Method and apparatus for manufacturing AC-generator's stator for vehicle

• US 6,249,956 B1
• Filed: 06/15/1999
• Issued: 06/26/2001
• Est. Priority Date: 10/16/1997
• Status: Expired due to Term

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Takahashi, Makoto, Kamakura, Youichi, Sugiyama, Masaru, Maeda, Kazutaka, Suko, Nobuo
• Primary Examiner(s): Young, Lee
• Assistant Examiner(s): Kim, Paul
• Application Number:
  US09/333,001
• Time in Patent Office: 742 Days
• Field of Search: 295/641, 295/96, 296/05, 296/06, 140/72, 140/102.5, 140/106, 724/58, 724/79
• 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: H02K 15/064 Windings consisting of separate segments, e.g. hairpin windings H02K15/063 takes precedence
• 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 29/49194 Assembling elongated conductors, e.g., splicing, etc.
• CPC Class Codes: Y10T 29/5137 including assembling or disassembling station
• CPC Class Codes: Y10T 29/53143 Motor or generator

Abstract

The object of the present invention is to provide a method and an apparatus for manufacturing a stator to improve accuracy in inserting conductor segments (3, 31, 32) into slots (2). The apparatus according to the present invention comprises a conductor holder (21, 22) holding the conductor segments (3, 31, 32) and an axial-moving-mechanisms (214) moving the conductor holder (21, 22) relative to a stator core (1) in an axial direction. The conductor holder (21, 22) holds straight portions (31b, 31c, 32b, 32c) of the conductor segments (3, 31, 32) to be inserted into the slots (2) from one end of the stator core (1).

Claims

1. A method of twisting plural U-shaped conductor segments, each of which has a turn portion, a first-side straight portion and a second-side straight portion comprising:

inserting said first-side straight portions into holding holes of a first turning-tool and inserting said second side straight portions into holding holes of a second turning-tool, said first turning-tool and second tuning-tool being disposed to be concentric to relatively rotate in circumferential directions opposite to each other;

holding only a middle portion of each of said turn portions in circumferential directions to restrict circumferential movement of said turn portions, and

twisting said turn portions by relative rotation of said first and second turning tools while said middle portion is held in said circumferential direction.

2. The method as claimed in claim 1, wherein

each of said first turning tool and second turning tool comprises a ring member, and

said holding holes are circumferentially aligned at said ring member.

3. The method as claimed in claim 1, wherein said inserting step comprises:

setting a smaller one of said-U-shaped conductor segments having a smaller turn portion and a bigger one of said U-shaped conductor segments having a bigger turn portion into a set;

inserting said first-side straight portions of said set of U-shaped conductor segments into said holding holes of said first turning-tool and inserting said second-side straight portions of said set of U-shaped conductor segments into said holding holes of said second turning-tool so that said turn portion of said bigger U-turn portion can surround said smaller U-turn portion.

4. The method as claimed in claim 1, wherein both sides of said middle potions in said circumferential direction are held.

5. The method as claimed in claim 1, further comprising:

pressing said turn portions by a segment presser to prevent said U-shaped conductor segments from jutting out from said holding holes of said first and second turning-tools.

6. The method as claimed in claim 5, wherein said middle portions are held by projections extending from said segment presser.

7. The method as claimed in claim 5, further comprising:

subsequent to said twisting, pushing said twisted conductor segments toward said segment presser by a segment pusher contacting tip portions of said first-side and second-side straight portions.