FR3081631A1 - Method for manufacturing a rotating stator station of rotating electric machine - Google Patents

Method for manufacturing a rotating stator station of rotating electric machine Download PDF

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Publication number
FR3081631A1
FR3081631A1 FR1854325A FR1854325A FR3081631A1 FR 3081631 A1 FR3081631 A1 FR 3081631A1 FR 1854325 A FR1854325 A FR 1854325A FR 1854325 A FR1854325 A FR 1854325A FR 3081631 A1 FR3081631 A1 FR 3081631A1
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FR
France
Prior art keywords
stator
step
conductive segments
characterized
conductive
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
FR1854325A
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French (fr)
Inventor
Vincent RAMET
Jean Duquesne
Stephane De-Clercq
Humberto Menezes
Denis Bodin
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Valeo Equipements Electriques Moteur SAS
Original Assignee
Valeo Equipements Electriques Moteur SAS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Valeo Equipements Electriques Moteur SAS filed Critical Valeo Equipements Electriques Moteur SAS
Priority to FR1854325 priority Critical
Priority to FR1854325A priority patent/FR3081631A1/en
Publication of FR3081631A1 publication Critical patent/FR3081631A1/en
Pending legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0056Manufacturing winding connections
    • H02K15/0068Connecting winding sections; Forming leads; Connecting leads to terminals
    • H02K15/0081Connecting winding sections; Forming leads; Connecting leads to terminals for form-wound windings
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K2213/00Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
    • H02K2213/03Machines characterised by numerical values, ranges, mathematical expressions or similar information
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/04Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots

Abstract

The invention relates primarily to a method of manufacturing a rotating electric machine stator, in particular for a motor vehicle, said stator being provided with a body and a coil having a plurality of conductive segments. The method comprises a step of inserting the conductive segments (13) into notches in the stator body, each conductive segment having at least one connecting end and a connecting end welding step ( 21) of a conductive segment (13) at the adjacent connecting end (21) of another conductive segment (13). The welding step is carried out by generating a photon beam, such that the photon beam forms a welding bead (28) between two adjacent connection ends (21), and the welding bead ( 28) is curved in two circumferential directions (D1, D2) opposite to each other.

Description

METHOD FOR MANUFACTURING A WINDED STATOR OF A ROTATING ELECTRIC MACHINE

The present invention relates to a method of manufacturing a wound stator of a rotating electric machine. The rotary electric machine is in particular an alternator or an alternator-starter or a reversible machine or an electric motor of a motor vehicle.

According to a conventional configuration, the stator windings of a rotary electric machine of a motor vehicle are produced by using preformed U-shaped conductive coil segments. These segments are inserted in notches formed in a body of the stator, so that the free end regions of the conductive segments project beyond the latter. The segments are then welded in pairs to form continuous wraps around the body.

According to this technique described for example in document EP1043828, the conductive segments are generally welded using arc type welding, for example of TIG type by creation of a discharge between an electrode and the respective free end zones. segments. It is therefore an electric welding by electrons.

As described in document EP1081830, the connection ends of the segments are welded, so that the welding arc forms weld beads. These weld beads are driven in a circumferential direction in order to bulge in this circumferential direction. However, such a welding technique can cause problems of robustness of the welded connections thus obtained.

The invention aims to effectively remedy this drawback by proposing a method for manufacturing a stator of a rotary electrical machine, in particular for a motor vehicle, said stator being provided with a body and a coil having a plurality of conductive segments. According to the invention, the method comprises a step of inserting the conductive segments inside the notches formed in the stator body, each conductive segment comprising at least one connection end and a step of welding the end of connection of a conductive segment to the adjacent connection end of another conductive segment. Furthermore, according to the invention, the welding step is implemented by generation of a photon beam, so that the photon beam forms a weld bead between two adjacent connection ends and the weld bead is convex in two circumferential directions opposite to each other.

It is therefore a laser type weld which is different from an electrical or TIG weld. The invention makes it possible, thanks to the type of weld used as well as to the geometry of the weld beads, to increase the robustness of the welds between the connection ends of the coil. The invention also has an economic character, insofar as it is applicable to production lines at high rates since this welding method is very fast.

According to one implementation, said method comprises a prior step of stripping the connection ends of the conductive segments.

According to one implementation, the stripping step comprises a step of burning an enamel layer covering the connection ends of the conductive segments and a step of cleaning the connection ends of the conductive segments.

According to one implementation, the burning step is carried out using a carbon dioxide laser.

According to one implementation, the cleaning step is carried out using a YAG type laser.

According to one implementation, the welding step is carried out by two beams of photons emitted simultaneously each on one of the connection ends to be welded.

According to one embodiment, the two beams each extend in a direction parallel to each other.

According to one embodiment, each beam comes from a laser source, the sources being arranged at the same distance and at the same inclination angle of the connection ends to be welded.

