Method of manufacturing rotary electric machine's stator

• US 6,339,871 B1
• Filed: 03/31/2000
• Issued: 01/22/2002
• Est. Priority Date: 04/02/1999
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Sugiyama, Masaru, Naka, Yoshio, Maesoba, Kazuki
• Primary Examiner(s): Young, Lee
• Assistant Examiner(s): Kim, Paul D
• Application Number:
  US09/538,942
• Time in Patent Office: 662 Days
• Field of Search: 295/96, 297/34, 295/97, 295/98, 297/32, 297/36, 297/92
• 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: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49011 Commutator or slip ring assembly
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/53143 Motor or generator
• CPC Class Codes: Y10T 29/53152 Means to position insulation
• CPC Class Codes: Y10T 29/53174 Means to fasten electrical component to wiring board, base, or substrate
• CPC Class Codes: Y10T 29/53404 including turret-type conveyor

Abstract

A method of manufacturing a stator of a rotary electric machine is comprised of the following steps: providing a plurality of U-shaped basic conductor segments and a plurality of U-shaped connection conductor segments; forming the U-turn portions and straight portions into crossover portions, inserting the pair of straight portions of the basic and connection conductor segments into prescribed two slots of a stator core from one end thereof to extend from the other end, bending one of the pair of straight portions in the direction opposite to the other of the pair of extended straight portions so that the edges of straight portions extending from the prescribed slots can adjoin each other, connecting the adjoining edges to form a plurality of phase coils, and removing the U-turn portion of the connection conductor segments to form terminals of the phase coils.

Claims

1. A method of manufacturing a stator of a rotary electric machine including a stator core having a plurality of slots formed in the circumferential direction thereof at equal intervals, said method comprising the steps of:

providing a plurality of U-shaped basic conductor segments having a U-turn portion and a pair of straight portions and a plurality of U-shaped connection conductor segments having a U-turn portion and a pair of straight portions;

forming said U-turn portion and said pair of straight portions of said basic and connection conductor segments into first crossover portions;

inserting said pair of straight portions of said basic and connection conductor segments into prescribed two of said slots from one end of said stator core to extend from the other end of said stator core;

bending each of said pair of straight portions of said basic and connection conductor segments extending from the other end in directions opposite to each other so that edges of said straight portions extending from said prescribed two of said slots can adjoin each other;

connecting said adjoining edges to form a plurality of second crossover portions and a plurality of coils; and

removing said U-turn portion of said connection conductor segments to respectively form opposite terminals of said coils.

2. The method as claimed in claim 1, wherein

each of said slots has outermost first slot layer, outer-middle second slot layer, inner-middle third slot layer, and innermost fourth slot layer;

said plurality of basic conductor segments comprise large segments having said straight portions to be disposed in said first and fourth slot layers and small segments having said straight portions to be disposed in said second and third slot layers; and

said plurality of connection conductor segments comprise first connection segments having said U-turn portion to be removed and said straight portions to be disposed in said first and third slot layers and second connection segments having said straight portions to be disposed in said second and fourth slot layers.

3. The method as claimed in claim 2, wherein

said step of forming said U-turn portion and said straight portions of said basic conductor segments and said connection conductor segments comprises:

a step of holding said straight portions to be disposed in said first and second slot layers by an outer ring and said straight portion to be disposed in said third and fourth slot layers by an inner ring coaxially rotatable within said outer ring; and

a step of rotating said outer and inner rings relative to each other in a prescribed angle.

4. The method as claimed in claim 2, wherein said first connection segments have longer straight portions than at least one of said straight portions of said second connection segments and said basic conductor segments.

5. The method as claimed in claim 3, wherein said step of forming U-turn portion and said straight portions further comprises a step of pressing said U-turn portions of said basic conductor segments by a presser.

6. The method as claimed in claim 5, wherein said presser has a portion for freeing said first connection segments from said step of pressing.

7. The method as claimed in claim 2, wherein the step of bending further comprises a step of pressing said U-turn portions of said basic conductor segments by said presser while said extended straight portions are bent.

8. The method as claimed in claim 1, wherein said step of bending comprises:

a step of holding said edge of said straight portions extending from said first slot layer by first ring of four coaxially rotatable rings;

a step of holding said edge of said straight portions extending from said second slot layer by second ring of said four rings;

a step of holding said edge of said straight portions extending from said third slot layer by third ring of said four rings;

a step of holding said edge of said straight portions in said fourth slot layer by fourth ring of said four rings; and

rotating said four rings relative to each other in a prescribed angle.

9. The method as claimed in claim 8, wherein said step of bending further comprises a step of pressing said U-turn portions of said basic conductor segments by a presser while said four rings are rotated.