Method and apparatus for manufacturing stator of rotary electric machine

• US 6,557,239 B2
• Filed: 01/12/2001
• Issued: 05/06/2003
• Est. Priority Date: 01/12/2000
• Status: Expired due to Term

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Takahashi, Makoto, Kamakura, Youichi, Sugiyama, Masaru
• Primary Examiner(s): Vidovich, Gregory
• Assistant Examiner(s): Kenny, Stephen
• Application Number:
  US09/758,169
• Publication Number:
  US 20010007169A1
• Time in Patent Office: 844 Days
• Field of Search: 295/96, 295/97, 295/98, 296/05, 310/154, 310/156, 242/599.1
• 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 29/53143 Motor or generator

Abstract

A method for manufacturing a stator of a rotary electric machine includes: a step of forming a plurality of conductor segments each having at least a straight leg; a step of inserting the plurality of conductor segments into each of the slots in a plurality of radially aligned layers so that the straight legs can extend outside an end of the stator core; a step of stratifying the straight legs in radially aligned layers to correspond to the layers in the slots; a step of holding each of the stratified portions at grip portions; a step of circumferentially shifting each of the grip portions in a prescribed circumferential direction of the stator core; and a step of axially shifting each of the grip portions separately from another in an axial direction of the stator core to locate those of the grip portions to be connected adjacent to each other.

Claims

1. A method for manufacturing a stator of a rotary electric machine including a cylindrical stator core with a plurality of conductor segments respectively disposed in said slots in a plurality of radially aligned layers, said method comprising:

forming a plurality of conductor segments each having at least a straight leg that has a grip portion at an end thereof;

inserting said plurality of conductor segments into each of said slots in a plurality of radially aligned layers so that said straight legs can extend outside an end of said stator core and so that said grip portions of those of said straight legs disposed in a radially more outside layer are higher than grip portions of other straight legs;

stratifying said straight legs in radially aligned layers, to correspond to said layers in said slots;

holding each of said stratified straight legs at said grip portions;

circumferentially shifting each of said grip portions of said straight portions relative to other portion thereof disposed in said slots in a prescribed circumferential direction of said stator core; and

shifting each of said grip portions in an axial direction of said stator core to a position adjacent to another grip portion to be connected to each other.

2. The method as claimed in claim 1, wherein said circumferentially shifting step comprises a step of shifting each of said grip portions the same angle in said circumferential direction, and said shifting step comprises a step of shifting each of said grip portions in said axial direction until all heights of said grip portions become equal.

3. The method as claimed in claim 1, wherein said grip portion are held so that distances thereof from said end of stator core can be equal to each other.

7. The method as claimed in claim 1, characterized in that

said grip portions are held at circumferential sides thereof.

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

machining said grip portions so that heights of said grip portions from said end of said stator core disposed in all said layers can be equal to each other.

4. A method for manufacturing a stator of a rotary electric machine including a cylindrical stator core with a plurality of slots and a plurality of conductor segments respectively disposed in said slots in a plurality of radially aligned layers, said method comprising:

forming a plurality of conductor segments each having at least a straight leg;

inserting said plurality of conductor segments into each of said slots in a plurality of radially aligned layers so that said straight legs can extend outside an end of said stator core;

stratifying said straight legs in radially aligned layers to correspond to said layers in said slots;

holding each of said stratified straight legs at grip portions;

circumferentially shifting each of said grip portions of said straight portions relative to other portion thereof disposed in said slots in a prescribed circumferential direction of said stator core; and

axially shifting each of said grip portions separately from another in an axial direction of said stator core to locate those of said grip portions to be connected adjacent to each other, wherein said grip portions are held so that distances thereof from said end of said stator core can be equal to each other and said grip portions are shifted the same angle in said circumferential direction and are separately shifted in said axial direction so that lengths of those of said grip portions disposed in a layer that is radially more outside are shorter.

5. A method for manufacturing a stator of a rotary electric machine including a cylindrical stator core with a plurality of slots and a plurality of conductor segments respectively disposed in said slots in a plurality of radially aligned layers, said method comprising:

forming a plurality of conductor segments each having at least a straight leg;

inserting said plurality of conductor segments into each of said slots in a plurality of radially aligned layers so that said straight legs can extend outside an end of said stator core;

stratifying said straight legs in radially aligned layers to correspond to said layers in said slots;

holding each of said stratified straight legs at grip portions;

circumferentially shifting each of said grip portions in a prescribed circumferential direction of said stator core; and

axially shifting each of said grip portions separately from another in an axial direction of said stator core to locate those of said grip portions to be connected to each other, wherein said grip portions are held so that the length of one of said grip portions disposed in a radially more outside layer from said end of said stator core is longer.

6. The method as claimed in claim 5, wherein

said grip portions are shifted the same angle in said circumferential direction and separately shifted in said axial direction so that said grip portions disposed in all said layers of said slots become equal in distance from said end of said stator core.

8. A method for manufacturing a stator of a rotary electric machine including a cylindrical stator core with a plurality of slots and a plurality of conductor segments respectively disposed in said slots in a plurality of radially aligned layers, said method comprising:

forming a plurality of conductor segments each having at least a straight leg;

inserting said plurality of conductor segments into each of said slots in a plurality of radially aligned layers so that said straight legs can extend outside an end of said stator core;

stratifying said straight legs in radially aligned layers to correspond to said layers in said slots;

holding each of said stratifying straight legs at grip portions;

circumferentially shifting each of said grip portions in a prescribed circumferential direction of said stator core; and

axially shifting each of said grip portions separately from another in an axial direction of said stator core to locate those of said grip portions to be connected adjacent to each other, wherein said grip portions are shifted by a holding member having a plurality of cavities while ends of said grip portions abut bottoms of said cavities.

9. The method as claimed in claim 8, wherein

said grip portions are shifted in said axial direction in response to shifting of said holding member.

10. The method as claimed in claim 8, wherein

said holding members moves in said axial direction in response to shifting of said grip ends of said grip portions.

11. The method as claimed in claim 8, wherein

each of said cavities of said holding members has a rectangular cross-section for holding one of said grip portions and twists said extended legs.