Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
  • H02K15/021—Magnetic cores
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/13—Applying slot closure means in the cores; Manufacture of slot closure means
• • 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
  • H02K3/00—Details of windings
  • H02K3/46—Fastening of windings on the stator or rotor structure
  • H02K3/48—Fastening of windings on the stator or rotor structure in slots
  • H02K3/487—Slot-closing devices
  • H02K3/493—Slot-closing devices magnetic

Definitions

• the present invention refers to an optimized process for manufacturing a dynamo- electric machine stator and, more particularly, a step of "calibrating" blades used for making an electric motor stator, which comprises the final step of said process of making the stator, and it is essentially based on concentric deformation of the edges of polar bases of the stator blades.
• the present invention refers to a system capable of carrying out a step of "calibrating" the manufacture of dynamo-electric machine stator.
• dynamo-electric machines refers to a machine capable of transforming electric energy into mechanical energy, or also mechanic energy into electric energy by electromagnetic interaction between at least a "fixed” portion and at least a "movable portion.”
• a dynamo-electric machine comprises a ("fixed” portion) stator and a rotor ("movable” portion", wherein said stator is composed of fixed inductive cores, and the rotor is composed of movable inductive cores.
• stator is composed of fixed inductive cores
• rotor is composed of movable inductive cores.
• the function principle of interaction between stator and rotor rely on electromagnetic induction concepts, where magnetic fields generated by said fixed inductive cores are capable of generating movement in the movable inductive cores and, more specifically, in the rotor, where mechanical energy is obtained.
• a dynamo-electric machine stator is essentially composed of a metal framework and a plurality of coils (electric conductors disposed in a circumventing way around a axis), wherein said coils are disposed in alignment with said metal framework.
• said metal framework of the stator defines circularly edges spaced therebetween (and circumferentially joined therebetween by means of the upper ends thereof, wherein the lower edges are spaced from one another) by channels equally spaced from one another.
• Each radial axis defines a structure capable of holding electric conductors (which are "coiled", thereby defining an electric coil). Therefore, the "sum" of a radial axis and its respective electric coils then defines a fixed inductive core.
• rotor and stator of a dynamo-electric machine have complementary embodiments such that a rotor is assembled inside its respective stator.
• the metal framework axes of the stator have a length sized to form a hollow circular space particular aimed at accommodating and positioned said rotor.
• FIG. 1A illustrates a plan and schematic view of a dynamo-electric machine stator in accordance with a conventional embodiment pertaining to the state of the art. It should be pointed out that in this merely illustrative figure, said stator is depicted with electric conductors forming the electric coils.
• the transversal "are" of electric conductors which form the stator coils comprises a feature capable of influencing the efficiency of the dynamo-electric machine. More specifically, it is already known that electric conductors of lower area more susceptible to the occurrence of Joule effect, in addition to the intrinsic limitation concerning the nominal electric current value which said conductors support. Therefore, it is convenient that said electric conductors forming the stator coils exhibit an area as great as possible (obeying the needs of each design).
• each of axes XE of the stator blade XL comprises a final edge defined by two side flaps XAL. Therefore, the area of the electric conductors forming the stator coils ends up being limited to the space existing between said side flaps XAL of consecutives axes XE.
• said space existing between the side flaps XAL of consecutive axes XE comprises a characteristic capable of influencing the efficiency of the dynamo-electric machine, this is why the higher the space the higher is the magnetic dispersion of the inductive core and, consequently, the higher is the yield of said dynamo-electric machine (relation between amount of electric energy transformed into mechanic energy or vice-versa).
• BR PI9702724-3 refers to an electric motor stator blade, which comprises side flaps which can be handled during the stator manufacture process, thus allowing for "opening” and “closing” the channel of electric conductors housing.
• US417644 and US4267719 both assigned to the same priority document, refer to a method and device for forming electric machine stators. Said method provides a series of steps which, in general, define that blades are firstly stamped and subsequently merged to form a stator metal framework. After forming said metal framework, the side flaps of the axes are subjected to pressure deformation and once said channels are open, the housing of the electric conductors is made. Next, said channels are opened, also by pressure deformation, and said method is complete.
• FIGs. 1 B, 1 C and 1 D respectively illustrate an axis of the stator blade having flaps as initially obtained, a stator blade axis with flaps which have been deformed after the "opening” process, and a stator blade axis with flaps which have been deformed after the "closing” process.
• Such illustrations clearly refer to the current state of the art.
• said final mentioned result explained above comprises negative characteristic which will compromise the general efficiency of the dynamo-electric machine.
• This stems from that fact that the final formats of the stator blade axes, when differing from the "original" format and/or when not homogeneous may cause physical interference (friction) in the rotor, and because of that a radial clearance between stator and rotor is increased, thereby resulting in a significant decrease of electric efficiency of the motor.
