Method of manufacturing stator for electric motor
First Claim
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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, whereinthe 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, andbringing the other electrode of the pair of electrodes near the extreme ends so as to cause an arc discharge at the extreme ends.
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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.
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Citations
8 Claims
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1. A method of manufacturing a rotary electric machine stator comprising steps of:
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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. - View Dependent Claims (2, 3, 4, 5)
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6. A method of manufacturing a rotary electric machine stator comprising the steps of:
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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. - View Dependent Claims (7, 8)
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Specification