Method for assembly of an automotive alternator stator assembly with rectangular continuous wire
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1. A method of forming a stator core assembly for an electric machine comprising:
- providing a stator core having a plurality of radially extending slots;
forming a wire pack having a plurality of continuous electrical wires, the wire pack being flat;
shaping the flat wire pack into a hollow cylindrical shape; and
engaging the hollow cylindrically shaped flat wire pack with the stator core such that the continuous electrical wires are interlaced within the slots of the stator core, wherein engaging the flat wire pack with the stator core includes one of radially expanding and compressing the hollow cylindrical shape of the flat wire pack radially into the slots of the stator core.
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Abstract
A method of forming a stator core assembly for an electric machine includes providing a stator core having a plurality of radially extending slots, forming a flat wire pack having a plurality of continuous electrical wires, shaping the flat wire pack into a substantially cylindrical shape, and engaging the substantially cylindrically shaped flat wire pack with the stator core such that the continuous electrical wires are interlaced within the slots of the stator core.
32 Citations
25 Claims
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1. A method of forming a stator core assembly for an electric machine comprising:
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providing a stator core having a plurality of radially extending slots; forming a wire pack having a plurality of continuous electrical wires, the wire pack being flat; shaping the flat wire pack into a hollow cylindrical shape; and engaging the hollow cylindrically shaped flat wire pack with the stator core such that the continuous electrical wires are interlaced within the slots of the stator core, wherein engaging the flat wire pack with the stator core includes one of radially expanding and compressing the hollow cylindrical shape of the flat wire pack radially into the slots of the stator core. - View Dependent Claims (2, 3)
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4. A method of forming a stator core assembly for an electric machine comprising:
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providing a stator core having a plurality of radially extending slots; providing a plurality of spools of continuous electrical wire; rotatably mounting the spools of continuous electrical wire to a rotating structure in a generally circular pattern wherein the spools are equally circumferentially spaced with respect to one another about a central axis; providing first and second springs spaced from one another at a distance from the spools of wire, each of the springs being rotatable about an axis extending longitudinally through the springs, the axis of each of the springs being parallel to the central axis; attaching ends of the electrical wire from each of the spools to consecutive coils of the first spring; rotating the spools about the central axis such that the electrical wires are wrapped around consecutive coils of the second spring; rotating the springs such that the electrical wires are carried along the springs away from the spools of wire; rotating the spools and the springs simultaneously and continuously such that the wires are wrapped alternately between consecutive loops of the first and second springs as the wires are carried along the springs, thereby forming a flat wire pack of interlaced continuous electrical wires; shaping the flat wire pack into a substantially cylindrical shape; and engaging the substantially cylindrically shaped flat wire pack with the stator core such that the continuous electrical wires are interlaced within the slots of the stator core, wherein engaging the flat wire pack with the stator core includes one of expanding and compressing the flat wire pack radially into the slots of the stator core. - View Dependent Claims (5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method of forming a stator core assembly for an electric machine comprising:
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providing a stator core having a plurality of radially extending slots; providing a plurality of spools of continuous electrical wire; rotatably mounting the spools of continuous electrical wire to a rotating structure in a generally circular pattern wherein the spools are equally circumferentially spaced with respect to one another about a central axis; providing first and second springs spaced from one another at a distance from the spools of wire, each of the springs being rotatable about an axis extending longitudinally through the springs, the axis of each of the springs being parallel to the central axis; attaching ends of the electrical wire from each of the spools to consecutive coils of the first spring; rotating the spools about the central axis such that the electrical wires are wrapped around consecutive coils of the second spring; rotating the springs such that the electrical wires are carried along the springs away from the spools of wire; rotating the spools and the springs simultaneously and continuously such that the wires are wrapped alternately between consecutive loops of the first and second springs as the wires are carried along the springs, thereby forming a flat wire pack of interlaced continuous electrical wires; shaping the flat wire pack into a substantially cylindrical shape; and engaging the substantially cylindrically shaped flat wire pack with the stator core such that the continuous electrical wires are interlaced within the slots of the stator core. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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Specification