• Such a physical interference in addition to jeopardizing the dynamo-electric machine, can also damage the rotor itself, and thereby reducing the service-life of said dynamo-electric machine.
• one object of the present invention is to provide a process for manufacturing a dynamo-electric machine stator particularly comprising a step for the "final finishing" of the stator format, and, more particularly, the format of the lower edge, including side flaps, of the stator blade axes.
• a further object of the present invention is that said step of "final finishing", ou calibration step, render the opening of the stator, in which the rotor is housed, homogeneous, together with the possibility of reducing radial clearance between stator and rotor, which leads to the increase of the efficiency of an electric motor.
• another object of the present invention is to provide a process capable of deforming the stator blades such that their format is substantially equivalent to the initial format and that prior to the steps of "closing" channels.
• a yet object of the present invention is to provide a process for manufacturing a dynamo-electric machine stator that can obtain a stator which will not damage its respective rotor.
• an object of the present invention is to provide a system for "calibrating" a dynamo-electric machine stator capable of “processing” said dynamo-electric machine stator in accordance with the basic concepts of the process for manufacturing the presently disclosed dynamo-electric machine stator.
• a process for manufacturing a dynamo-electric machine stator which comprises at least a step of stamping the stator blades, at least a step of merging multiple stator blades, at least a step of forming inductive cores in the housing channels of the electric conductors, at least a step of closing the housing channels of the electric conductors, and at least a step of calibrating the dynamo-electric machine stator.
• said step of calibrating the dynamo-electric stator comprises at least a sub-step of aligning said blades and at least a sub-step of concentrically deforming the edges of the polar bases of the blades.
• Said sub-step of aligning the blades which comprises simultaneously aligning all stator blades from the center of the polar bases of said blades is carried out by means of radial force directed to the centers of the polar bases of the blades.
• all the center of the polar bases of the blades are subjected to the same radial force, which comprises a mechanical force against the center of the polar bases and, more particularly, a mechanical force produced by at least a radial displacement body.
• Said sub-step of concentrically deforming the edges of the polar bases of the blades comprises simultaneously deforming all the edges of the polar bases of the stator blades from the center of said stator and this is carried out by a radial force directed to spaces existing between the spaces existing between the edges of the two consecutive polar bases.
• all the spaces existing between the edges of two consecutive polar based are subjected to one same radial force, which comprises force dimensional mechanic adjustment and, more particularly, one comprises force for dimensional mechanical adjustment generated by means of a radial displacement body.
• radial force comprises force dimensional mechanic adjustment and, more particularly, one comprises force for dimensional mechanical adjustment generated by means of a radial displacement body.
• the centers and edges of the polar bases of all stator blades comprise, in the end of the step of calibrating the dynamo-electric machine stator, a substantially circular general arrangement based on a virtual radius, this being substantially equivalent to the radius existing between the stator center and center of any one of the polar bases of the blades.
• a system for calibrating dynamo-electric machine stator which comprises multiple radial displacement bodies, at least a force transmission mechanical capable of generating, in an equal form, radial forces in the direction to multiple surfaces and/or segments of surfaces circularly disposed by means of radial displacements of said formerly mentioned multiple bodies, and at least an alignment adjustment mechanism capable of promoting alignment between said multiple bodies and surfaces and/or segments of surfaces circularly disposed in the stator.
• the force transmission mechanism comprises at least a housing structure for said multiple radial displacement bodies (comprising multiple equidistant vertical hips which are concentrically arranged), at least a vertical displaceable central piston, and means for converting the central piston vertical displacement to radial displacement of the multiple bodies.
• the conversion of said central piston vertical displacement to radial displacement of the multiple bodies is carried out by means of at least a sphere disposed between each of the multiple bodies and its respective portion of the central piston.
• Multiple vertically aligned spheres disposed between each of the multiple bodies and their respective housings in the central piston area also disclosed.
• the alignment adjustment mechanism comprises at least a base provided with at least one angularly movable ring- shaped body and at least a locking element of the angularly movable ring-shaped body.
• the angularly movable ring-shaped body comprises at least one oblong hip defining the limits of angular movement of said ring-shaped body and the housing region of the locking element of the angularly movable ring-shaped body.
• said alignment adjustment mechanism further provides for an assembling guide for a dynamo-electric stator machine.
• said force transmission mechanism and said alignment adjustment mechanism are disposed in one same operational matrix.
