CA2358603A1

CA2358603A1 - Method and apparatus for installing multiple continuous strand conductor sections onto the stator frame of a polyphase dynamoelectric machine

Info

Publication number: CA2358603A1
Application number: CA 2358603
Authority: CA
Inventors: Martin Houle; Eric Carbonneau; Andre Langlois
Original assignee: Technologies M4 Inc
Current assignee: Individual
Priority date: 2001-10-10
Filing date: 2001-10-10
Publication date: 2002-10-26

Abstract

A method and apparatus for installing multiple continuous strand conductor sections onto the stator frame of a polyphase dynamoelectric machine is described herein. The method involves the positioning of the segments of pre-wound rectangular wires onto an assembly frame that is generally flat and, once the segments are mounted thereon, the resulting flat stator windings are transferred to a cylindrical stator armature.

Description

TITLE OF THE INVENTION
[0001] Method and Apparatus for Installing Multiple Continuous Strand Conductor Sections Onto the Stator Frame of a Polyphase Dynamoelectric Machine FIELD OF THE INVENTION

[0002] The invention relates to polyphase dynamoelectric machines. In particular, the invention relates to a method and apparatus for installing multiple conductor sections onto a stator frame, whereby the conductor sections for a given phase are wound from a continuous strand of conductive wire.
BACKGROUND OF THE INVENTION

[0003] Known in the art, there is U.S. Pat. No. 5,714,824 granted on February 3~d, 1998 to the Couture et al.. In this patent, there is disclosed a stator for a dynamoelectric machine and a method for mounting at least one stator winding onto a circular shaped stator frame. The stator frame is provided with a series of parallel elongate slots adapted for receiving respectively a series of conductor sections. Each conductor section is essentially a rectangular shaped coil fabricated from a conductive wire having a rectangular cross section.
Each coil has two sides and two heads which serve to interconnect the sides, the heads being shorter in length than the sides. Typically, three windings make up each coil. Additionally, the ends of the piece of conductive wire used to fabricate the coil extend beyond the coil.

[0004] The coil sides fit into two of the parallel elongate slots of the stator frame. Depending on the characteristics of the stator, a number of parallel slots are located between the two parallel elongate slots in question. The conductor section is inserted in the parallel elongate slots such that the first of the two coil sides rests at the bottom of the parallel elongate slot while the second of the two coil sides rests on the coil side of another conductor section. Given that one or more of the parallel slots are located between the two parallel elongate slots, and that the edges of two conductor sections are inserted into each slot, one on top of the other, the coils of the conductor sections are necessarily interleaved.
To facilitate the interleaving and maintain sufficient distance between conductor sections necessary to avoid short circuit, the two heads of each coil are adequately shaped. The shape of the heads is substantially U-shaped when viewed from above and substantially S-shaped when viewed from the side.

[0005] One drawback of the above cited prior art is that each conductor section is fabricated individually from a continuous strand of wire, requiring the conductor sections for a given phase to be attached together using solder or other electrical interconnection technique once all the conductor sections have been mounted on the stator frame.
OBJECT OF THE INVENTION

[0006] It is an objective of the present invention to reduce or eliminate the need for interconnecting conductor sections by fabricating two or more conductor sections from a continuous strand of conductive wire and providing a method of interleaving such multiple conductor sections so they may be assembled onto a stator frame.
BRIEF DESCRIPTION OF THE DRAWINGS
In the appended drawings:

[0007] Figure 1 is a top plan view of a stator assembly frame and a partially mounted first continuous strand conductor segment according to an embodiment of the present invention;

[0008) Figure 2 is a top plan view of a stator assembly frame similar to Figure 1 illustrating partially mounted first and second continuous strand conductor segments;

[0009] Figure 3 is a top plan view of a stator assembly frame similar to Figure 1 illustrating partially mounted first, second and third continuous strand conductor segments;

[0010] Figure 4 is a top plan view of a stator assembly frame similar to Figure 1 illustrating partially mounted first, second, third and fourth continuous strand conductor segments;

[0011] Figure 5 is a top plan view of a stator assembly frame similar to Figure 1 illustrating partially mounted first, second, third, fourth and fifth continuous strand conductor segments;

[0012] Figure 6 is a top plan view of a stator assembly frame similar to Figure 1 illustrating partially mounted first, second, third, fourth, fifth and sixth continuous strand conductor segments;

[0013] Figure 7 is a top plan view of a stator assembly frame similar to Figure 1 illustrating partially mounted first, second, third, fourth, fifth and sixth continuous strand conductor segments, wherein the first conductor segment has been manipulated such that the second coil of the first conductor segment is on the assembly frame;

[0014] Figure 8 is a top plan view of a stator assembly frame similar to Figure 7 illustrating partially mounted first, second, third, fourth, fifth and sixth continuous strand conductor segments, wherein the first and second conductor segments have been manipulated such that the second coils of the first and second conductor segments are on the assembly frame;

