Classifications

• • 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
  • H02K15/026—Wound cores
• • 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
  • H02K15/0025—Shaping or compacting conductors or winding heads after the installation of the winding in the core or machine ; Applying fastening means on winding heads
  • H02K15/0037—Shaping or compacting winding heads
• • 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
  • H02K1/14—Stator cores with salient poles
  • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
• • 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
  • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
  • H02K15/0435—Wound windings
• • 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
  • H02K15/06—Embedding prefabricated windings in machines
  • H02K15/062—Windings in slots; salient pole windings
  • H02K15/065—Windings consisting of complete sections, e.g. coils, waves
  • H02K15/067—Windings consisting of complete sections, e.g. coils, waves inserted in parallel to the axis of the slots or inter-polar channels
  • H02K15/068—Strippers
• • 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
  • H02K15/08—Forming windings by laying conductors into or around core parts
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49002—Electrical device making
  • Y10T29/49009—Dynamoelectric machine

Definitions

• the invention relates to a method for producing a wound stator of a rotating electrical machine, as well as to the corresponding wound stator.
• the invention finds a particularly advantageous application for winding a stator of a rotating electrical machine, such as for example an alternator, a starter-alternator, or even a starter motor vehicle.
• the rotating electrical machines comprise a stator and a rotor secured to a shaft.
• the rotor may be integral with a driving shaft and / or driven and may belong to a rotating electrical machine in the form of an alternator as described in EP0803962 or an electric motor as described in EP0831580.
• the electric machine has a housing carrying the stator. This housing is configured to rotate the rotor shaft for example by means of bearings.
• the rotor comprises a body formed by a stack of sheets of sheet metal held in pack form by means of a suitable fastening system, such as rivets passing axially through the rotor from one side to the other.
• the rotor comprises poles formed for example by permanent magnets housed in cavities formed in the magnetic mass of the rotor, as described for example in document EP0803962.
• the poles are formed by coils wound around rotor arms.
• the stator comprises a ferromagnetic body consisting of a stack of thin sheets and a coil received in stator slots open inwards.
• the winding is formed by a plurality of phase windings each corresponding to a phase of the machine.
• Each winding is formed by a set of turns each formed by one or more continuous son usually made of copper.
• These wires follow a corrugated shape and have loop structures located alternately on each side of the stator connecting between them segment structures located inside the notches.
• a set of loop structures protruding from one side of the stator constitutes a coil winding.
• the winding of the stator is conventionally carried out phase by phase.
• the six phase windings are made in the same way one after the other. Closing wedges are inserted into the notches during the realization of each phase winding.
• an intermediate forming operation consisting of releasing the space above and below the notches of the next phase to be inserted, by application in the bunches of a radial force going from the inside to the outside the stator. This force is applied by means of jaws acting simultaneously and identically on the lower and upper parts of winding buns.
• the force transmitted by the jaws on the son of the buns induces a force in the notches tending to bring out the closing wedges of the notches, or the son in the case where the method does not involve closing wedge.
• the radial expansion of the jaws is limited by this phenomenon, which therefore does not allow to release sufficient space in the notches of the stator to insert the following phase windings.
• the consequence is that the notches are not filled optimally, so that the filling coefficient of the notches (that is to say the ratio between the section of bare conductive wire and the complete section of the notch), and therefore the performance of the machine, are degraded.
• the known methods make it possible to produce wound stators having a maximum filling ratio of 52% for three-phase applications and 50% for hexaphase applications.
• the aim of the invention is to remedy these drawbacks effectively by proposing a method for producing a wound stator comprising:
• an insertion step comprising an insertion of said phase winding into a corresponding series of notches in said stator
• the insertion step further comprises an insertion of closing wedges in the series of notches corresponding to the inserted phase winding, in this case, said bearing surface is pressed against at least one of said closing wedges during the intermediate forming step.
• said first radial force is applied to a portion of said winding bunches so as to release at least the series of notches corresponding to the next phase winding to be inserted. For this, the radial force from an axis of said stator to the outside of said stator is applied in a radius aligned with at least one notch of the series of notches of the next phase winding to be inserted.
