WO2015159032A1

WO2015159032A1 - Method for the production of an electric machine stator, comprising a conductor deforming step, and corresponding stator

Info

Publication number: WO2015159032A1
Application number: PCT/FR2015/051035
Authority: WO
Inventors: Ludovic Darras; Vincent Ramet; Mostafa Kadiri; Denis Even; Jean Duquesne; Larry SAPOTILLE
Original assignee: Valeo Equipements Electriques Moteur
Priority date: 2014-04-17
Filing date: 2015-04-16
Publication date: 2015-10-22
Also published as: FR3020196A1; FR3020196B1; EP3132526A1

Abstract

The invention essentially relates to a method for the production of a winding of a stator comprising a body (16) equipped with a yoke (26) and teeth (25) arranged on the internal periphery of the yoke (26), with slots (28) being defined between pairs of teeth (25), characterised in that it comprises: a step of inserting segment structures (38) of conductors forming a winding into the slots (28) of the stator; and a step of using a punch (170) to deform the segment structures (38) of the conductors (37) located in a radial layer of conductors closest to an axis of the stator.

Description

METHOD FOR PRODUCING AN ELECTRIC MACHINE STATOR COMPRISING A CONDUCTOR DEFORMATION STEP AND CORRESPONDING STATOR

The present invention relates to a method of producing an electric machine stator comprising a step of deformation of the conductors as well as on the corresponding stator.

The invention finds a particularly advantageous application for a stator of a rotary electrical machine such as for example an alternator, an alternator-starter, or an electric motor. In known manner, 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. Alternatively, in a so-called "salient" poles architecture, the poles are formed by coils wound around rotor arms.

The stator comprises a body constituted by a stack of thin sheets and a winding of the phases received in slots of the stator open towards the inside. Phases are usually three or six. In the stators of alternators of this type, the most commonly used types of windings are, on the one hand, so-called "concentric" windings constituted by coils closed on themselves which are wound around the teeth of the stator, and secondly, the windings of the type called "corrugated", which are described for example in the document FR2483702.

The corrugated winding comprises a plurality of phase windings, of the type in which each winding comprises at least one spiral conductor of which each turn forms undulations passing through the notches of the body. These conductors have loop structures located alternately on each side of the rotor or the stator interconnecting segment structures located within the slots of the stator. A set of loop structures protruding from one side of the stator constitutes a coil winding.

In order to improve the performance of the electric machine, it is preferable to fill the slots of the stator as much as possible while facilitating the formation of winding bunches. For this, for stators component alternators especially for automotive applications, it has been proposed in US6459187 to achieve "front-rear" type windings having phase windings formed by conductors having segment structures positioned alternately in an inner radial layer and an outer radial layer of conductor. In order to facilitate the insertion of the conductors inside the notches by the inner open end of the notches, the applicant has developed stators without tooth roots. However, such a configuration does not make it possible to optimally maintain the conductors inside the notches. The invention aims to effectively remedy this disadvantage by proposing a method for producing a winding of a stator comprising a body provided with a yoke and teeth arranged on an inner periphery of said yoke, said teeth defining two by two. notches, characterized in that it comprises:

a step of inserting conductor segment structures forming a winding in the stator slots, and a step of deformation, by means of a punch, of segment structures of the conductors located in a radial layer of conductors closest to an axis of the stator.

The invention thus ensures the maintenance of the conductors inside the notches, ensuring that the deformed edges of the conductors bear against the inner faces of the notches. Indeed, the deformation by means of the punch allows a flow of the material to the inner faces of the notches.

According to one embodiment, said method comprises the step of producing three axially distributed deformations on each of the segment structures of the conductor layer closest to the axis of the stator.

According to one implementation, the deformations are made so that a ratio between a length of a deformation and a gap between two successive deformations is between 0.8 and 1.2. In one implementation, extreme deformations are spaced from corresponding axial ends of the segment structures by at least three millimeters.

According to one embodiment, said method comprises the step of producing two axially distributed deformations on each of the segment structures of the conductor layer closest to the axis of the stator.