[0015] Figure 9 is a top plan view of a stator assembly frame similar to Figure 7 illustrating partially mounted first, second, third, fourth, fifth and sixth continuous strand conductor segments, wherein the first, second and third conductor segments have been manipulated such that the second coils of the first, second and third conductor segments are on the assembly frame;

[0016] Figure 10 is a top plan view of a stator assembly frame similar to Figure 7 illustrating partially mounted first, second, third, fourth, fifth and sixth continuous strand conductor segments, wherein the first, second, third and fourth conductor segments have been manipulated such that the second coils of the first, second, third and fourth conductor segments are on the assembly frame;

[0017] Figure 11 is a top plan view of a stator assembly frame similar to Figure 7 illustrating partially mounted first, second, third, fourth, fifth and sixth continuous strand conductor segments, wherein the first, second, third, fourth and fifth conductor segments have been manipulated such that the second coils of the first, second, third, fourth and fifth conductor segments are on the assembly frame;

[0018] Figure 12 is a top plan view of a stator assembly frame similar to Figure 7 illustrating partially mounted first, second, third, fourth, fifth and sixth continuous strand conductor segments, wherein the first, second, third, fourth, fifth and sixth conductor segments have been manipulated such that the second coils of the first, second, third, fourth, fifth and sixth conductor segments are on the assembly frame;

[0019] Figure 13 is top plan view similar to Figure 6, where the stator assembly frame has been removed to show the other conductor segments;

[0020] Figure 14 is a sectional side elevation view taken along line 14-14 in Figure 13.

[0021] Figure 15 is a sectional side elevational view showing the insertion of the coils onto a cylindrical stator; and [0022] Figure 16 is a sectional side elevational view showing an alternative method for the insertion of the coils onto a cylindrical stator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0023] Referring now to the appended Figures, a preferred embodiment of the method in accordance with the present invention will be described.

[0024] Figure 1 shows a first continuous strand conductor segment 20 provided with a plurality of coils (only two shown, referred to as 20a and 20b).
The first phase conductor 20 is fabricated from a wire 21 having a rectangular cross section. The wire 21 is fabricated from a conductive material, preferably copper, coated with a non-conductive finish. It will be apparent to one of ordinary skill in the art that any other conductive material with suitable electrical and physical characteristics could be used for the wire.

[0025] Of course, a rectangular stranded conductor wire (not shown) could also be used.

[0026] One phase conductor is required for each phase of the polyphase dynamoelectric machine. In the three phase configuration, as described in the present preferred embodiment, each phase conductor is fabricated from two (2) continuous strand conductor segments similar to segment 20. As will be described hereinbelow, following the assembly of the continuous strand conductor segments onto a cylindrical stator frame, the two (2) conductor segments for a given phase are joined together, preferably by ultrasonic welding (in series or parallel depending on the implementation).

[0027] In the preferred embodiment described herein, each continuous strand conductor segment is comprised of seven (7) conductor coils as in, each conductor coil being comprised of three (3) windings of the conductor wire.
The use of a wire 21 with a rectangular cross section minimises the presence of air gaps between the windings increasing the efficiency of the dynamoelectric machine.

[0028] Each conductor coil, for example coil 20a, is comprised of a pair of connecting heads 22 and 24. Each connecting head 22, 24 is shaped such that it is generally U-shaped when viewed from above and generally S-shaped when viewed from the side. The shaping of the connecting heads 22, 24 allows successive conductor coils of different phases to be interleaved while maintaining sufficient distance to avoid short circuit. Additionally, the shaping of the connecting heads 22, 24 maintains the planes defined by the top and bottom surface of the rectangular wire 21 parallel.

[0029] Referring now to Figures 1 through 12, the assembly of a three phase stator comprised of fourteen (14) coils per phase will be disclosed, although it will be understood by one of ordinary skill in the art that the assembly method could be used to assemble a variety of stators for polyphase dynamoelectric machines with varying number of phases and stator coils.

[0030) An assembly frame 26 comprised of forty-five (45) parallel elongate slots 28. The open ends of the slots 18 are preferably wider than the closed ends to facilitate placing of conductor coils therein (see Figure 15, for example).
Additionally, the width of the slots 28 should be such that a conductor coil fits snugly therein. Finally, the placement of the slots 28 in relation to one another should be equal to 1/3 of the width of the coils.

[0031] Referring now to Figure 1, the first coil 20a of the first segment 20 is placed on the assembly frame 26 with the lower edge of the first coil 20 resting on the bottom of the first and fourth slots.

[0032] Referring to Figure 2, the second coil 20b and subsequent coils of the first conductor segment 20 are deflected towards the front of the assembly frame 26 and slightly upwards (see arrow 30) to facilitate placement of the first coil 32a of the second conductor segment 32. The first coil 32a of the second conductor segment 32 is then placed on the assembly frame 26 with the lower edges of the first coil 32a resting on the bottom surface of the second and fifth slots.

[0033] The shape of the connecting heads 22, 24 of the first coil 20a of the first conductor segment 20 and the first coil 32a of the second conductor segment 32 are such that the first conductor segment 20 and the second conductor segment 32 are not in contact when ultimately mounted to a cylindrical stator as will be described hereinbelow. Additionally, the second coil 32b of the second conductor segment 32 is placed below the second coil 20b of the first conductor segment 20.

