METHOD OF P-FORMING A CONTINUOUS CONDUCTOR HAVING A RECTANGULAR CROSS SECTION AND A STATOR INCLUDING A STATOR WINDING FORMED FROM A P-FORMED CONDUCTOR HAVING A RECTANGULAR CROSS-SECTION

• US 20130127287A1
• Filed: 11/17/2011
• Published: 05/23/2013
• Est. Priority Date: 11/17/2011
• Status: Active Grant

• Current Assignee: BorgWarner Incorporated
• Original Assignee: Remy Technologies LLC (BorgWarner Incorporated)
• Inventors: Stephenson, Mark A.
• Granted Patent: US 8,745,847 B2
• Time in Patent Office: Days
• US Class Current: 310/179
• 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

Abstract

A method of P-forming a conductor having a rectangular cross-section to create a continuous stator winding. The method includes forming a conductor having a rectangular cross-section into a series of first and second substantially parallel segments that meet at a vertex, deforming the conductor such that each of the first and second segments are non-parallel to form a cross-over feature at the vertex, and deforming a section of each of the first and second segments to include corresponding first and second portions that are generally parallel to create the continuous stator winding.

Claims

1. A method of P-forming a conductor having a rectangular cross-section to create a continuous stator winding, the method comprising:

forming a conductor having a rectangular cross-section into a series of first and second substantially parallel segments that meet at a vertex;

deforming the conductor such that each of the first and second segments are non-parallel to form a cross-over feature at the vertex; and

deforming a section of each of the first and second segments to include corresponding first and second portions that are generally parallel to create the continuous stator winding.

2. The method of claim 1, wherein deforming the conductor to form the cross-over feature includes imparting a twist at the vertex.

3. The method of claim 1, wherein deforming the section of each of the first and second segments includes die forming the section of each of the first and second segments to include the corresponding first and second portions that are generally parallel.

4. The method of claim 1, wherein forming the conductor having a rectangular cross-section into a series of first and second substantially parallel segments that meet at a vertex includes forming a P-formed preform.

5. A method of forming a stator winding for an electric machine, the method comprising:

forming a conductor having a rectangular cross-section into a series of first and second substantially parallel segments that meet at a vertex;

deforming the conductor such that each of the first and second segments are non-parallel to form a cross-over feature at the vertex;

deforming a section of each of the first and second segments to include corresponding first and second portions that are generally parallel to establish a stator winding formed from a conductor having a rectangular cross-section; and

inserting the continuous conductor having a rectangular cross-section into a stator core to establish a continuous phase winding of the stator.

6. The method of claim 5, wherein inserting the continuous conductor having a rectangular cross-section into the stator core includes laying the first and second portions into slot segments formed in the stator core.

7. The method of claim 5, wherein the continuous conductor includes a first width that is greater than a second width, inserting the continuous conductor having a rectangular cross section into the stator includes arranging the continuous conductor in one or more slot segments with the first width extending along a radius of the stator.

8. The method of claim 5, wherein forming the conductor having a rectangular cross-section into a series of first and second substantially parallel segments that meet at a vertex includes forming a P-formed preform.

9. An electric machine comprising:

a housing;

a rotor rotatably mounted relative to the housing; and

a stator fixedly mounted relative to the stator, the stator comprising;

a stator core having a plurality of slot segments; and

a continuous P-formed stator winding element having a rectangular cross-section, the continuous P-formed stator winding element including first and second generally parallel portions that meet at a vertex, and a cross-over feature at the vertex, each of the first and second generally parallel portions being positioned in select ones of the plurality of slot segments with the cross-over feature being configured and disposed to nest with another continuous P-formed stator winding element.

10. The electric machine according to claim 9, wherein the rectangular cross-section includes a first dimension and a second dimension, the second dimension being greater than the first dimension, the first and second parallel portions being oriented in the select ones of the plurality of slot segments with the second dimension extending along a radius of the stator core.