Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
  • H02K1/12—Stationary parts of the magnetic circuit
  • H02K1/16—Stator cores with slots for windings
  • H02K1/165—Shape, form or location of the slots
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
  • H02K15/024—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with slots

Definitions

• PROCESS FOR MANUFACTURING A DYNAMO-ELECTRIC MACHINE STATOR AND SYSTEM FOR DEFORMATION OF DYNAMO-ELECTRIC MACHINE STATOR
• This invention is concerned with a process for manufacturing a dynamo- electric machine stator, and more particularly, to the step of "unfolding” or “closing” of lateral flaps of the polar bases of dynamo-electric machines stators.
• Said step of "unfolding” or “closing” which includes the aforementioned process of manufacturing a dynamo-electric machine stator is mainly carried out by physical deformation of the sides of the polar bases of the stator.
• the present invention further relates to the system for deformation of a dynamo-electric machine stator, and in particular, to a deformation system capable of perform the step of "unfolding” or “closing” lateral flaps of the polar bases of dynamo-electric machines stators.
• Dynamo-electric machines comprise machines capable of transforming electrical energy into mechanical energy (electric motor, for example) or mechanical energy into electrical energy (voltage generator, for example), and are fundamentally integrated by fixed inductive cores and movable inductive cores.
• the fixed inductive cores are disposed in the stator while the movable inductive cores are arranged in the rotor.
• a stator of a dynamo-electric machine is mainly composed of a metal frame and a plurality of coils (contouring electrical conductors arranged around an shaft), and the coils are arranged in alignment in relation to the metal frame.
• the metal frame defines radial shafts circumferentially spaced apart and circumferentially joined together by their upper ends (the lower ends being spaced from each other). These shafts ultimately define structures in which electrical conductors are wound, and the spaces between these shafts have the function to accommodate the volume formed by electrical conductors. In this sense, it is possible to note that each shaft and its respective coil comprise a fixed inductive core.
• a rotor of a dynamo-electric machine is mainly mounted within the stator, and due to this, the shafts of the metal frame of the stator have a length dimensioned to conform an empty central space, said space being intended to the reception of the rotor.
• stator and rotor of a dynamo-electric machine can be obtained from the junction of multiple metal blades of formats being equivalent to each other.
• An example of this embodiment can be seen in document US 2011/0127876, wherein it is illustrated and described that a single metal blade (raw material) when subjected to a stamping process may be used for the manufacturing of multiple blades of stator and multiple rotor blades. It is also emphasized that the rotor blades are manufactured from the raw material "waste" of the stator blades.
• the area of electrical conductors that constitute the stator coils comprises a feature capable of influencing the efficiency of the dynamo-electric machine (electric conductors of smaller area are more susceptible to the occurrence of Joule effect, as well as an intrinsic limitation on the nominal value of the electric current that these conductors support). Therefore, there is an interest that electrical conductors that form the stator coils exhibit the largest possible area.
• the shafts 11 , 12 of the stator blade has a final end defined by two lateral flaps 4, which ultimately define the size of "entry" of spaces 2 intended for the accommodation of electrical conductors that form the stator coils.
• the size of the "inputs" of spaces 2 for the accommodation of electrical conductors also includes a feature capable of influencing the efficiency of the dynamo- electric machine, wherein the higher are these dimensions, the greater the magnetic dispersion of the inductive core and consequently the greater the loss of yield of the dynamo- electric machine.
• the side flaps of the shafts can be manipulated during the process of manufacturing the stator, thereby allowing the "opening” and “closure” of the channel housing of the electrical conductors. More particularly, it is noted that the "opening” and “closure” of the channels occur by means of pivoting the side flaps of the. shafts.
• the main negative aspect related to the embodiment described in document PI 9702724-3 refers to the need of pivoting the side flaps of the shafts to close and above all, open the channels, since it is extremely complex to group multiple blades whose side flaps of the shafts are pivoted.
• the documents US 4176444 and US 4267719 both derived from a single priority, describes a method and a device for forming stators of electrical machines.
• the method in question provides a series of steps that, in general, define that the blades are first printed, and subsequently grouped, forming the metal frame of the stator. With the metal frame already formed, the side flaps of the shafts are subjected to deformation by pressure, and since all channels are opened, the housing of electrical conductors is made. Then, the channels are also closed by deformation by pressure, the method is deemed to be completed.
• the "opening" of the channels is performed in a puncture equipment, where each one of the channels is filled with a puncture tool, and each of the lower ends of the shafts is supported in a sort of deformation template.
