from each other.

8. The method of manufacturing the coil assembly of the rotary electric machine according to claim 7, wherein:

the in-slot portions and each of the turn portions are connected to each other through connecting portions that are bent.

9. The method of manufacturing the coil assembly of the rotary electric machine according to claim 1, wherein:

each of the first and second coil wire segments includes odd-numbered turn portions and even-numbered turn portions alternately placed in positions displaced by an angle of 180 degrees in phase about the axis direction.

10. The method of manufacturing the coil assembly of the rotary electric machine according to claim 1, wherein:

each of the turn portions includes a plurality of cranked portions formed in stepwise shapes.

11. A method of manufacturing a coil assembly of a rotary electric machine, comprising:

a preparing step for preparing first and second woven coil wire segments;

a locating step for locating the first and second woven coil wire segments in opposition to each other on the axis direction such that a first turn portion of the first woven coil wire segment and a first turn portion of the second woven coil wire segment intersect with each other;

a first engaging step for conducting an engaging movement, composed of a forward transferring movement to transfer the second woven coil wire segment forward to the first woven coil wire segment, a rotating movement to rotate the second woven coil wire segment about the axis direction, and a translating movement to translate the second woven coil wire segment, for causing the first turn portion of either one of the first and second woven coil wire segments to engage a second turn portion of the other one of the first and second woven coil wire segments; and

a second engaging step for conducting the engaging movement to allow the first turn portion of the either one of the first and second woven coil wire segments to engage a third turn portion of the other one of the first and second woven coil wire segments;

whereby the first and second woven coil wire segments are woven to form the coil assembly.