According to another aspect, the invention relates to a stator of a rotating electric machine, in particular for a motor vehicle. The stator comprises a body provided with a plurality of notches, a winding comprising a plurality of conductive segments inserted in notches of the stator body, each conductive segment comprising at least one connection end electrically connected via a welding bead to a adjacent connection end of another conductive segment. According to the invention, the weld bead has a curved shape in two circumferential directions opposite to each other.

According to one embodiment, the convex shape of the weld bead has an asymmetry with respect to an axis of the connection ends.

According to one embodiment, the weld bead has an oblong shape.

According to one embodiment, a radial length of the weld bead is substantially equal to twice a circumferential width of said bead. This provides a more resistant weld bead.

According to one embodiment, a radial length of the weld bead is substantially equal to a radial length of a connection end of one of said conductive segments. This allows better fixation of the two conductive segments with each other.

According to one embodiment, a circumferential width of a connection end of one of the conductive segments is substantially equal to a circumferential width of the adjacent connection end with which it is welded.

According to one embodiment, an axial height of the weld bead is greater than or equal to half the radial length of said bead.

According to one embodiment, the stator comprises an even number of conductive segments per notch and in particular 2, 4, 6, 8 or 10 conductive segments per notch. However, the invention can be applied regardless of the number of conductors per notch.

According to one embodiment, the connection ends are located on one side of the stator. Alternatively, the connection ends are located on both sides of the stator.

According to one embodiment, each conductive segment has a rectangular cross section.

According to one embodiment, the connection ends of the conductive segments are chamfered. These chamfers allow the conductive segments to be easily inserted into the notches. The chamfers also favor welding because it helps to locate the heat better. For example, the chamfers form an angle with respect to the extension axis of the connection ends between 40 ° and 55 °.

The invention also relates to a rotary electric machine comprising such a stator. This rotating electric machine can form an alternator, an alternator-starter, a reversible machine or even an electric motor.

The invention will be better understood on reading the description which follows and on examining the figures which accompany it. These figures are given only by way of illustration but in no way limit the invention.

Figure 1 is a top view of an example of a stator portion of a rotary electrical machine provided with a winding produced in accordance with the invention. Figures 2a and 2b are respectively cross-sectional and axial views of a portion of the stator of Figure 1. Figures 3a, 3b, 3c, and 3d are perspective views, from the front, from above and from the side. of a weld bead between two conductive segments of the winding of FIG. 1. FIG. 4 is a diagram of the steps of the process for manufacturing a wound stator according to the present invention. Identical, similar, or analogous elements keep the same reference from one figure to another.

FIG. 1 shows a wound stator 10 for a polyphase rotary electrical machine of a motor vehicle. This wound stator 10 comprises a body 11 carrying a winding 12, said to be of the pin type, consisting of an assembly of electrically conductive segments 13.

The body 11 is produced from sheets of sheets stacked axially on one another to limit the eddy currents. The stator body 11 is provided with notches 16 regularly distributed along the internal periphery of the body 11 and in each of which is inserted at least one conductive segment 13.

Preferably, as can be seen in FIG. 2a, an electrical insulator 17, for example based on mica, is interposed between the segments 13 and the edges of the notches 16. The notches 16 are here of the semi-closed type and lead to the internal periphery of the body 11 via an opening of width less than that of the notches 16. As a variant, the notches 16 may be of the closed or open type.

For example as visible in FIG. 2b, each conductive segment 13 has a general shape of U whose base 18 extends projecting from one of the axial end faces of the body 11 and whose branches 19a, 19b each fit into a respective notch 16, so that their free connection ends 21 project beyond the other end face of the body 11. The portions of the segments 13 project from on either side of the stator body 11 are called winding buns.

As can be seen in FIG. 2a, each conductive segment 13 has a cross-section of generally rectangular shape and is coated with an electrically insulating layer so that the segments 13 are electrically insulated from each other in the notches 16. In alternatively, the segments 13 may have a section of square or round shape. In an exemplary embodiment, the conductive segments 13 are made from an electrically conductive copper wire coated with an electrically insulating layer of enamel.

More specifically, two branches 19a, 19b of the same conductive segment 13, forming a first conductor, are inserted in a first notch and a second notch distant from each other by a predetermined number of notches. A second conductor which also has two branches 19a, 19b has one of its branches inserted in the same notch as one of the branches of the first conductor, that is to say the first or the second notch, and the other of its branches inserted in a third notch distant from the first or second notch, in particular, of said predetermined number of notches. Thus each notch has several branches aligned radially and forming different layers. For example, FIG. 2a shows a notch comprising four layers of conductive segment 13. For example, the two branches of the same conductive segment are arranged in different layers. To complete the winding, the free ends of the adjacent branches are welded together in pairs.