• the movement (from inside outwards) of the puncture tool forces the side flaps of the shafts against the template, and this makes said side flaps to assume the shape of said template.
• the document US 6742238 describes, among other aspects, a means to perform the "closing" of the ends of the channels of the blades of the stator, comprising an equipment formed by a support structure and spheres capable of radial movement.
• the spheres are positioned at the "open” ends of the channels of the blades and pressed against them. This axial force imposed on the spheres is transmitted to "open" ends of the channels of the blades, performing their "closing".
• none of the processes, methods or tools described above is capable of providing or construct a stator made by blades whose "waste" can be used to obtain the rotor.
• Another objective of the present invention is that the step of closing channels for housing the electrical conductors to conform the ends of the substantially standardized polar bases.
• this step “final finishing”, or calibration step makes the opening of the stator, wherein the rotor is housed, to be homogeneous. Therefore, it is also one of the objectives of the present invention that this process be capable of deforming the stator blades so that their format be substantially equivalent to the initial shape and previous to the step of "opening" of channels.
• the process of manufacturing of the dynamo-electric machine stator comprises at least a step of stamping the blades of the stator, at least one step of grouping stator blades, at least one step of forming the inductive cores in the housing channels of electrical conductors and at least one step of closing the housing channels of electrical conductors.
• said step of closing the housing channels of electrical conductors comprises the deformation of the ends of the same polar basis of an shaft of the stator from rotating movement imposed by at least one roller capable be circumferentially moved clockwise and counterclockwise, of which at least one from the circumferential movements of the roller provides a displacement begun in the center of a polar base, and terminated at one of the ends in the same polar base, and at least one of the circumferential movements of the roller provides a displacement begun in stopping point of the circumferential movement previously performed, and finished at the other end of the same polar base.
• first circumferential movements of the roller are performed in a first sub-step belonging to the step of closing the housing channels of the electrical conductors and the second circumferential movements of the roller are performed in a second sub-step belonging to the step of closing the housing channels of the electrical conductors. Both movements of the rollers are performed in opposite clockwise directions.
• the briefly discussed process is preferably performed in the system of deformation of the dynamo-electric machine stator, which comprises multiple rollers concentrically arranged in at least one alignment structure and at least one cooperating shaft associated with said frame alignment.
• Such alignment structure is capable of performing rotational motion in clockwise and anti-clockwise directions.
• the alignment structure basically comprises a fundamentally annular body provided with fastening means able to retain the multiple rollers, and capable of performing rotating movement in clockwise and counterclockwise directions by driving at least one driving source (functionally associated with the shaft).
• this driving source may comprise an electric stepper motor, among other options.
• rollers are also capable of rotating movement by means of at least one driving source.
• the rollers comprise bodies with fundamentally cylindrical profile.
• said system provides a first alignment structure provided with multiple rollers and a in cooperated association with the shaft, and a second alignment structure provided with multiple rollers and in cooperated association with the same shaft, wherein alignment structures are interchangeable to each other.
• Figure 1 .1 illustrates, in schematic manner, a dynamo-electric machine stator with its housing channels of electrical conductors opened, according to the present invention
• Figure 1 .2 illustrates an enlarged detail taken from Figure 1 .1 ;
• Figure 2.1 illustrates in schematic manner a dynamo-electric machine stator with its housing channels of electrical conductors closed, according to present invention
• Figure 2.2 illustrates an enlarged detail taken from Figure 2.1 ;
• the figures 3.1 , 4.1 and 5.1 illustrate, in general, a dynamo-electric machine stator when subjected to the first sub-step of the step of closing the housing channels of electrical conductors, according to the present invention
• the figures 6.1 , 7.1 and 8.1 illustrate, in general, a dynamo-electric machine stator when subjected to the second sub-step of the step of closing the housing channels of electrical conductors, according to the present invention
• Figure 9 illustrates in exploded view and in a schematic manner, a preferred embodiment of the deformation system of dynamo-electric machine stator.
• the aforementioned step of closing of the housing channels of electrical conductors comprises deforming the ends of the same polar base of the shaft of the stator from rotating friction imposed by at least one roller capable to be circumferentially moved in clockwise and counterclockwise directions.
• One of these circumferential movements (clockwise or counterclockwise) of the roller provides a displacement initiated in the center of a polar base, and terminated at one of the ends of the same polar base.
• This circumferential movement is responsible for deformation of only one of the ends of the same polar base, making thus performing the partial closing of a housing channel of electrical conductors.