• said first radial force is applied to a portion of said winding bunches so as to first release the series of notches corresponding to the last phase winding to be inserted, then the series of notches corresponding to the next phase winding to be inserted.
• the radial force going from one axis of said stator to the outside of said stator is first applied along a radius aligned with at least one notch of the series of notches corresponding to the last phase winding to be inserted and then following a radius aligned with at least one notch of the series of notches of the next phase winding to be inserted.
• said coil windings comprising a first lower portion located on the side of one of the two axial ends of the stator and a second upper portion located on the side of the other axial end of said stator, said first radial force is applied. on each of the two parts by means of jaws between a starting position and an arrival position, in which the radial distances of the jaws relative to the axis of the side of the lower part and the side of the upper part are different.
• said insertion step comprising a step of tilting from a horizontal position to a vertical position of said phase winding by means of a tilt ring located on one side of one of the two ends axial position of the stator, said arrival position is closer to the axis on the side of said tilt crown.
• the insertion of said closing wedges being made from a first axial end of the stator to a second axial end of the stator, said arrival position is further away from said axis on the side of said second end of the stator. This facilitates the insertion of the closing wedges.
• teeth of said stator delimiting said notches are positioned inside recesses of complementary shape extending between two successive bearing surfaces.
• the positioning of said teeth inside said housings is such that the bearing surfaces substantially completely obstruct the space of the notch on a diameter corresponding to about an inner diameter of the stator to which is added two-thirds of a notch depth.
• said method before the insertion of the phase winding, comprises a step of placing radial fingers over at least one axial end face of teeth of said stator.
• said radial fingers are positioned to come into contact with a connecting face extending between two successive bearing surfaces.
• the preparation step consists of preparing two half-phase windings comprising a superposition of identical star-shaped plane turns.
• the turns of the half-windings are angularly offset relative to one another so as to obtain a distributed corrugated winding.
• said half-phase windings are inserted at the same time into a series of notches by progressive twist of the turns so as to effect a tilting of the phase winding from a horizontal position to a vertical position.
• said method comprises the step of successively performing the insertion of a first, a second, and a third phase winding of a first three-phase system, then insertions of a first, a second, and a third phase winding of a second three-phase system, so that the insertions are carried out successively in a series of notches out of two. This limits the twist on the winding son during successive insertions.
• said method comprises a step of shaping the coil winding.
• Figure 1 is a perspective view of a wound stator obtained following the implementation of the method according to the present invention
• Figure 2 is a top view of the half-phase windings positioned around the blades of an insertion tool used with the method according to the present invention
• Figure 3 is a perspective view of the interior of the stator body and the insertion tool
• FIG. 4 is a fragmentary sectional view of the stator during the step of intermediate formation of the coil windings following the insertion of a first phase winding;
• Figure 5 shows a perspective view of an intermediate forming tool used in the implementation of the winding method according to the present invention
• FIG. 6 is a detailed perspective view of the bearing surfaces of the intermediate forming tool of Figure 5 positioned opposite the notches without the closing wedges and winding son;
• FIG. 7 is a partial sectional view of a stator according to the present invention showing the order of the phases of a three-phase double system obtained with the method according to the present invention.
• FIG. 1 shows a perspective view of a wound stator 1 of a rotating electrical machine that can be, for example, an alternator or an alternator-starter.
• a rotating electrical machine that can be, for example, an alternator or an alternator-starter.
• This machine is preferably intended to be implemented in a motor vehicle.
• an alternator-starter is a rotating electrical machine able to work in a reversible manner, of a on the one hand, as an electric generator in alternator function, and on the other hand as an electric motor, in particular for starting or restarting the engine of the motor vehicle in a mode of operation called "stop and start" (or in French mode of stopping and restarting the engine according to the traffic conditions).
• This stator 1 comprises a body 2 of annular cylindrical shape X axis consisting of an axial stack of flat sheets each having a small thickness.
• the body 2 is delimited radially by an internal cylindrical face 21 and by an outer cylindrical face 22.
• the body 2 is delimited axially by a lower end face 23 and by an upper end face 24.
• the body 2 has on its circumference teeth 4 delimiting pairs of notches 5, two consecutive notches 5 being thus separated by a tooth 4.
• the notches 5 open axially into the axial end faces 23, 24 of the body 2.
• the notches 5 are radially open in the internal face 21 of the body 2.
• the notches 5 all substantially identical are angularly distributed regularly around the axis X.