The following describes, with reference to FIG. 4, the method of manufacturing a wound stator 10 according to the present invention.

In a step 101, one of the branches 19a of each segment 13 is inserted into a radially internal portion of a respective notch 16, the other branch 19b being inserted into a radially external portion of another notch 16 respectively for radially forming at least two layers of conductors.

In this case, the mounting is carried out by axial threading of the branches 19a, 19b in the notches 16. As a variant, the mounting can be carried out by radial threading of the said branches 19a, 19b in notches

16. In particular, it is possible to transform the open notches into semi-closed notches 16 after the insertion of the conductive segments 13, for example by folding down the material, as described in document FR631056.

As can be seen in FIG. 1, after assembly of all of the conductive segments 13 of the stator 10, all the notches 16 are provided with branches 19a, 19b of conductive segments 13.

In the exemplary embodiment, the stator 10 is arranged so as to be provided, for each notch 16, with four branches 19a, 19b of conductive segments 13 forming outside the body 11 two pairs of connection ends 21 in particular separated from each other to be welded. More generally, the invention applies to a stator 10 having any number of segments 13 per notch 16. Preferably, the number of segments 13 per notch is worth 2, 4, 6, 8 or 10.

As can be seen in the example of FIGS. 3a and 3b, the connection ends 21 of the segments 13 each have chamfers 24 with an angle between 40 ° and 55 ° and preferably equal to 45 degrees.

After the step of mounting 101 of the conductive segments 101 in the notches 16 of the body 11, there is a twisting step 102 of the free ends of the conductive segments 13. For example for two adjacent layers of conductors, it is possible to fold the free ends of the conductive segments 13 located in the radially external position in the clockwise direction, considering the direction of rotation of the rotor, and the free ends of the conductive segments 13 in the radially internal position in the counterclockwise direction.

After having carried out this assembly and this twisting step 102, a stripping step 103 is carried out on the connection ends 21 of the conductive segments 13. Alternatively, this stripping step 103 can be carried out during the formation of the conductors, therefore before the assembly step 101.

The stripping step 103 comprises for example a step 104 of burning the enamel layer covering the connection ends 21 of the segments 13 and a cleaning step 105 of the connection ends 21 of the segments 13.

Advantageously, the step of burning 104 of the enamel is carried out using a carbon dioxide laser and the cleaning step 105 is carried out using a laser of YAG type (Garnet of yttrium-aluminum).

To produce a continuous winding 12 along the periphery of the body 11, the connection ends 21 adjacent to the conductive segments 13 are welded to each other using a laser capable generating a photon beam in a step 106.

To this end, the stator 10 is rotated so as to present successively pairs of two connection ends 21 to be welded opposite the welding means used. The connection ends 21 can be driven in one or the other of the circumferential directions D1, D2 with respect to the photon beam. Alternatively, the welding means can be moved and the stator remain stationary.

The welding step is carried out by two photon beams F1, F2 each emitted on one of the adjacent connection ends to be welded together. The beams are emitted at the same time and for the same duration. For example, the beams emitted are identical, that is to say that they have the same power.

The two beams F1, F2 each extend in one direction, the two directions being parallel to each other. Preferably, these directions are also parallel with the direction of extension of the connection ends, in particular this direction is parallel to the axis of the machine. Each beam F1, F2 comes from a laser source (not shown). The sources are arranged at the same distance and the same angle of inclination of the connection ends to be welded. Preferably, this angle of inclination is zero.

At the end of the welding operation, the welding beads 28 provide the electrical connections between two adjacent connection ends 21, as shown in Figures 3a, 3b, 3c, and 3d. Each weld bead 28 enters a window 29 of generally rectangular shape extending between the chamfers 24. The depth of penetration of the weld bead 28 can be adapted according to the application.

As shown in FIG. 3c in particular, the weld beads 28 obtained each have a convex shape in two circumferential directions D1, D2 opposite one with respect to the other. The convex shape of the weld bead 28 may have an asymmetry with respect to an axis of the connection ends 21.

For example, the weld bead 28 has an oblong shape whose circumferential section forms an ellipse.

A radial length L1 of the weld bead 28 is substantially equal to twice a circumferential width L2. In addition, the radial length L1 is substantially equal to a radial length L3 of a connection end 21 of one of said conductive segment 13. The welding bead 28 being centered relative to the two connection ends 21, it extends therefore substantially on half of each connection end 21.

An axial height H1 of the weld bead 28 is greater than or equal to half of the radial length L1 of said bead. For example, the axial height H1 is also greater than or equal to the radial length L3 of a connection end 21.

In the embodiment shown, all the connection ends 21 of the conductive segments 13 are located on the same side of the stator 10. As a variant, the connection ends 21 of the segments 13 could be located on both sides of the stator 10, the segments 13 then being inserted axially into the notches 16 along two opposite sides of the stator body 11. In another variant, the conductive segments 13 each comprise a single branch 19a, 19b. The connection ends 21 of the conductive segments 13 are then located on both sides of the stator body.