• the fundamental concept disclosed above refers to close all housing channels of electrical conductors of the stator at a single step provided with two movements which are subsequent and performed in opposite clockwise directions.
• the step of closing the housing channels of electrical conductors is preferably performed on two separate sub-steps, thereby involving a total of four circumferential movements the rollers.
• the first sub-step is responsible for closing twelve from the twenty-four housing channels of electrical conductors (or even deform the ends of twelve of the twenty-four polar bases) and the second sub-step responsible for closing the remaining twelve from the twenty-four housing channels of electrical conductors (or even deform the ends of another twelve of the twenty-four polar bases).
• the shafts of the stator 1 are purposefully referred with different indications 1 1 and 12, which are used interchangeably, as best illustrated in Figures 1.1 and 2.1.
• This differentiation is only symbolic and aims to facilitate the understanding of the preferred embodiment of said step of closing the housing channels (where the first sub-step changes only the ends 4 of the polar bases of the shafts 11 and the second step only changes the ends 4 of the polar bases of the shaft 12).
• the shafts 11 and 12 of the stator 1 are similar among them.
• Figures 3.1 , 3.2, 4.1 , 4.2, 5.1 and 5.2 illustrate - schematically - the first sub- step which includes the step of closing the housing channels of electrical conductors.
• rollers 5 after performing the circumferential clockwise movement D1 , already deform the right ends 4 of polar bases 4 of the shafts 11 , partially closing the channels 21.
• rollers 5 after performing the circumferential counterclockwise movement D2, already deform the left ends of the polar bases 4 of shafts 11 , fully closing the channels 21.
• the circumferential movement D1 provides a displacement initiated at the center 3 of a polar base, and terminated at one of the ends 4 of the same polar base.
• the circumferential movement D2 provides a displacement initiated at the stopping point of the circumferential movement D1 previously performed, and terminated at the other end 4 of the same polar base.
• Figures 6.1 , 6.2, 7.1 , 7.2, 8.1 and 8.2 illustrate - schematically - the second sub-step which includes the step of closing the housing channels of electrical conductors.
• each sub-phase is responsible for unfolding dose arranged interchangeably polar bases (closing twelve channels arranged interchangeably).
• the first sub-step route of cylinders is small and must not reach the ends of polar bases which have not yet been developed (unfolded be in the second sub-step), after all, these polar bases, if met, will have their ends deformed in a direction wrong (which is totally prohibitive, because it leads to the collapse of these ends, making the stator 1 unusable).
• the second sub-step can be limited to the polar bases still undamaged (comprising only a "repeat" of the first sub-step), or may be further extended to all polar bases.
• the first movement is started at the center of a polar base unharmed and terminated near the center of polar base adjacent (already deformed), and the second movement is initiated at the stopping point circumferential movement of the anterior and terminated near the center of the "other "polar base adjacent (now deformed).
• the system should be able to provide means capable of performing the process described above, and with respect to obtaining the torque moment, which is the driving force to generate the unfolding, which can be obtained in different ways.
• the system of deflection of dynamo- electric machine stator comprises multiple rollers 5, 6 concentrically disposed in at least one alignment structure 51 , 61 and at least one shaft 52, 62 cooperatively associated with said alignment structure 51 , 61.
• the whole set is associated with an operational base 8 which has means of maintaining static the stator of the dynamo-electric machine.
• the alignment structure 51 , 61 which is apt to perform rotating movement in clockwise and anti-clockwise direction comprises an essentially annular body provided with fastening means able to retain the multiple rollers, preferably, it is also noticed that the rollers 5, 6 are in fact "stuck" to the alignment structure 51 , 61 by intermediates of closing plates 7.
• said alignment structure 51 , 61 is apt to carry out rotating movement in clockwise and counterclockwise through at least one driving source (not shown), which is functionally associated with the shaft 52, 62 and can comprise an electric stepper motor, among other alternatives.
• rollers may be subject to rotating movement, and this feature aids in the reduction of the sliding friction of the stator (in the unfolding operations of the nozzles of the stator shoes).
• This movement can be free, or even by at least one driving source (not shown).

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• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Manufacture Of Motors, Generators (AREA)

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• 2012
  • 2012-08-31 BR BR102012022080A patent/BR102012022080A2/pt not_active Application Discontinuation
• 2013
  • 2013-08-30 CN CN201380055085.7A patent/CN104737419A/zh active Pending
  • 2013-08-30 MX MX2015002748A patent/MX2015002748A/es not_active Application Discontinuation
  • 2013-08-30 EP EP13766883.6A patent/EP2891228A2/de not_active Withdrawn
  • 2013-08-30 WO PCT/BR2013/000338 patent/WO2014032154A2/en active Application Filing

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