Method for manufacturing rotary electric machine

• US 6,698,083 B2
• Filed: 10/04/2002
• Issued: 03/02/2004
• Est. Priority Date: 03/30/1999
• Status: Expired due to Term

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Taira, Mitsuaki, Tokizawa, Takashi, Kato, Mitsuru
• Primary Examiner(s): Vo, Peter
• Assistant Examiner(s): Kenny, Stephen
• Application Number:
  US10/263,695
• Publication Number:
  US 20030024101A1
• Time in Patent Office: 515 Days
• Field of Search: 295/96, 295/98, 296/05, 296/06, 242/432, 310/133, 310/179, 310/42, 310/178
• 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 of manufacturing a rotary electric machine comprising a core and a plurality of conductors on the core, the method comprising the steps of:

placing end portions of the conductors to be joined between holding tools that hold the end portions in a predetermined shape;

joining the end portions by forming a joining mark thereon while holding the end portions by the holding tools; and

removing both of the holding tools by moving both of the holding tools in a manner that the holding tools are prevented from contact with the joining mark.

2. The method of manufacturing a rotary electric machine according to claim 1, wherein the step of removing is performed by moving both of the holding tools in a manner that the holding tools slide on surfaces of the conductors except for the joining mark.

3. The method of manufacturing a rotary electric machine according to claim 2, wherein the step of placing is performed by placing the end portions between the holding tools that is movable between an engaged position in which the end portions are held in a predetermined shape and a disengaged position in which the end portions are free from the holding tools.

4. The method of manufacturing a rotary electric machine according to claim 3, wherein the step of placing comprises the steps of:

arranging the end portions in an manner that the end portions are adjacent each other; and

moving the holding tools from the disengaged position to the engaged position so that the end portions arranged in the step of arranging are held between the holding tools.

5. The method of manufacturing a rotary electric machine according to claim 4, wherein the step of removing is performed by moving both of the holding tools simultaneously.

6. A method of manufacturing a rotary electric machine comprising a core and a plurality of conductors on the core, the method comprising the steps of:

placing end portions of the conductors to be joined among holding tools;

joining the end portions while holding the end portions by the holding tools; and

removing the holding tools,

wherein the step of placing comprises;

placing the end portions between first pair of the holding tools that hold the end portions with respect to a first direction; and

placing the end portions between second pair of holding tools that holds the end portions with respect to a second direction perpendicular to the first direction.

7. The method of manufacturing a rotary electric machine according to claim 6, wherein the end portions are located on an axial end of the core, the first pair of the holding tools hold the end portions with respect to a radial direction of the core, and the second pair of the holding tools hold the end portions with respect to a circumferential direction of the core.

8. The method of manufacturing a rotary electric machine according to claim 6, wherein both of the first pair of holding tools and the second pair of holding tools are movable in the same direction.

9. The method of manufacturing a rotary electric machine according to claim 8, wherein the holding tools are movable in the radial direction.

10. A method of manufacturing a rotary electric machine comprising a core and a plurality of conductors on the core, the method comprising the steps of:

placing end portions of the conductors to be joined among holding tools;

joining the end portions while holding the end portions by the holding tools; and

removing the holding tools,

wherein the step of placing comprises;

placing the end portions between first pair of the holding tools that hold the end portions with respect to a first direction; and

placing the end portions between second pair of holding tools that holds the end portions with respect to a second direction perpendicular to the first direction;

wherein the step of placing the end portions between the first pair of the holding tools is performed before the step of placing the end portions between the second pair of holding tools, and the step of placing the end portions between the second pair of holding tools is performed by moving the second pair of holding tools relative to the end portions held by the first pair of holding tools.