ARMATURE COIL AND METHOD OF MANUFACTURING THE SAME

• US 20170324291A1
• Filed: 06/30/2017
• Published: 11/09/2017
• Est. Priority Date: 04/26/2013
• Status: Active Grant

• Current Assignee: Mitsubishi Electric Corporation
• Original Assignee: Mitsubishi Electric Corporation
• Inventors: TAMURA, Koji, TAMURA, Shuichi, YAMAMURA, Akihiro, DOI, Issei, MATSUO, Hiroyuki, NISHIMURA, Yasukazu, KAWASAKI, Sachiko, MORI, Akihiko
• Granted Patent: US 10,644,556 B2
• Time in Patent Office: Days
• CPC Class Codes: H02K 1/16 Stator cores with slots for windings
• CPC Class Codes: H02K 15/04 of windings, prior to mounting into machines insulating windings H02K15/10, H02K15/12
• CPC Class Codes: H02K 15/0407 Windings manufactured by etching, printing or stamping the complete coil
• CPC Class Codes: H02K 15/0414 Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils
• CPC Class Codes: H02K 15/0421 consisting of single conductors, e.g. hairpins
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/53235 Means to fasten by deformation
• CPC Class Codes: Y10T 29/5327 Means to fasten by deforming

Abstract

In an armature coil according to the present invention and, more particularly, in an armature coil including a plurality of coil conductors wound around a plurality of slots which are formed in a stator core and opened on the radially inner side, the circumferential width of the plurality of the coil conductors is formed in a substantially trapezoidal shape which gets narrower toward the radially inner side and the cross-sectional areas of the plurality of the coil conductors in the slot are each substantially the same and the circumferential width thereof is formed narrower as the coil conductor is arranged toward the radially inner side; and one coil conductor is formed in a convex shape and another coil conductor is formed in a concave shape along the convex shape.

Claims

1. A method of manufacturing an armature coil, comprising the steps of:

arranging a plurality of coil conductors on a lower metal die having a taper-shaped groove substantially the same as a slot which is wound with the plurality of said coil conductors of said armature coil and is formed in a trapezoidal shape which gets narrower in width toward the radially inner side;

pressing said coil conductors arranged in the groove of said lower metal die by an upper metal die having a rod-shaped end portion slightly narrower than the width of the groove;

forming more flattened toward said coil conductor arranged at the end of the groove by being pressed to a predetermined position by the rod-shaped end portion of said upper metal die, forming an aspect ratio smaller toward said coil conductor near an opening portion of the groove, and forming such that one coil conductor is formed in a convex shape and another coil conductor is formed in a concave shape along the convex shape at between said coil conductors; and

removing said coil conductors formed in the convex shape and the concave shape from said lower metal die.

2. A method of manufacturing an armature coil, comprising the steps of:

having a lower metal die which is provided with an end metal die at a left end portion and a back portion metal die at a right end portion and an upper metal die which is provided with an inclined portion on the lower metal die side and is to be pressed, forming such that a space formed by said respective metal dies is substantially the same as the shape of a slot and the width of the space gets gradually narrower toward the direction of said end metal die when said upper metal die is moved to come in contact with the upper surfaces of said end metal die and said back portion metal die of said lower metal die, and arranging a plurality of coil conductors of said armature coil between said end metal die and said back portion metal die on said lower metal die;

pressing the plurality of said coil conductors arranged between said end metal die and said back portion metal die on said lower metal die by said upper metal die;

forming more flattened toward said coil conductor near said end metal die by being pressed to a position coming in contact with the upper surfaces of said end metal die and said back portion metal die of said lower metal die by said upper metal die, forming an aspect ratio smaller toward said coil conductor near said back portion metal die, and forming such that one coil conductor is formed in a convex shape and another coil conductor is formed in a concave shape along the convex shape at between said coil conductors; and

removing said coil conductors formed in the convex shape and the concave shape from said lower metal die.