Method of manufacturing a stator of a motor

Patent metadata

Field	Value
Publication number	US-11146153-B2
Application number	US-201916418326-A
Country	US
Kind code	B2
Filing date	May 21, 2019
Priority date	May 30, 2018
Publication date	Oct 12, 2021
Grant date	Oct 12, 2021

Abstract

An arm of a coil segment having an approximate U shape is placed in a slot of a stator core, and a portion protruding from the slot is bent in a circumferential direction. An arm is bent in a direction of an arrow A, and another arm positioned at an inner side in the radial direction in relation to this arm is bent in a direction of an arrow B. The arm positioned at the outer side has at least a part of a bending inner side surface of a bent portion hardened by pressurization.

First claim

The invention claimed is:

1. A method of manufacturing a stator of a motor, comprising:
forming a coil segment by bending a flat type conductive wiring in an approximate U shape with two arms;
inserting the coil segment into a slot, of a stator core having teeth arranged in a circumferential direction, between adjacent teeth, wherein the arms of the coil segments are placed to form a radial direction line arranged in a radial direction and to form a circumferential direction line arranged in the circumferential direction;
forming a coil end portion by bending the arm of the coil segment in the circumferential direction, wherein arms belonging to the same circumferential direction line are bent in a first direction and arms belonging to a circumferential direction line adjacent to this circumferential direction line are bent in a second direction which is opposite the first direction; and
welding together tips of corresponding arms, wherein
in the forming the coil segment, at least a part of a bending inner side surface, of a portion which is bent in the forming the coil end portion, of the arms belonging to at least one circumferential direction line is pressurized and hardened.

2. The method of manufacturing the stator of the motor according to claim 1 , wherein
in the forming the coil segment, a portion of the bending inner side surface of the arm at an outer side in the radial direction is hardened.

3. The method of manufacturing the stator of the motor according to claim 1 , wherein
in the forming the coil end portion, a circumferential direction line pair is formed by two adjacent circumferential direction lines, and the arms are bent in the circumferential direction in an order from a circumferential direction line pair positioned at an outer side or at an inner side in the radial direction, and
the arm which is pressurized and hardened in the forming the coil segment is an arm belonging to a circumferential direction line positioned at an outer side in the radial direction, of the circumferential direction lines forming the circumferential direction line pair.

4. The method of manufacturing the stator of the motor according to claim 1 , wherein
in the forming the coil end portion, a sectioning wall which sections the circumferential direction lines every two lines is placed between the circumferential direction lines, and the arm is bent in the circumferential direction, and
the arm which is pressurized and hardened in the forming the coil segment is an arm belonging to a circumferential direction line positioned at an outer side in the radial direction, of the two sectioned circumferential direction lines.

5. The method of manufacturing the stator of the motor according to claim 1 , wherein
in the forming the coil segment, a tip of the arm which is welded later is formed into a predetermined shape by pressurization.

Assignees

• Toyota Motor Co Ltd

Inventors

• Takanezawa Yu
• Mizushima Daisuke
• Takagi Rikuto

Classifications

• H02K1/146 Primary

  consisting of a generally annular yoke with salient poles · CPC title

• H02K15/33 Primary

  Connecting winding sections; Forming leads; Connecting leads to terminals · CPC title

• H02K15/36 Primary

  Processes or apparatus for simultaneously twisting two or more open ends of hairpins after their insertion into the machine (for simultaneously twisting two or more hairpins prior to mounting into the machine H02K15/0428) · CPC title

• Y10T29/53143

  Motor or generator · CPC title

• Y10T29/49009

  Dynamoelectric machine · CPC title