• the notches 5 are for example 36, 48, 60, 72, 84, or 96.
• the stator 1 comprises 36 notches. Insulators 8 visible in FIG. 4 are preferably arranged in the notches 5, before making insertion of the winding, to avoid damaging the conductors during this delicate operation and for electrically isolating the conductors relative to the body 2.
• each tooth 4 preferably comprises a tooth root 1 1 which extends circumferentially on either side of the free end of each tooth 4.
• the solid portion 12 of the stator 1 which extends between the bottom of the notches 5 and the outer periphery 22 is called the cylinder head.
• Phase windings E1-Ek each corresponding to one of the phases of the electrical machine are inserted into the notches 5.
• Each phase winding E1-Ek consists of corrugated turns 13 corrugated radially. These turns 13 are formed by electrical conductors each comprising one or more son 15.
• the son 15, generally copper, are covered with an enamel layer for their isolation. These son 15 preferably have a round section. Alternatively, the wires 15 could have a square, rectangular, or flat-shaped section.
• each turn 13 has a series of segment structures 18 which are received in a series of associated slots 5.
• Each turn 13 also comprises loop structures 19 connecting the consecutive segment structures 18 and extending alternately projecting on either side of the axial end faces 23, 24.
• the coil windings 26 correspond to the loop structures 19 extending between two notches 5 of each series of phase windings E1-Ek.
• the buns 26 comprise an upper part situated on the side of the upper end face 24 and a lower part situated on the side of the lower end face 23.
• Two consecutive notches 5 of a given series of notches are separated by adjacent notches 5 each corresponding to another series of notches 5 associated with one of the other phase windings.
• the son 15 of a phase winding E1-Ek are received in a notch 5 on k adjacent notches.
• two adjacent notches are left free between two notches 5 of each series.
• the wires of a phase winding E1-Ek are inserted into a notch on three adjacent notches.
• the machine may comprise from three to seven phases.
• the method of producing the wound stator 1 according to the present invention based on the successive insertion of the phase windings E1-Ek is described below. More precisely, the method comprises a step of preparing a winding of a phase E1-Ek from a wire 15.
• This phase winding E1-Ek comprises two half-windings of higher phase 271 and lower 272 represented on Figures 2 and 3.
• Each half-winding 271, 272 comprises a superposition of star-like plane turns 13, each having a plurality of structures of loops 19 interconnecting the segment structures 18 of substantially radial orientation intended to be inserted into the notches 5.
• the turns 13 of the same half-winding 271, 272 are superimposed on one another.
• the upper half-winding 271 is plated above the lower half-winding 272, the axes of symmetry of the two half-windings 271, 272 being aligned and substantially coinciding with the axis X of the stator 1.
• the turns 13 of the upper half-winding 271 are also angularly offset relative to the turns 13 of the lower half-winding 272, so that each loop structure 19 of one of the half-windings 271 intended to extend from one of the sides the stator is interposed angularly between two loop structures 19 of the other half-winding 272 intended to extend on the same side of the stator. This will result in a distributed wavy winding.
• the method then comprises a step of inserting the two half-windings 271, 272 of a phase in the corresponding series of notches 5. For this purpose, as can be seen in FIG.
• an insertion tool 30 on which the half-windings 271, 272 have been transferred is positioned on the side of the lower end face 23 of the body 2, the turns 13 being centered on the X axis of the body 2 and extending in planes substantially perpendicular to this axis.
• the half-windings 271, 272 are then inserted at the same time in the notches 5 of the corresponding series, by progressive twisting of the turns 13 so as to effect a tilting of the phase winding E1-Ek from a horizontal position to a vertical position in which said turns 13 are oriented in a direction parallel to the X axis.
• the insertion tool 30 comprises blades 31 positioned in a circle centered on the axis X each associated with a counterblade 32 located behind the blade 31, and a tilting ring 33 located on the the lower axial end 23.
• the insertion of the half-windings 271, 272 is carried out by moving the tilt ring 33 upwards so as to push the turns 13 into the notches 5 by twisting, until the turns 13 fill the notches 5. over their entire length.
• the blades 31 moved in the same direction as the ring 33 slide on the inner cylindrical face 21 of the body 2 so as to serve as a guide for the segment structures 18; while against-blades 32 provide a guide blades 31 during their movement.
• closing wedges 36 shown in FIG. 4 are inserted in each notch 5 of the series corresponding to the phase winding E1 -Ek inserted.
• the insertion of the wedges 36 is carried out going from the lower axial end 23 towards the upper axial end 24 of the stator.
• the stator 1 is then positioned around an intermediate forming tool 39 shown in FIG. 5, so that bearing surfaces 40 located on a circumference of the central portion 43 of the tool are pressed against the closing wedges. 36. These bearing surfaces 40 extend along the entire height of the notches 5 between the two axial end faces 23, 24 of the stator 1 so as to close the notches 5.
