Stator manufacturing method

Patent metadata

Field	Value
Publication number	US-11196313-B2
Application number	US-201916516678-A
Country	US
Kind code	B2
Filing date	Jul 19, 2019
Priority date	Sep 20, 2018
Publication date	Dec 7, 2021
Grant date	Dec 7, 2021

Abstract

Provided is a stator manufacturing method including: inserting a plurality of segment coils into a plurality of slots formed in a stator core; bending arms of the segment coils that protrude from the stator core, in a circumferential direction of the stator core; before or after bending the segment coils in the circumferential direction, directing parallel to each other leading end portions of the segment coils that are adjacent to each other in a radial direction of the stator core; and welding together the leading end portions of the segment coils with the leading end portions directed parallel to each other.

First claim

What is claimed is:

1. A stator manufacturing method comprising:
inserting a plurality of segment coils into a plurality of slots formed in a stator core;
bending arms of the segment coils that protrude from the stator core, in a circumferential direction of the stator core;
before or after bending the segment coils in the circumferential direction, directing parallel to each other leading end portions of the segment coils that are adjacent to each other in a radial direction of the stator core; and
welding together the leading end portions of the segment coils with the leading end portions directed parallel to each other,
wherein, after the arms of the segment coils are bent in the circumferential direction of the stator core, the leading end portions of the adjacent segment coils are directed parallel to each other by grasping the leading end portion of one of the adjacent segment coils and twisting the grasped leading end portion so as to turn around a root portion of the leading end portion, and
wherein the root portion is an end portion of a region coated with the insulating film.

2. The stator manufacturing method according to claim 1 , wherein:
peripheral surfaces of the segment coils are coated with an insulating film; and
the insulating films on the leading end portions of the segment coils are peeled off before the arms of the segment coils are bent in the circumferential direction of the stator core.

3. The stator manufacturing method according to claim 1 , wherein the leading end portion is bent to an angle of 2-5 degrees.

4. A stator manufacturing method comprising:
inserting a plurality of segment coils into a plurality of slots formed in a stator core;
bending arms of the segment coils that protrude from the stator core, in a circumferential direction of the stator core;
before or after bending the segment coils in the circumferential direction, directing parallel to each other leading end portions of the segment coils that are adjacent to each other in a radial direction of the stator core; and
welding together the leading end portions of the segment coils with the leading end portions directed parallel to each other,
wherein, before the arms of the segment coils are bent in the circumferential direction of the stator core, the leading end portion of one of the adjacent segment coils is sandwiched between a pair of positive mold and negative mold that have a bend of a predetermined angle and bent with respect to a root portion of the leading end portion at the predetermined angle, and after the arms of the segment coils are tilted in the circumferential direction of the stator core, the leading end portions of the adjacent segment coils are directed parallel to each other.

5. The stator manufacturing method according to claim 4 , wherein:
peripheral surfaces of the segment coils are coated with an insulating film;
the insulating films on the leading end portions of the segment coils are peeled off before the arms of the segment coils are bent in the circumferential direction of the stator core; and
the root portion is an end portion of a region coated with the insulating film.

Assignees

• Toyota Motor Co Ltd
• Denso Corp

Inventors

• Hirao Yasuyuki
• Mizushima Daisuke
• Takeda Hiroaki
• Yasuda Sho

Classifications

• H02K15/35 Primary

  Form-wound windings · CPC title

• H02K15/24

  Shaping or compacting winding heads (H02K15/0428, H02K15/28, H02K15/36 take precedence) · CPC title

• H02K15/33

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

• H02K15/085 Primary

  by laying conductors into slotted stators · CPC title

• H02K3/12 Primary

  arranged in slots · CPC title