[0034] Referring now to Figure 3, continuing in a similar fashion, the second coils 20b and 32b are deflected towards the front of the assembly frame 26 (see arrows 34 and 36) to facilitate placement of the first coil 38a of the third conductor segment 38. The first coil 38a of the third conductor segment 38 is placed on the assembly frame 26 with the lower edges resting on the bottom surfaces of the third and sixth slots.

[0035] Additionally, the second coil 38b of the third conductor segment 38 is placed below the second coil 20a and the second 32a.

[0036] Referring now to Figure 4, continuing in a similar fashion, the second coils 20b, 32b and 38b are deflected towards the front of the assembly frame (see arrows 20, 42 and 44) to facilitate placement of the first coil 46a of the fourth conductor segment 46. The first coil 46a of the fourth conductor segment 46 is placed on the assembly frame 26 with the lower edges respectively resting on the coil 20a, in the third slot, and into the seventh slot such that it rests on the bottom of the slot. Additionally, the second coil 46b of the forth conductor segment 46 is placed below the second coil 20b, the second coil 32b and the second coil 38b.
It is to be noted that the second coil 46b is deflected towards the rear of the assembly frame 26 (see arrow 48).

[0037] Referring now to Figures 5 and 6, a similar procedure is used for placing the first coil 50a and the first coil 52a of respectively, the fifth conductor segment 50 and the sixth conductor segment 52 onto the assembly frame 26.

(0038] Referring now to Figure 7, interconnection wire 54, integral with and between the first coil 20a and the second coil 20b of the first conductor segment 20 is bent such that the upper edge of the second coil 20b rests upon the lower edge of the first coil 46b of the forth conductor segment 46. The length of interconnection wire 54 having been selected such that introduction of a bend into interconnection wire 54 does not bring it into contact with any of the connecting heads (for example 22 and 24). The third coil 20c of the first conductor segment 20 is placed below the second coil 32b, the second coil 38b, the second coil 46b, the second coil 50b and the second coil 52b.

(0039] Referring now to Figures 8 through 12 a similar procedure is used for placing the second coil 32b, the second coil 38b, the second coil 46b, the second coil 50b and the second coil 52b onto the assembly frame 26.

[0040] This procedure is then repeated with the third conductor coils 20c, 32c, 38c, 46c, 50c and 52c, continuing until the seventh coil of the sixth conductor segment 52 has been placed on the assembly frame 26.

[0041] Figures 13 and 14 illustrate the position of the coils that are not yet installed onto the assembly frame 26. These coils may be mounted to a post 54 to prevent them from becoming tangled.

[0042] Referring now to Figure 15, a first method to transfer the assembled conductor segments from the assembly frame 26 to a cylindrical stator frame 56 will be described.

[0043] Following installation of all coils of all conductor segments on the assembly frame 26, the lower edge of the first coil 20a of the first conductor segment 20 is placed in an initial slot 58 of the stator frame 56.

[0044] The stator frame 56 is then rotated 1/42 of a turn clockwise (see arrow 60) such that second slot 62 of the stator frame 56 is positioned over the lower edge of the first coil 32a of the second conductive segment 32 which is then inserted in slot 62 via a lifting action (see arrow 64).

[0045] The stator frame 56 is rotated another 1/42 of a turn clockwise such that third slot 66 of the stator frame 56 is positioned over the lower edge of the first coil 38a of the third conductive segment 38 which is then inserted in slot 66.

[0046] This procedure is continued for all lower edges of all subsequent coils until the seven (7) coils of the six (6) conductor segments have been inserted into corresponding slots on the stator frame 56. The upper edges of the final coils of the fourth, fifth and sixth conductor segments rest in slots 58, 62 and 66 upon the lower edge of, respectively, the first coil 20a of the first conductor segment 20, the first coil 32a of the second conductor segment 32 and the first coil 38a of the third conductor segment 38.

[0047] Referring now to Figure 16 an alternative method to transfer the assembled conductor segments from the assembly frame 26 to a cylindrical stator frame 56 will be described. Again, the stator frame 56 is provided with a series of forty-two (42) elongated parallel slots as in 58 adapted for receiving the conductor coils.

[0048] Following installation of all coils of all conductor segments on the assembly frame 26, the stator frame 56 is aligned with the center of the assembly frame 26. The coils are then removed from the assembly frame 26 and inserted in the slots 58 (see arrows 68).

[0049] It is to be noted that, depending on the configuration of the stator of the electric machine to be constructed, the number, order and size of each of the conductor segments would vary without departing from the present invention.

[0050] Although the present invention has been described hereinabove by way of preferred embodiments thereof, it can be modified, without departing from the spirit and nature of the subject invention as defined in the appended claims.

Claims

What is claimed is:

1. A method for mounting N interleaved conductor segments of a stator winding onto a circular shaped stator frame of a dynamoelectric machine generally as shown and described herein.