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

• US 6,530,140 B2
• Filed: 04/17/2001
• Issued: 03/11/2003
• Est. Priority Date: 10/16/1997
• Status: Expired due to Term

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Suko, Nobuo, Takahashi, Makoto, Kamakura, Youichi, Sugiyama, Masaru, Maeda, Kazutaka
• Primary Examiner(s): Bryant, David P.
• Assistant Examiner(s): Kenny, Stephen
• Application Number:
  US09/835,524
• Publication Number:
  US 20010013167A1
• Time in Patent Office: 693 Days
• Field of Search: 295/96, 295/98, 296/05, 296/06, 296/032.3, 296/032.4, 297/32, 310/156.01, 310/254, 242/432
• 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 manufacturing an alternator stator for a vehicle that has a plurality of U-shaped conductor segments welded to form a stator winding disposed in slots (2) formed circumferentially in an annular stator core (1), said method comprising:

holding straight portions (31b, 31c, 32b, 32c) of said U-shaped conductor segments (3, 31, 32),

inserting said straight portions (31b, 31c, 32b, 32c) from edge portions (31d, 31e, 32d, 32e) thereof into axial-end openings of said slots, and

pressing said U-shaped conductor segments (3, 31, 32) at turn portions (31a, 32a) thereof in an axial direction until said straight portions are fitted into said slots (2) to form coil ends of a prescribed height,

wherein said inserting step comprises guiding said edge portions (31d, 31e, 32d, 32e) to said axial-end openings of slots (2).

2. The method for manufacturing an alternator stator for a vehicle as claimed in claim 1, wherein

said inserting step comprises restricting movement of said turn portions (31a, 32a) of said U-shaped conductor segments (3, 31, 32) in the circumferential direction of said stator core (1).

3. The method of manufacturing an alternator stator for a vehicle as claimed as claimed in claim 2, wherein

said pressing step further comprising restricting movement of said turn portions at the middle thereof.

4. The method of manufacturing an alternator stator for a vehicle as claimed in claim 1, wherein

said pressing step further comprises restricting movement of said turn portions at the middle thereof.

5. A method of manufacturing a vehicle alternator stator including an annular stator core and a plurality of circumferentially aligned slots with a plurality of U-shaped conductors having a pair of straight portions and a turn portion being disposed therein, said method comprising:

holding said straight portion of said plurality of U-shaped conductor segments between opposite sides thereof,

inserting said pair of straight portions into axial-end openings of a corresponding pair of said slots at edges thereof, and

pressing each of said U-shaped conductor segments at said turn portion thereof in an axial direction of said stator until said straight portions are inserted into said slots (2) to form coil ends of a prescribed height, wherein

said pressing step further comprises holding said turn portion by the middle to restrict circumferential movement thereof, and

said inserting step comprises guiding said edge portions to said axial-end openings of said slots.

6. The method as claimed in claim 5, wherein said inserting step further comprises holding said turn portion by the middle to restrict circumferential movement thereof.

7. The method as claimed in claim 5, wherein

said plurality of U-shaped conductor segments comprises relatively large segments having a turn portion of a larger radius and relatively small segments having a turn portion of a smaller radius surrounded by said relatively large segments, and

said pressing step comprises holding said turn portions of said relatively large and small segments to restrict circumferential movement of said turn portions.

8. A method of manufacturing an alternator stator for a vehicle that has a plurality of U-shaped conductor segments welded to form a stator winding disposed in slots formed circumferentially in an annular stator core, wherein each of said U-shaped conductor segments has a turn portion at the middle thereof and a pair of straight portions extending from said turn portion, said method comprising:

holding said straight portions,

guiding said straight portions to axial-end openings of said slots, and

pressing said turn portion of said U-shaped conductor segments in an axial direction until said straight portions are fitted into said slots to form coil ends of a prescribed height.