• the teeth 4 of the stator 1 are positioned inside housings 44 of complementary shape extending between two successive bearing surfaces 40.
• the positioning is such that the bearing surfaces 40 substantially completely obstruct the space of the notches 5 between the lower end face 23 and the upper end 24 of the stator, on a diameter L1 corresponding approximately to an inside diameter of the body 2 to which is added twice the third of the slot depth L2 measured in a radial direction.
• the bearing surfaces 40 are connected together via their axial ends by connecting faces 47 which extend on the side of the upper end faces 24 and lower 23 of the body 2.
• the tool 39 comprises a first series of jaws 48 lower ones distributed in a circle and located under the central portion 43, and a second series of upper jaws 48 distributed in a circle and located above the central portion 43.
• These jaws 48 are intended to apply on the buns 26 a first radial force F1 from the X axis of the stator 1 to the outside of the stator 1.
• This first radial force F1 is applied by the first and second series of jaws 48 respectively on the lower part and the upper part of the buns 26, so as to release at least the series of notches 5 corresponding to the winding of the phase to insert.
• the jaws 48 are activated so as to first release the notches 5 of the series corresponding to the last phase winding E1 - Ek to be inserted then the notches 5 of the series corresponding to the next phase winding E1 -Ek to insert.
• the bearing surfaces 40 located opposite the notches 5 make it possible to counteract the second radial force F 2 resulting from the application of the first force F1 and going from the outside towards the X axis of the stator 1. This prevents the son 15 to exert in the notches 5 a stress likely to bring out the closing wedges 36 of previously inserted phases.
• the jaws 48 move between a starting position P1 and an arrival position P2 (see Figure 4).
• the radial distances separating the arrival positions of the jaws 48 with respect to the X axis on the side of the lower face 23 and the side of the upper face 24 of the stator 1 are different.
• the arrival position P2 is closer to the axis X on the side of the tilting crown 33.
• the arrival position P2 of the jaws 48 is then further away from the axis X on the side the upper end face 24, that is to say the side opposite the side by which are inserted the closing wedges 36. This facilitates the insertion of shims 36 for E1 -Ek phase winding next to insert.
• the stator 1 is then indexed in the insertion position of the next phase winding E1-Ek to be inserted.
• the operations are carried out n-1 times, n being the number of phases to be inserted.
• n being the number of phases to be inserted.
• the operations are performed five times for hexaphase applications (1 to 2, 2 to 3, 3 to 4, 4 to 5, and 5 to 6), or twice for three-phase applications (1 to 2, and 2 to 3).
• a stator 1 with six phases of double three-phase type comprising, as shown in FIG. 7, series of notches 5 successively corresponding to the first phase winding E1 of a first three-phase system, at the first phase winding.
• E1 'of a second three-phase system the second phase winding E2 of the first three-phase system, the second phase winding E2' of the second three-phase system, the third phase winding E3 of the first three-phase system, the third phase winding E3 ' of the second three-phase system.
• the insertions of the first E1, the second E2, and the third E3 phase winding of the first three-phase system are successively carried out, then the insertions of the first E1 ', the second E2', and the third E3 'phase winding.
• the inserts are made in a series of notches 5 out of two to limit the twist on the son 15 of the winding.
• the intermediate forming steps described above are carried out.
• an independent machine performs a step of shaping the upper and lower portions of the buns 26 as a function of a size of the bun to obtain. Such a dimensional depends on the intended application.
• the method comprises a step of placing radial fingers 50 above the axial end faces of the teeth 4 of the stator 1.
• the fingers 50 are positioned so as to come into contact with a connecting face 47 extending between two bearing surfaces 40. This limits the risk that the buns 26 can slide along typically shorter fingers 50 and come into contact with the sheets of the body 2 having burrs likely to damage the son 15. This avoids the conductive wires 15 come into contact with the body 3 of the stator 1 during insertion operations of the phase windings E1-E6.
• stator 1 that does not include closing wedges 36, the bearing surfaces 40 then being positioned opposite the notches 5 to prevent the wires 15 from escaping during intermediate forming operations.

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• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Manufacture Of Motors, Generators (AREA)
• Iron Core Of Rotating Electric Machines (AREA)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

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Citations (2)

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• 2014
  • 2014-07-15 FR FR1456774A patent/FR3023994B1/fr not_active Expired - Fee Related
• 2015
  • 2015-07-09 CN CN201580038115.2A patent/CN106575906B/zh active Active
  • 2015-07-09 WO PCT/FR2015/051905 patent/WO2016009137A1/fr active Application Filing
  • 2015-07-09 KR KR1020177001219A patent/KR102442368B1/ko active IP Right Grant
  • 2015-07-09 US US15/325,676 patent/US10637335B2/en active Active
  • 2015-07-09 EP EP15748283.7A patent/EP3170246A1/de not_active Withdrawn

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