Method for manufacturing a stator

Patent metadata

Field	Value
Publication number	US-11616426-B2
Application number	US-201917281538-A
Country	US
Kind code	B2
Filing date	Oct 9, 2019
Priority date	Oct 19, 2018
Publication date	Mar 28, 2023
Grant date	Mar 28, 2023

Abstract

A method and an apparatus are provided for manufacturing a stator with a plurality of hairpin conductors. For inserting the hairpin conductors (15, 15) into the slots (11) of a stator core (12) a stator core template (22) is provided. Hairpin conductors (15) are axially inserted into slots (21) of the stator core template (22) such that the hairpin conductor (15) is arranged at a first position (P1) within said slot (21). The hairpin conductor (15) is then moved within said slot (21) to a different position (P2). A complete nest (20) of hairpin conductors (15) formed within the stator core template (22) is then transferred to the stator core (12).

First claim

The invention claimed is:

1. A method for manufacturing a stator with a plurality of hairpin conductors arranged in slots of a stator core, comprising:
a. providing a stator core template having a number of radially and axially extending slots corresponding to the number of slots of the stator core, said slots of the stator core template having at least one of a circumferential width larger than the circumferential width of the slots of the stator core and a radial length larger than the radial length of the slots of the stator core;
b. inserting at least one hairpin conductor into at least one of said slots of the stator core template such that said hairpin conductor is arranged at a first position within said slot, wherein in said first position the hairpin conductor is arranged differently than in the intended position in the stator core;
c. moving said hairpin conductor within said slot of said a stator core template from said first position to a second position;
d. repeating the inserting and the moving for at least one additional hairpin conductor such as to form a first layer of a partial nest or a nest of hairpin conductors;
e. removing the partial nest or the nest of hairpin conductors from the stator core template before starting to insert the nest or the partial nest into the slots of the stator core; and
f. inserting the nest or the partial nest that has been completely removed from the stator core template into the slots of the stator core.

2. The method according to claim 1 , wherein in the moving, the hair pin conductor is radially moved within said slot of said stator core template such that it is arranged at a second position radially different from the first position.

3. The method according to claim 2 , wherein the second position is inwardly from the first position.

4. The method according to claim 1 , wherein the inserting, the moving, and the repeating of the providing and the inserting, are repeated in order to form at least one further layer of the partial nest or the nest of hairpin conductors.

5. The method according to claim 4 , wherein the first layer and the at least one further layer are axially removed jointly from the stator core template and axially inserted jointly into the stator core.

6. The method according to claim 1 , wherein at least some hairpin conductors are preformed and comprise a pair of leg portions joined together by a bridge portion and wherein a first leg portion is arranged in the stator core template in a first slot at a first radial distance and a second leg portion is arranged in the stator core template in a second slot at a second radial distance larger than the first radial distance.

7. The method according to claim 6 , wherein the second leg portion of at least some hairpin conductors is arranged in a slot of said stator core template such as to be adjacent a first leg portion of a hairpin conductor previously inserted into said slot.

8. The method according to claim 6 , further comprising:
arranging the second leg portion of an initial group of hairpin conductors in a slot of the stator core template neighboring a spacer element;
by means of said spacer element, keeping the second leg portion at or moving the second leg portion to a predefined radial distance equal to or larger than the second radial distance, thereby maintaining or creating a radial gap within the respective slot of the stator core template; and
inserting a first leg portion of a further hairpin conductor into the gap within the respective slot adjacent to said second leg portion.

9. The method according to claim 8 , further comprising removing the spacer element.

10. The method according to claim 8 , wherein the hairpin conductors of a subsequent group are inserted into slots of the stator core template and arranged with their second leg adjacent a first leg of another hairpin conductor of the initial group or of the subsequent group, and wherein the hairpin conductors of a final group are inserted into slots of the stator core template with first legs inserted into the gap maintained or created by said spacer.

11. The method according to claim 10 , wherein the hairpin conductors of the initial, subsequent and final group are inserted in a continuous circumferential sequence.

12. The method according to claim 8 , wherein a leg of at least one hairpin conductor of a different type is inserted.

13. The method according to claim 1 , wherein each hairpin conductor is at least one of axially inserted by means of a manipulator and moved by means of a pusher.

14. The method according to claim 1 , wherein for axially removing and for axially inserting the partial nest or the nest, a head portion of the partial nest or the nest is grasped with a gripper.

15. The method according to claim 14 , wherein, prior to axially inserting the partial nest or the nest, a guide is inserted between the legs of circumferentially neighboring hairpin conductors at a site axially distant from the head portion.

16. The method according to claim 15 , wherein the partial nest or the nest is only partially inserted by means of said gripper to an intermediate axial position and wherein the nest or the partial nest is inserted into a final axial position in the stator core by means of a separate presser.

17. The method according to claim 1 , wherein providing the stator core template comprises providing the stator core template having a body with a radial inner abutment face.

18. The method according to claim 1 , wherein providing the stator core template having a number of radially and axially extending slots comprises providing the stator core template wherein the slots of the stator core template are axially extending holes in a body of the stator core.

19. The method according to claim 1 , wherein providing the stator core template comprises providing the stator core template as a single body having a circular shape.

Assignees

• Atop Spa

Inventors

• Ponzio Massimo
• Corbinelli Rubino
• Nocciolini Daniele

Classifications

• H02K15/021

  Magnetic cores · CPC title

• H02K1/16

  Stator cores with slots for windings · CPC title

• H02K15/0421 Primary

  and consisting of single conductors, e.g. hairpins · CPC title

• H02K2213/03

  Machines characterised by numerical values, ranges, mathematical expressions or similar information · CPC title

• H02K15/064 Primary

  Windings consisting of separate segments · CPC title