Automotive alternator stator assembly with rectangular continuous wire

• US 6,826,823 B2
• Filed: 01/29/2004
• Issued: 12/07/2004
• Est. Priority Date: 01/24/2002
• Status: Expired due to Fees

• Current Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Original Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Inventors: Neet, Kirk E.
• Primary Examiner(s): NGUYEN, TRAN N
• Application Number:
  US10/767,022
• Publication Number:
  US 20040183389A1
• Time in Patent Office: 313 Days
• Field of Search: 295/96--98, 296/05--09, 297/32, 297/34, 297/39, 310/179-180, 310/184, 310/207, 310/208
• US Class Current: 29/596
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49011 Commutator or slip ring assembly
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49078 Laminated

Abstract

A method of forming a stator core assembly for an electric machine, for example, for an automotive alternator, which presents a rotating, alternating polarity magnetic field, the stator core assembly having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to the inside diameter but terminating short of the outside diameter, the core further defining a lead side and an opposite non-lead side. The method includes providing at least two electrical conductors designated as conductor A and conductor B and interlacing the conductors into the winding slots such that the conductors.

Claims

1. A method of forming a stator core assembly for an alternator having a rotor assembly which presents a rotating, alternating polarity magnetic field, the stator core assembly having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to the inside diameter but terminating short of the outside diameter, the core further defining a lead side and an opposite non-lead side, the method comprising the steps of:

a) providing at least two electrical conductors designated as conductor A and conductor B,

b) winding the conductors into the winding slots where;

n=number of phases of the stator core assembly,

m=number of the winding slots in the stator core, with the winding slots numbered 1 through m,

L=number of layers of the conductors A and B in the winding slots, wherein a pair of the conductors A and B define one layer,

by the following winding steps;

c) the winding including placing a first lead of conductor A into the slot number 1 with the conductor A first lead extending from the stator lead side end,

d) the winding including placing a first lead of the conductor B into slot number n+1 with the conductor B first lead extending from the stator lead side end,

e) the winding including shifting the conductor A to the slot number n+1 thereby forming an end loop on the non-lead side end and lying in the slot number n+1 radially shifted inwardly from the conductor B, wherein the pair of the conductors A and B lying in the same slot define a layer L,

f) the winding including shifting the conductor A to the slot number 2n+1 thereby forming an end loop on the lead side,

g) the winding including shifting the conductor B to the slot number 2n+1 thereby forming an end loop on the non-lead side and lying in the slot number 2n+1 radially shifted inwardly from the conductor A,

h) repeating winding steps c) through g) for all the slots numbered through m+1−

n, thereby forming a first layer L,

i) repeating steps a) through d) for additional layers L, and

j) completing the winding by having the conductor A extending from the slot number m+1−

n on the lead side end thereby defining a conductor A second lead, and having the conductor B extending from the slot number 1 thereby defining a conductor B second lead.

2. A method of forming a stator core assembly for an alternator according to claim 1 wherein the conductors are of the type having a rectangular cross-sectional shape.

3. A method of forming a stator core assembly for an alternator according to claim 1 wherein the conductors are of the type having a square cross-sectional shape.

4. A method of forming a stator core assembly for an alternator according to claim 1 wherein the provided conductors have a width of a dimension to be closely received by the winding slots.

5. A method of forming a stator core assembly for an alternator according to claim 1 wherein the number of phases of the stator core assembly, n=3.

6. A method of forming a stator core assembly for an alternator according to claim 1 wherein the number of phases of the stator core assembly, n=6.

7. A method of forming a stator core assembly for an alternator according to claim 1 wherein the number of layers of the conductors A and B in the winding slots, L=3.

8. A method of forming a stator core assembly for an alternator according to claim 1 wherein the two conductors A and B are series connected.

9. A method of forming a stator core assembly for an alternator according to claim 1 wherein the two conductors A and B are parallel connected.

10. A method of forming a stator core assembly for an alternator according to claim 1 wherein the two conductors A and B are formed to a shape to be placed into the winding slots before being placed into the winding slots.

11. A method of forming a stator core assembly for an alternator according to claim 10 wherein the two conductors A and B are interleaved prior to the step of being placed into the winding slots.