Method for manufacturing rotary electric system

• US 6,490,779 B1
• Filed: 03/30/2000
• Issued: 12/10/2002
• Est. Priority Date: 03/30/1999
• Status: Expired due to Term

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Tokizawa, Takashi, Kato, Mitsuru, Taira, Mitsuaki
• Primary Examiner(s): Hughes, S. Thomas
• Assistant Examiner(s): Kenny, Stephen
• Application Number:
  US09/538,983
• Time in Patent Office: 985 Days
• Field of Search: 295/96, 295/98, 296/05, 293/32, 297/32, 219/86.24
• US Class Current: 29/596
• CPC Class Codes: H02K 15/0056 Manufacturing winding connections
• CPC Class Codes: H02K 15/0081 for form-wound windings
• CPC Class Codes: H02K 15/064 Windings consisting of separate segments, e.g. hairpin windings H02K15/063 takes precedence
• CPC Class Codes: H02K 3/12 arranged in slots
• 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 29/53143 Motor or generator

Abstract

A winding on a stator of a rotary electric machine is constructed by welding end portions of a plurality of segments. A plurality of pairs arranged on an end of the stator are welded by a welder. In a welding stage, the pairs are held by a plurality of insertion rods of a circumferential side holding tool. The insertion rods are radially disposed. The insertion rods are movable in a radial direction. The insertion rods are moved back toward a radial outside to release a holding of the pairs after ball-shaped welding marks are formed. Holding is released without damage on the welding mark.

Claims

1. A method for manufacturing a rotary electric machine comprising a core and a plurality of conductors positioned on said core and provided as a part of a winding, the method comprising the steps of:

arranging a plurality of pairs into a ring, said pairs comprising end portions of said conductors to be joined and extending from said core;

holding said plurality of pairs by disposing holding tools in between circumferentially adjacent two pairs to contact both of said pairs respectively;

joining the plurality of pairs under a holding condition of said pairs; and

releasing the holding condition of the pairs by moving the holding tools in a direction crossing an extending direction of said end portions.

2. A method for manufacturing a rotary electric machine according to claim 1, wherein:

a joining mark is formed in said joining step, the joining mark is larger than an end of a non-joined pair.

3. A method for manufacturing a rotary electric machine according to claim 1, wherein:

said plurality of pairs are arranged to extend in an axial direction from said core in said arranging step.

4. A method for manufacturing a rotary electric machine according to claim 3, wherein:

two of said end portions to be joined are arranged in a radial direction of said core in said arranging step.

5. A method for manufacturing a rotary electric machine according to claim 3, wherein:

said holding tools are moved in the radial outside direction relative to the ring arrangement of said pairs in said releasing step.

6. A method for manufacturing a rotary electric machine according to claim 1, wherein:

said holding tools are inserted between said plurality of pairs by moving in a radial direction relative to a ring arrangement of said pairs in said holding step.

7. A method for manufacturing a rotary electric machine according to claim 1, wherein:

a plurality of segments are positioned on said core as said conductors in said arranging step.

8. A method for manufacturing a rotary electric machine according to claim 7, wherein:

U-shaped segments are inserted in said core from one axial end of said core to provide a plurality of end portions extending from the other axial end of said core in said arranging step.

9. A method for manufacturing a rotary electric machine according to claim 1, wherein:

said plurality of pairs are arranged into a multiple coaxial rings on one axial end of said core in said arranging step.

10. A method for manufacturing a rotary electric machine according to claim 9, wherein:

one of said pairs belonging to said inner ring and one of said pairs belonging to said outer ring are contacted with a common piece of said holding tool extending in the radial direction in said holding step.

11. A method for manufacturing a rotary electric machine according to claim 1, wherein:

said end portion positioned on an end of a radial direction is held relative to the radial direction by said holding tool in said holding step.

12. A method for manufacturing a rotary electric machine according to claim 1, wherein:

a tip of said holding tool positioned between said pairs is coupled with a coupling portion to fix the holding tool in said holding step.

13. A method for manufacturing a rotary electric machine according to claim 1, wherein:

said end portion is modified into a designated proper shape by using a cross sectional shape of said holding tool corresponding to said designated proper shape of said end portion in said holding step.

14. A method for manufacturing a rotary electric machine comprising a core and a plurality of conductors positioned on said core and provided as a part of a winding, the method comprising the steps of:

arranging a plurality of pairs into a ring, said pairs comprising end portions of said conductors to be joined and extending from said core;

holding said plurality of pairs by disposing holding tools in between circumferentially adjacent two pairs to contact both of said pairs respectively;

joining the plurality of pairs under a holding condition of said pairs; and

releasing the holding condition of the pairs by moving the holding tools in a direction crossing an extending direction of said end portions, wherein said plurality of pairs are arranged to extend in an axial direction from said core in said arranging step, and wherein said holding tools are moved in the radial outside direction relative to the ring arrangement of said pairs in said releasing step.

15. A method for manufacturing a rotary electric machine comprising a core and a plurality of conductors positioned on said core and provided as a part of a winding, the method comprising the steps of:

arranging a plurality of pairs into a ring, said pairs comprising end portions of said conductors to be joined and extending from said core;

holding said plurality of pairs by disposing holding tools in between circumferentially adjacent two pairs to contact both of said pairs respectively;

joining the plurality of pairs under a holding condition of said pairs; and

releasing the holding condition of the pairs by moving the holding tools in a direction crossing an extending direction of said end portions, wherein said holding tools are inserted between said plurality of pairs by moving in a radial direction relative to a ring arrangement of said pairs in said holding step.

16. The method for manufacturing a rotary electric machine according to claim 15, wherein:

the plurality of pairs of the end portions are arranged into two rings that are coaxially positioned on an axial end of the core in the arranging step; and

each of the holding tools is inserted between the pairs belonging to an inner ring and between the pairs belonging to an outer ring in the holding step.

17. The method for manufacturing a rotary electric machine according to claim 16, wherein the pairs belonging to the inner ring are further held by positioning an inside holding tool on a radial inside of the inner ring, and the pairs belonging to the outer ring are further held by positioning an outer holding tool on a radial outside of the outer ring.

18. The method for manufacturing a rotary electric machine according to claim 15, wherein:

four of the end portions are arranged radially to provide two of the pairs in the arranging step;

the holding tool is inserted to circumferentially hold all of the radially arranged four end portions in the holding step;

an outside holding tool is positioned to radially hold the end portion positioned most outside in the holding step; and

an inside holding tool is positioned to radially hold the end portion positioned most inside in the holding step.

19. The method for manufacturing a rotary electric machine according to claim 15, wherein the holding tools are inserted simultaneously.

20. The method for manufacturing a rotary electric machine according to claim 15, wherein the holding tools are moved in a radial direction in the releasing step.