Method for producing electrical machines

• US 7,194,794 B2
• Filed: 06/22/2004
• Issued: 03/27/2007
• Est. Priority Date: 06/30/2003
• Status: Active Grant

• Current Assignee: Seg Automotive Germany GMBH
• Original Assignee: Robert Bosch GmbH
• Inventors: Seidel, Maik, Blenkle, Lars, Bunzel, Mirko, Werthmann, Christian, Arendes, Dieter
• Primary Examiner(s): Tugbang; A. Dexter
• Assistant Examiner(s): PHAN, THIEM D
• Application Number:
  US10/874,033
• Publication Number:
  US 20040263018A1
• Time in Patent Office: 1,008 Days
• Field of Search: 295/96, 295/97, 295/98, 296/05, 296/06, 298/25, 310/201, 310/208, 310/214, 310/234
• US Class Current: 29/596
• CPC Class Codes: H02K 15/06 Embedding prefabricated windings in machines
• CPC Class Codes: H02K 3/48 in slots
• 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 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

An electrical machine has a base body provided with conductors fixed in grooves of the base body by a material which limits a groove slot at both sides, and the conductors in the grooves are deformed by a stamping punch introducible through the groove slot into the corresponding groove so that a conductor cross-section is adjusted to a groove cross-section in a region of the corresponding conductor.

Claims

1. A method of producing electrical machines, comprising the steps of providing a base body, wherein said base body is an armature of said electrical machine, said base body comprising a drum-shaped packet of metal sheets, wherein said metal sheets are made of soft-magnetic material, said base body having a periphery which limits a working air gap and has a plurality of grooves with an elongated cross-section and with a groove slot adapted to face the working air gap;

introducing at least one insulated electrical conductor in each of said grooves so that said at least one insulated electrical conductor extends over a length of the groove and is fixed in said grooves by a material of the base body which limits the groove slot at both sides; and

after insertion of the at least one insulated electrical conductor in the grooves of the base body, introducing a stamping punch into the open groove slot of the grooves and deforming the at least one insulated electrical conductor with the stamping punch over a whole groove length so that its conductor cross-section is adjusted to a groove cross-section in the region of the at least one insulated electrical conductor.

2. The method as defined in claim 1;

and further comprising inserting a plurality of the conductors into the grooves parallel to one another; and

adjusting a total conductor cross-section of all conductors of one groove by the stamping punch to a total groove cross-section.

3. The method as defined in claim 2;

and further comprising inserting two conductors which extend axially parallel to one another and are located radially over one another into the grooves, so that an upper one of the conductors is located in an open groove slot and partially extends above the grove; and

adjusting a conductor cross-section of the upper conductor by the stamping punch to a groove cross-section in a region of the corresponding conductor.

4. The method as defined in claim 1;

and further comprising after the stamping of the conductor of one groove, pressing and deforming a material of the base body at both sides of the groove slot in a further stamping step against the conductor for fixing the conductor in the groove, so that the groove slot is at least partially closed.

5. The method as defined in claim 4;

and further comprising moving back the stamping punch from the groove slot for deforming the at least one conductor of one groove, after the further stamping step for deforming the material on the groove slot.

6. The method as defined in claim 1;

and further comprising performing a stamping process on an element selected from the group consisting of the groove slot, the at least one conductor of one groove, and both, in steps from one groove to another groove.

7. The method as defined in claim 1;

and further comprising performing a stamping process on an element selected from the group consisting of a groove slot, at least one conductor of one groove, and both, simultaneously on oppositely located grooves of the base body.

8. The method as defined in claim 1;

and further comprising performing a stamping process on an element selected from the group consisting of a groove slot, at least one conductor of one groove, and both, simultaneously on all grooves of the base body.