• Fig. 1A illustrates an embodiment of a blade of the dynamo-electric machine stator in accordance with the concepts already known in the current state of the art
• Fig. 1 B illustrates a stator blade axis in accordance with the concepts already known in the current state of the art, having flaps as initially obtained;
• Fig. 1 C illustrates a stator blade axis in accordance with the concepts already known in the current state of the art, having deformed flaps after the "opening" process;
• Fig. 1 D illustrates a stator blade axis in accordance with the concepts already known in the current state of the art, having deformed flaps after the "closing" process;
• Fig. 2 illustrates a perspective view of an example of a dynamo-electric machine stator in accordance with the current state of the art
• Fig. 3 illustrates a top view of a dynamo-electric machine stator prior to the carrying out of the calibration step in accordance with the present invention
• Fig. 4 schematically illustrates the sub-step of final alignment of the stator blades in accordance with the present invention
• Fig. 5 schematically illustrates the sub-steps of concentrically deforming the edges of the polar bases of the stator blades in accordance with the present invention
• Fig. 6 illustrates a top view of the stator depicted in Fig. 2 after the carrying out of the calibration step in accordance with the present invention
• Fig. 7 illustrates a preferred embodiment of the system for calibrating the dynamo- electric machine stator according to the invention, in a perspective view
• Fig. 8 illustrates a preferred embodiment of the system for calibrating the dynamo- electric machine stator in accordance with the present invention, in an exploded view.
• one of the objects of the present invention is to manufacture, by means of a process for manufacturing dynamo-electric stator, a stator of substantially homogeneous inner opening, that is, it is substantially cylindrical.
• a dynamo-electric machine e.g. an electric motor
• which rotor can freely act on the opening of its respective stator without causing physical interferences between both of them, wherein it comprises a minimal clearance between the rotor and stator.
• the format of the low edge, including the edges of the polar bases of the stator blade axes are delicately deformed such that the format thereof is substantially equivalent to the initial format (format prior to the step of "opening" the housing channels of electric conductors).
• a step of calibrating the dynamo-electric machine stator comprises a last step of the process for manufacturing dynamo-electric machine stator, this preferably also comprising former steps, viz.: step of stamping the stator blades; steps of merging multiple stator blades; step of forming inductive cores in the housing channels of the electric conductors; and the step of closing the housing channels of the electric conductors.
• said calibration step is preferably conducted only after the carrying out of the step of closing the housing channels of the electric conductors, this is why said calibration step generally comprises a step responsible for delicately deforming the edges of the polar bases of the stator blade axes.
• said calibration step comprises a sub-step of finally aligning the stator blades and a sub-step of concentrically deforming the edges of the polar bases of the stator blades.
• the main idea is that in the end of said calibration step the centers of the polar bases of the stator blades and the edges of the polar based of the stator blades exhibit an essentially uniform and circumferentially equivalent alignment.
• a dynamo-electric machine stator 2 (capable of being subjected to the referred to "calibration" step) is essentially composed of a plurality of blades 1 , which - when duly merged - defines a structural framework, whose interior comprises a series of axes (radially disposed and spaced therebetween) intended to coil electric conductors.
• each axis of a blade 1 comprises a polar base 1 1 which contains a lower and/or inner edge of said axis.
• Each polar base 1 has a mild curvature, which can be better observed through a combined visualization of all polar bases 1 1 of a blade 1 .
• the sum of said mild curvatures results in forming a circular contour. Since said stator 2 is duly assembled, multiple polar bases 1 of multiple blades 1 will define in the stator 2 a housing or a substantially cylindrical channel which is capable of receiving a (not shown) rotor.
• each of the polar bases 1 1 provides two laterally opposite edges 12.
• the occurrence of said edges 12 stems from the fact that one polar base 1 1 is substantially wider than its respective axis, then the "remaining" side portions can be identified as edges 12.
• each polar base 1 1 further provides a center 13.
• the mild curvature of each polar base 1 1 is disposed at the edges 12 and at the center 13 thereof.
• Fig. 3 illustrates a stator 2 not yet subjected to the presently disclosed calibration step.
• stator 2 to the calibration step, as defined and claimed by the present invention.
• Figure 4 schematically illustrates the first sub-step pertaining to the calibration step.
• This sub-step comprises simultaneously aligning all blades 1 of stator 2 from centre 13 of polar bases 1 1 of said blades 1.
• Said sub-step, event that it is "preparatory”, is of extreme importance due to the fact to obtain an essential uniform and circumferentially equivalent alignment there will be required that all polar bases 1 1 of the stator 2 are longitudinally aligned with one another.
• the term “longitudinally” refers to the length of stator 2.
• Such a simultaneous alignment is carried out by means of radial pressure P1 directed to centers 13 of polar bases 1 1 of blades 1.
• said radial pressure P1 comprises pressure by mechanical interference and, more particularly, pressure by mechanical interference generated by means of a radial displacement body 3.
• the "stroke" of the expansive pressure P1 or further the “stroke” of the bodies 3 capable of generating expansive pressure P1 is radially equal and this then permits that all the centers 13 of the polar bases 11 are aligned in conjunction.
