Rectangular wire stator coil manufacturing method

Patent metadata

Field	Value
Publication number	US-9825513-B2
Application number	US-201415316564-A
Country	US
Kind code	B2
Filing date	Jun 9, 2014
Priority date	Jun 9, 2014
Publication date	Nov 21, 2017
Grant date	Nov 21, 2017

Abstract

A rectangular wire is wound on a stator core having a plurality of teeth and a plurality of slots. A plurality of rectangular wire elements is provided by cutting a rectangular wire into a predetermined length and bending into a substantial U-shape. A plurality of rectangular wire pieces configured to form a coil by connecting predetermined end portions of the rectangular wire elements is molded as a sub-assembly. Each of the plurality of the rectangular wire elements is inserted into a predetermined pair of the slots from a first end face of the stator core such that the respective end portions of the rectangular wire elements project from a second end face of the stator core. The rectangular wire pieces of the sub-assembly are fixed to the end portions of the rectangular wire elements, thereby manufacturing a stator coil having compact coil ends easily.

First claim

The invention claimed is:

1. A rectangular wire stator coil manufacturing method for winding a rectangular wire on a stator core, the stator core having a first end face, a second end face, a plurality of teeth extending between the first and second end faces, and a plurality of slots each of which is formed between adjacent teeth, the method comprising:
forming in advance a plurality of rectangular wire elements by cutting the rectangular wire to a predetermined length and bending into a substantial U-shape;
forming in advance a plurality of rectangular wire pieces configured to connect predetermined pairs of end portions of the rectangular wire elements as a sub-assembly;
inserting each of the rectangular wire elements into a predetermined pair of the slots of the stator core from the first end face and causing the end portions of the rectangular wire elements to project from the second end face;
fitting the sub-assembly to the second end face by fixing the rectangular wire pieces to the predetermined pairs of the end portions of the rectangular wire elements that project from the second end face;
forming a first group of the rectangular wire elements each of which has a bent portion bent radially inward along the first end face; and
forming a second group of the rectangular wire elements each of which has a bent portion bent radially outward along the first end face.

2. The rectangular wire stator coil manufacturing method according to claim 1 , further comprising:
disposing the first group of the rectangular wire elements on a radially inner side of the second group of the rectangular wire elements.

3. The rectangular wire stator coil manufacturing method according to claim 1 , further comprising:
forming each of the rectangular wire pieces to have a bent portion bent along the second end face.

4. The rectangular wire stator coil manufacturing method according to claim 1 , wherein fixing the rectangular wire pieces to the predetermined pairs of the end portions of the rectangular wire elements includes binding an end portion of a rectangular wire element and a tip end of a rectangular wire piece together by a binding member.

5. The rectangular wire stator coil manufacturing method according to claim 1 , further comprising:
forming the sub-assembly from the plurality of the rectangular wire pieces and a heat conductive resin that holds the plurality of the rectangular wire pieces in predetermined positions.

6. The rectangular wire stator coil manufacturing method according to claim 5 , further comprising:
forming the sub-assembly to have a coolant passage within a portion made of the heat conductive resin.

7. The rectangular wire stator coil manufacturing method according to claim 5 , further comprising:
forming the sub-assembly to have a heat radiation fin made of the heat conductive resin.

8. The rectangular wire stator coil manufacturing method according to claim 1 , further comprising:
forming both the end portions of the rectangular wire elements and tip ends of the rectangular wire pieces into a convergent shape toward a leading end.

9. The rectangular wire stator coil manufacturing method according to claim 1 , further comprising:
forming a cutout in one of an end portion of a rectangular wire element and a tip end of a rectangular wire piece to accept another of the end portion and the tip end.

10. A rectangular wire stator coil manufacturing method for winding a rectangular wire on a stator core, the stator core having a first end face, a second end face, a plurality of teeth extending between the first and second end faces, and a plurality of slots each of which is formed between adjacent teeth, the method comprising:
forming in advance a plurality of rectangular wire elements by cutting the rectangular wire to a predetermined length and bending into a substantial U-shape;
forming in advance a plurality of rectangular wire pieces configured to connect predetermined pairs of end portions of the rectangular wire elements as a sub-assembly;
inserting each of the rectangular wire elements into a predetermined pair of the slots of the stator core from the first end face and causing the end portions of the rectangular wire elements to project from the second end face; and
fitting the sub-assembly to the second end face by fixing the rectangular wire pieces to the predetermined pairs of the end portions of the rectangular wire elements that project from the second end face,
wherein fixing the rectangular wire pieces to the predetermined pairs of the end portions of the rectangular wire elements includes binding an end portion of a rectangular wire element and a tip end of a rectangular wire piece together by a binding member.

Assignees

• Nissan Motor

Inventors

• Sekikawa Takashi
• Nishimura Kimio
• Omata Masahiro
• Matsushita Yasushi
• Wu Min
• Ohshima Takumi
• Shibukawa Hiroaki
• Higaki Koji
• Ishiguro Kunitomo
• Yamane Yuhei

Classifications

• H02K15/064

  Windings consisting of separate segments · CPC title

• H02K15/0421

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

• H02K15/085 Primary

  by laying conductors into slotted stators · CPC title

• H02K3/12 Primary

  arranged in slots · CPC title

• H02K15/0081

  Electricity · mapped topic