Method of manufacturing stator for electric motor

• US 7,293,342 B2
• Filed: 06/14/2005
• Issued: 11/13/2007
• Est. Priority Date: 02/28/2002
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Kato, Mitsuru
• Primary Examiner(s): TRINH, MINH N
• Application Number:
  US11/151,226
• Publication Number:
  US 20050229381A1
• Time in Patent Office: 882 Days
• Field of Search: 29596-598, 29732-735, 219/137.R, 219/85.14, 219/125.11, 310/201, 310234-235
• 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 3/505 for large machine windings, e.g. bar windings H02K3/51 takes precedence
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/53143 Motor or generator

Abstract

A method of manufacturing a rotary electric machine stator includes inserting straight portions of conductor segments into a plurality of slots of a stator core. The conductor segments are then bent so that connection ends of the conductor segments that are disposed adjacent to each other in a radial direction can incline in opposite circumferential directions to cross one another. Pairs of the connection ends crossing each other are then welded.

Claims

1. A method of manufacturing a rotary electric machine stator comprising steps of:

inserting straight portions of conductor segments into each one of a plurality of circumferentially aligned slots of a stator core in a plurality of radially aligned layers;

bending at least a portion of the conductor segments in a first group that project from a first layer of the radially aligned layers of the slots to incline in one circumferential direction;

bending at least a portion of the conductor segments in a second group that project from a second layer adjacent to the first layer of the slots to incline in another circumferential direction so that each extreme end of the conductor segments in the first group crosses one extreme end of the conductor segments in the second group at an angle much greater than 0 degrees; and

welding the extreme ends crossing each other to form connection ends, wherein

the welding comprises bringing one of a pair of electrodes in face-contact with intermediate portions of the conductor segments between one of the extreme ends and the stator core, and

bringing the other electrode of the pair of electrodes near the extreme ends so as to cause an arc discharge at the extreme ends.

2. The method as claimed in claim 1, wherein the steps of bending comprise a step of attaching a bending tool to a side surface of the conductor segments and a step of turning the bending tool about a position near one of the slots.

3. The method as claimed in claim 1, wherein the bending steps comprise inclining the first and second of the conductor segments to cross one another at the intermediate portions.

4. The method as claimed in claim 3, wherein the one of the pair of electrodes is formed to have a triangular cross-section having one side in face-contact with one of the intermediate portions.

5. The method as claimed in claim 1, wherein bending the first and second conductor segments joins the connection ends so that they contact each other at side surfaces thereof.

6. A method of manufacturing a rotary electric machine stator comprising the steps of:

inserting straight portions of a plurality of U-shaped conductor segments into a plurality of slots of a stator core from a first end of the stator core in a plurality of radial layers in each slot so that the straight portions respectively project from the slots on a second end of the stator core;

bending the straight portions so that each of the conductor segments that projects from a first layer group of the radially aligned layers inclines in one circumferential direction, and each of the conductor segments that projects from a second layer group of the radially aligned layers adjacent to the first layer group inclines in an opposite circumferential direction, so that the conductor segments inclined in the one circumferential direction and the conductor segments inclined in the opposite circumferential direction cross each other at extreme ends and at intermediate portions between the extreme ends and the stator core; and

welding together the extreme ends that cross each other to form connection ends, wherein

the welding comprises bringing one of a pair of electrodes in face-contact with the intermediate portions, and

bringing the other of the pair of electrodes near the extreme ends of the conductor segments so as to cause an arc discharge at the extreme ends.

7. The method as claimed in claim 6, wherein the bending steps comprise attaching a bending tool to a side surface of the conductor segments and turning the bending tool about a position near one of the slots.

8. The method as claimed in claim 6, wherein the bending step comprises bending the straight portions so that the extreme ends of the conductor segments inclined in one circumferential direction and the conductor segments inclined in the opposite circumferential direction cross each other at an angle much greater than 0 degrees.