• Fig. 5 schematically illustrates the second sub-step pertaining to the calibration step.
• simultaneous deformation of all edges 12 of polar bases 1 1 of blades 1 of stator 2 occurs from the centre of said stator 2.
• Said simultaneous deformation is conducted by radial pressure P2 directed to spaces existing between the edges 12 of two consecutive polar bases 1 1 , wherein all spaces existing between the edges 12 of two consecutive polar bases 1 1 are subjected to one same radial pressure P2.
• Said radial pressure P2 comprises pressure by mechanical interference and, more particularly, by mechanical interference generated by at least one radial displacement body.
• centers 13 and edges 12 of polar bases 1 1 of all blades 1 of stator 2 comprises an essentially circular general arrangement based on a virtual radius R1 , which is substantially equivalent to the radius existing between the centre of the stator 2 and the center 13 of any of the polar bases 1 1 of the blades 1.
• the system defined below is capable of generating radial pressures P1 and P2, at different times, by mechanical force of a sole "game” of bodies 3.
• said system is essentially composed of multiple bodies 3, a mechanism 5 that generates force responsible of the calibration procedure, and an alignment adjustment mechanism 6. Both mechanism 5 and alignment adjustment mechanism 6 are disposed in one same operational matrix 7.
• Each of the multiple bodies 3, all of having radial displacement, comprises (for all effects) a metal bar, wherein its contact surface has a central point and two lateral contact grooves. As formerly described in detail, the central point of each body 3 acts on its alignment sub-step and lateral grooves act on the physical deformation sub-step.
• Said mechanism 5 which is capable of generating in equal form, radial pressures
• P1 and P2 in direction to multiple surfaces and/or segments of surfaces circularly disposed by radial displacement of said multiple bodies 3, comprises a structure 51 , which contains a type of cage housing multiple bodies 3, and comprises a tubular body of cylindrical profile provided with equidistantiy and concentrically disposed multiple vertical hips, a displaceable vertically central piston 53, and means for converting said vertical displacement of the central piston 53 to radial displacement of said multiple bodies 3.
• the above-mentioned conversion means generally comprise multiple spheres 54 installed in vertically aligned cages disposed between each of said multiple bodies 3 and their respective housings in the central piston 53.
• Such an embodiment allows for the central piston 53 to vertically displace inside the structure 51 (wherein said bodies 3 are assembled/aligned on their respective vertical hips 52), the displacement force is transferred, also in a vertical direction, to said spheres 54, which layer the bodies 3 by "pushing them outwardly.” It is worth mentioning that this embodiment is particularly interesting because all the force (or effort) used to perform the vertical displacement of said central piston 53 converted to radial force (effort).
• said mechanism 5 is in fact capable of generating forces P1 and P2 which are able to conduct the above-mentioned process.
• the force exerted on the bodies by said mechanism 5 originates form a press or actuator 4.
• Said alignment adjustment mechanism 6 which is capable of promoting alignment between the multiple bodies 3 and said surfaces and/or segments of circularly disposed surfaces, comprises a mechanism particularly intended to reposition said bodies 3 such that they in a first moment exert radial force P1 and in a second moment they exert radial force P2.
• said alignment adjustment mechanism 6 comprises a base 61 provided with an angularly movable ring-shaped body 62 and a locking element 63 to lock said ring-shaped body 62.
• said ring-shaped body 62 comprises at least one oblong hip 64, which defines the angular moving limits of said ring- shaped body 62 (within which a housing region of the locking element 63 is defined).
• assembling guides 65 for a dynamo-electric machine stator 2 are also disclosed.
• such assembling guides comprise rods having a height equivalent to the height of said stator 2 to be processed.
• locking elements such as, for example, bolts and similar may also be provided.
• Said assembling guides 65 are disposed in the ring-shaped body 62.
• stator 2 once housed on the assembling guides 65 follow the angular movement of said ring-shaped 62.
• mechanism 5 can provide the radial force P1.
• said ring-shaped body 62 can angularly move (thus altering the alignment between the multiple bodies 3 and edges 12/centers 13 of the polar bases 1 1 of blades 2), followed by providing the radial force P2 comprising the own calibration.

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

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Publications (1)

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• 2012
  • 2012-08-31 BR BR102012022079-2A patent/BR102012022079A2/pt not_active Application Discontinuation
• 2013
  • 2013-08-28 WO PCT/BR2013/000333 patent/WO2014032150A2/en not_active Ceased
  • 2013-08-28 CN CN201380056030.8A patent/CN104756375A/zh active Pending
  • 2013-08-28 MX MX2015002746A patent/MX2015002746A/es unknown
  • 2013-08-28 EP EP13762378.1A patent/EP2891232A2/de not_active Withdrawn

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