Rotary electric machine stator having deformed teeth and a plurality of bosses to secure windings

• US 10,840,749 B2
• Filed: 02/12/2018
• Issued: 11/17/2020
• Est. Priority Date: 02/13/2017
• Status: Active Grant

• Current Assignee: Valeo Equipements Electriques Moteur (Valeo SE)
• Original Assignee: Valeo Equipements Electriques Moteur (Valeo SE)
• Inventors: Chaillou, Jimmy, Bilteryst, Pierre-Yves, Delianne, Henri, Margueritte, David, Jozefowiez, Eric, Perreaut, Sylvain, El-Ghazal, Mohamed
• Primary Examiner(s): Patel, Tulsidas C
• Assistant Examiner(s): Johnson, Rashad H
• Application Number:
  US15/894,299
• Publication Number:
  US 20180233969A1
• Time in Patent Office: 1,009 Days
• Field of Search: 310216049
• CPC Class Codes: H02K 1/165 Shape, form or location of the slots
• CPC Class Codes: H02K 15/0018 Applying slot closure means in the core; Manufacture of slot closure means
• CPC Class Codes: H02K 15/024 with slots
• CPC Class Codes: H02K 15/085 by laying conductors into slotted stators
• CPC Class Codes: H02K 15/10 Applying solid insulation to windings, stators or rotors
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/345 between conductor and core, e.g. slot insulation
• CPC Class Codes: H02K 3/493 magnetic

Abstract

A rotary electric machine stator (2) includes a stator body (20) and a stator winding (22) supported by the stator body (20), in which the stator body extends around an axis (X) while being delimited by an internal radial surface (3) and an external radial surface (4), said stator bodies having a plurality of teeth (6) formed respectively between two slots (5) arranged in said stator body from the internal radial surface and extending axially to receive at least one stator winding element (22).

The stator has at least one deformed tooth (6) which comprises, at its loose end (7) helping to define the internal radial surface, at least one protrusion (10) extending across an adjacent slot, said protrusion (10) being obtained by material deformation of said deformed tooth (6).

Claims

1. A rotary electric machine stator comprising:

a stator body; and

a stator winding supported by the stator body,

wherein the stator body is formed by a core of stacked laminations and extends around an axis while being delimited by an internal radial surface and an external radial surface,

said stator body having a plurality of teeth formed respectively between two slots arranged in said stator body from the internal radial surface and extending axially to receive at least one stator winding element, so that along the circumference of the rotary electric machine stator the latter has an alternation of slots and teeth,

wherein the plurality of teeth comprise at least one deformed tooth having, at a loose end helping to define the internal radial surface of the rotary electric machine stator, at least one protrusion extending across at least one adjacent slot, said protrusion being obtained by material deformation of said deformed tooth,

wherein said protrusion is formed by a bead resulting from displacement of material in the deformed tooth, from the external radial surface of the rotary electric machine stator towards the internal radial surface of the rotary electric machine stator, and

wherein two successive teeth of the plurality of teeth have protrusions arranged at different axial positions along the circumference of the rotary electric machine stator.

2. The rotary electric machine stator according to claim 1, wherein the loose end of the deformed tooth comprises the protrusion extending on either side of the tooth, across each directly adjacent slot of said deformed tooth.

3. The rotary electric machine stator according to claim 1, wherein the loose end of the deformed tooth has on the internal radial surface of the rotary electric machine stator a furrow forming a point-like or straight entry, centered in relation to the thickness of the tooth defined as the dimension between the two successive slots surrounding said tooth.

4. The rotary electric machine stator according to claim 1, wherein each tooth of the plurality of teeth is a deformed tooth which comprises at a loose end at least one protrusion obtained by radial deformation.

5. The rotary electric machine stator according to claim 1, further comprising at least one boss which is crushed on the external radial surface in the radial prolongation of the deformed tooth.

6. The core of laminations stacked axially over one another so as to form the stator body of the stator according to claim 5, wherein the at least one boss, projecting from the external wall of said core of laminations corresponding to the external radial surface of the stator body, is created.

7. The core of laminations according to claim 6, wherein the at least one boss extends axially over a defined number of laminations of the core of laminations.

8. Tools for obtaining the rotary electric machine stator according to claim 1 by deformation of the core of laminations stacked axially over one another to form the stator body, the tools comprising an internal tool brought into contact with the loose end of the teeth of at least one lamination of the core of laminations;

and an external tool brought into contact with the external wall of at least one lamination of the core of laminations, the external tool having a regular profile, configured to systematically lie on the circumference of the core of laminations and on at least one boss.

9. The tools according to claim 8, wherein the internal tool has at least one point, the internal tool being positioned so that this point is in contact with a loose end of a tooth of a lamination of the core of laminations.

10. A process for obtaining the stator according to claim 1, comprising:

inserting the stator winding elements into the slots arranged in the core of laminations; and

deforming material of the core of laminations by pressing at least one boss on the external wall of the core of laminations, via an external tool and an internal tool which move in relation to one another, while the stator winding elements are placed in their respective slots, so as to create a protrusion at an opposite end of the external wall of the core of laminations, across the slots.

11. The process according to claim 10, further comprising, as part of the deforming, positioning an internal tool against the loose end of the teeth, the internal tool also preventing the stator winding elements from passing outside the slots;

moving an external tool against the external wall of the core of laminations in the direction of the internal tool remaining fixed; and

bringing the tools together.

12. The process according to claim 10, further comprising applying an electric insulation member against the body of the stator, prior to inserting the stator winding element(s) into the stator body.

13. A rotary electric machine comprising at least one of the rotary electric machine stators according to claim 1.