Of course, the foregoing description has been given by way of example only and does not limit the scope of the invention from which one would not depart by replacing the various elements with any other equivalent.

Furthermore, the different features, variants, and / or embodiments of the present invention can be combined with one another in various combinations, insofar as they are not incompatible or mutually exclusive of one another.

Claims (10)

1. Method for manufacturing a stator (10) of a rotary electrical machine, in particular for a motor vehicle, said stator (10) being provided with a body (11) and a winding (12) having a plurality of conductive segments (13), said method comprising:
a step (101) of inserting the conductive segments (13) inside the notches (16) formed in the stator body (11), each conductive segment comprising at least one connection end (21),
a step of welding (106) the connection end (21) of a conductive segment (13) to the connection end (21) adjacent to another conductive segment (13), and the method being characterized in that said welding step (106) is carried out by generation of a photon beam, so that the photon beam forms a welding bead (28) between two adjacent connection ends (21) and that the welding bead is curved in two circumferential directions (D1, D2) opposite to each other.
2. Method according to claim 1, characterized in that it comprises a prior stripping step (103) of the connection ends (21) of the conductive segments (13).
3. Method according to claim 2, characterized in that the stripping step (103) comprises a step of burning (104) a layer of enamel covering the connection ends (21) of the conductive segments (13) and a step of cleaning (105) the connection ends (21) of the conductive segments (13).
4. Method according to any one of claims 1 to 3, characterized in that the welding step (106) is carried out by two beams of photons emitted simultaneously each on one of the connection ends (21) to be welded.
5. A stator (10) of a rotating electric machine, in particular for a motor vehicle, comprising:
- a body (11) provided with a plurality of notches (16),
- a winding (12) comprising a plurality of conductive segments (13) inserted in notches (16) of the stator body (11), each conductive segment (13) comprising at least one connection end (21) electrically connected via a weld bead (28) at an adjacent connection end (21) of another conductive segment, characterized in that the weld bead (28) has a curved shape in two circumferential directions (D1, D2) opposite one compared to each other.
6. Stator according to claim 5, characterized in that the welding bead (28) has an oblong shape.
7. Stator according to claim 5 or 6, characterized in that a radial length (L1) of the weld bead (28) is substantially equal to twice a circumferential width (L2) of said bead.
8. Stator according to any one of claims 5 to 7, characterized in that a radial length (L1) of the weld bead (28) is substantially equal to a radial length (L3) of a connection end (21 ) of one of said conductive segments (13).
9. A stator according to any one of claims 5 to 8, characterized in that the connection ends (21) of the conductive segments are chamfered.
10. Rotating electric machine in particular for a motor vehicle comprising a stator according to any one of claims 5 to 9.
FR1854325A 2018-05-23 2018-05-23 Method for manufacturing a rotating stator station of rotating electric machine Pending FR3081631A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
FR1854325 2018-05-23
FR1854325A FR3081631A1 (en) 2018-05-23 2018-05-23 Method for manufacturing a rotating stator station of rotating electric machine

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR1854325A FR3081631A1 (en) 2018-05-23 2018-05-23 Method for manufacturing a rotating stator station of rotating electric machine

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FR3081631A1 true FR3081631A1 (en) 2019-11-29

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FR1854325A Pending FR3081631A1 (en) 2018-05-23 2018-05-23 Method for manufacturing a rotating stator station of rotating electric machine

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FR (1) FR3081631A1 (en)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1081830A2 (en) * 1999-08-06 2001-03-07 Denso Corporation Electric rotary machine having a plurality of conductor segments and method of manufacturing the same
US20030159269A1 (en) * 2001-02-28 2003-08-28 Romaric Lenoir Method for assembling conductive segments of a rotor winding or stator winding in a rotary electric machine
EP2696475A1 (en) * 2011-04-05 2014-02-12 Toyota Jidosha Kabushiki Kaisha Stator and method of manufacturing stator
DE102014226710A1 (en) * 2014-12-19 2016-06-23 Continental Automotive Gmbh Method and apparatus for welding wire segment pairs

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1081830A2 (en) * 1999-08-06 2001-03-07 Denso Corporation Electric rotary machine having a plurality of conductor segments and method of manufacturing the same
US20030159269A1 (en) * 2001-02-28 2003-08-28 Romaric Lenoir Method for assembling conductive segments of a rotor winding or stator winding in a rotary electric machine
EP2696475A1 (en) * 2011-04-05 2014-02-12 Toyota Jidosha Kabushiki Kaisha Stator and method of manufacturing stator
DE102014226710A1 (en) * 2014-12-19 2016-06-23 Continental Automotive Gmbh Method and apparatus for welding wire segment pairs

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