Method of manufacturing a vehicle AC generator

• US 6,604,272 B1
• Filed: 11/22/2000
• Issued: 08/12/2003
• Est. Priority Date: 11/02/1998
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Takahashi, Makoto, Kamakura, Youichi, Sugiyama, Masaru, Maeda, Kazutaka
• Primary Examiner(s): Tugbang, A. Dexter
• Assistant Examiner(s): NGUYEN, TAI V
• Application Number:
  US09/717,297
• Time in Patent Office: 993 Days
• Field of Search: 310/216, 310/179, 310/180, 310/184, 310/201, 310/58, 310/254, 310/257, 310/270, 295/96, 295/98
• 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 3/12 arranged in slots
• CPC Class Codes: H02K 3/44 Protection against moisture or chemical attack; Windings specially adapted for operation in liquid or gas
• CPC Class Codes: H02K 3/48 in slots
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 Rotor

Abstract

In a method of manufacturing a stator of a vehicle AC generator, U-shaped conductor segments having a turn portion and a pair of forked in-slot portions are formed so that the radial width of each conductor segment can be larger than the radial depth of each slot of a stator core. The in-slot portions of the conductor segments are compressed from radially outside and inserted into each slot in an axial direction of the stator core so that the conductor segments can provide a spring-back force in the slots. Then, the U-shaped conductor segments are welded at ends of the in-slot portions in a prescribed pattern.

Claims

1. A method of manufacturing a stator that includes a stator core having a plurality of slots and a stator winding, said method comprising the steps of:

forming U-shaped conductor segments each having a turn portion and a pair of forked in-slot portions so that a radial width of each said conductor segment is larger than a radial depth of said slots;

compressing said in-slot portions of said conductor segments from radially outside;

inserting said compressed in-slot portions of said conductor segments into each of said slots in an axial direction of said stator core so that said conductor segments provide a spring-back force; and

welding said U-shaped conductor segments at ends of said in-slot portions in a prescribed pattern.

2. The method as claimed in claim 1, wherein segment ends are widened after inserting said conductor segments into said slots.

3. The method as claimed in claim 1, wherein four in-slot portions of said conductor segments are inserted into each of said slots, two radially-aligned inner and outer segment ends extending outward from said in-slot portions are welded to other two radially-aligned inner and outer segment ends.

4. The method as claimed in claim 1, wherein said conductor segments are formed so that each of said in-slot portions has the same circumferential width as said slots.

5. The method as claimed in claim 1, wherein:

each of said slots has four radially aligned slots; and

said U-shaped conductor segments are formed into pairs of a large segment having a pair of in-slot portions disposed in the radially innermost layer in one slot and in the radially outermost layer in another slot and a small segment having in-slot portions disposed in the radially inner middle layer in one slot and in the radially outer middle layer in another slot.