ASSEMBLY METHOD FOR STATOR OR DYNAMO-ELECTRIC MACHINE

• US 3,802,066 A
• Filed: 04/06/1972
• Issued: 04/09/1974
• Est. Priority Date: 04/06/1972
• Status: Expired due to Term

• Current Assignee: Edward L. Barrett
• Original Assignee: Edward L. Barrett
• Inventors: Barrett, Edward L.
• Primary Examiner(s): Lanham, Charles W.
• Assistant Examiner(s): Hall, Carl E.
• Application Number:
  US05/241,768
• Time in Patent Office: 733 Days
• Field of Search: 29/596,598,606 310/42,216,218,254,258,259
• US Class Current: 29/596
• CPC Class Codes: H02K 1/16 Stator cores with slots for windings
• CPC Class Codes: H02K 15/00 Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
• 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

Abstract

A method of assembling the stator of a dynamo-electric machine, either a motor or an alternator, and the stator produced by that method; the stator core is fabricated as a plurality of core segments, preferably L-shaped in configuration, each segment including a tangent rim element and a radial leg element. The stator core segments are loosely assembled in a cylindrical core and the electrical windings, preferably skein wound, are mounted on the core by insertion from the outside of the assembly through temporary gaps between the rim elements of adjacent core segments formed by spreading the segments, each winding encompassing the leg elements on two or more core segments. Subsequently, the core segments are bound tightly together to complete the stator.

Claims

1. The method of manufacturing a stator for a dynamo-electric machine, of the kind comprising a magnetic core including a cylindrical rim and a plurality of radially inwardly directed legs terminating at closely spaced intervals around the periphery of a rotor-receiving axial opening, with electrical windings mounted on the core and extending through windows between the core legs, said method comprising the following steps:

A. loosely assembling a plurality of magnetic stator core segments, each comprising a tangent rim element and a radial leg element, into a cylindrical preliminary stator core assembly corresponding approximately to the required stator configuration B. spreading a first pair of adjacent core segments in the stator core assembly to afford a substantial temporary gap between their rim elements;

C. inserting an electrical winding element through the gap between the rim elements of the first pair of core segments and into the window between their respective leg elements;

D. closing the gap between the first pair of core segments;

E. repeating steps B through D for additional pairs of adjacent core segments around the periphery of the preliminary stator core assembly until at least one complete electrical winding, with winding elements encompassing all of the radial core legs, is mounted on the core segments of the assembly;

F. and thereafter binding the core segments together, with the rim element of each core segment in abutting contact with the rim elements of the two adjacent core segments to afford a continuous magnetic path around the periphery of the stator core.

2. The method of manufacturing a stator for a dynamo-electric machine, according to claim 1, in which the temporary gaps formed in carrying out step B, for a given electrical winding, are displaced by at least two core segments, and the completed electrical winding comprises a series of coils encompassing all of the legs of the stator core.

3. The method of manufacturing a stator for a dynamo-electric machine, according to claim 1, utilizing a single large multi-turn skein for each electrical winding, in which one end of the skein is inserted into a first core window in the first step C, the two sides of the skein are inserted into and crossed over within a different core window during each subsequent step C until the last, and the other end of the skein is inserted into the first core window in the last step C.

4. The method of manufacturing a stator for a dynamo-electric machine, according to claim 3, in which the temporary gaps formed in step B, for a given electrical skein winding, are displaced by at least two core segments, and the skein forms a series of coils encompassing all of the stator core legs.

5. The method of manufacturing a stator for a dynamo-electric machine, according to claim 4, utilizing two skeins to provide two electrical windings, the windows into which the first skein is inserted being alternated with windows into which the second skein is inserted, around the periphery of the stator core, and each skein being inserted into every second window around the core.

6. The method of manufacturing a stator for a dynamo-electric machine, according to claim 4, utiLizing three skeins to provide three electrical windings, each skein being inserted into every third window around the core, and each window into which the first skein is inserted being interposed between a window into which the second skein is inserted and a window into which the third skein is inserted.

7. The method of manufacturing a stator for a dynamo-electric machine, according to claim 1, including the additional step of mounting individual insulator linings in the core windows before insertion of any electrical winding element into the windows, each insulator having a discontinuity aligned with the juncture of the rim elements of the two adjacent core segments forming the window in which the insulator is mounted to allow insertion of an electrical winding element into the insulator lining.

8. The method of manufacturing a stator for a dynamo-electric machine, according to claim 7, in which each insulator lining is bonded to the tangent rim element of one of the core segments forming the window in which the insulator lining is mounted.

9. The method of manufacturing a stator for a dynamo-electric machine, according to claim 1, in which assembling step A is effected by mounting the core segments on a magnetic bobbin having a diameter slightly larger than the diameter of the completed stator.

10. The method of manufacturing a stator for a dynamo-electric machine, according to claim 1, in which assembling step A is effected by depositing the core segments in a jig having a central aperture with a diameter slightly larger than the finished stator diameter and a gap in the periphery of the jig, and positioning a bobbin in the center of the assembled core segments to prevent inward displacement of the core segments.