According to one implementation, each deformation is spaced from the corresponding axial ends of the segment structures by at least three millimeters.

According to one embodiment, said method comprises the step of producing an axially elongate elongated deformation on each of the segment structures of the conductor layer closest to the axis of the stator.

According to one implementation, the deformation is carried out so that ends of this deformation are spaced from the corresponding axial ends of the segment structures by at least three millimeters. According to one embodiment, a ratio between a segment structure width and a notch width before deformation of the conductors is between 0.9 and 2.

According to one embodiment, said method comprises a step of producing a rounded shape in corners located at the free ends of the teeth.

According to one embodiment, said method comprises a step of producing a coil comprising a plurality of phase windings.

According to one embodiment, the winding is made so that the segment structures of two conductors of the same phase winding are alternately positioned in an inner radial layer and an outer layer of conductors along a circumference of the stator.

According to one implementation, said method comprises the step of producing each phase winding from a single wire. According to one embodiment, said winding is formed, so that for two adjacent notches of a series of notches associated with a phase winding, the winding has two loop structures located on either side of the stator connecting segment structures of one of said notches adjacent to those of the other. According to one implementation, said two loop structures respectively connect a segment structure belonging to an inner layer to a segment structure belonging to an outer layer and a segment structure belonging to an outer layer to a segment structure belonging to an outer layer. inner layer. According to one implementation, the conductors have a square or rectangular section.

According to one embodiment, said method comprises a step of stamping the segment structures intended to be inserted into the notches of the stator. According to one embodiment, said method comprises the step of producing a winding comprising four, six or eight layers of conductors radially superimposed in the notches of the stator.

According to one embodiment, said method comprises the step of producing a coil comprising eight radially superposed layers of conductors in the notches of the stator.

According to one implementation, each deformation is performed by applying the punch in a radial direction.

According to one implementation, said method comprises a step of placing a continuous notch insulation before inserting the segment structures inside the stator slots.

The invention also relates to a wound stator comprising a body provided with a yoke and teeth arranged on an inner periphery of said yoke, said teeth delimiting pairs of notches in which are inserted conductor segment structures of a winding, characterized in that the segment structures of the conductors located in the layer closest to an axis of the stator have traces of deformations.

In other words, the segment structures corresponding to portions of a wire intended to be inserted into said slots.

In one embodiment, each of the segment structures of the conductor layer closest to the stator axis has three axially distributed deformation traces.

According to one embodiment, a ratio between a length of a deformation and a gap between two successive deformations is between 0.8 and 1.2.

In one embodiment, extreme deformations are spaced from corresponding axial ends of the segment structures by at least three millimeters. In one embodiment, each of the segment structures of the conductor layer closest to the stator axis has two axially distributed deformation traces.

In one embodiment, each deformation is spaced from the corresponding axial ends of the segment structures by at least three millimeters.

In one embodiment, each of the segmental structures of the conductor layer closest to the stator axis has a single axially elongated deformation trace. In one embodiment, ends of this deformation are spaced from the axial ends of the corresponding segment structure by at least three millimeters.

In one embodiment, the teeth of the stator are devoid of toes.

In one embodiment, corners located at the free ends of the teeth have a rounded shape.

In one embodiment, the coil comprises a plurality of phase windings.

According to one embodiment, the winding comprises segment structures of two conductors of the same phase winding positioned alternately in an inner radial layer and an outer layer of conductors along a circumference of the stator.

In one embodiment, each phase winding consists of a single wire.

According to one embodiment, for two adjacent notches of a series of notches associated with a phase winding, the coil has two loop structures located on either side of the stator connecting segment structures lying in said adjacent notches .

In other words, the loop structures corresponding to portions of a wire interconnecting the segment structures. In one embodiment, said two loop structures respectively connect a segment structure belonging to an inner layer to a segment structure belonging to an outer layer and a segment structure belonging to an outer layer to a segment structure belonging to an inner layer. .

In one embodiment, the conductors have a square or rectangular section.

In one embodiment, the segment structures for insertion into the stator slots are stamped. According to one embodiment, said coil comprises four, six, or eight layers of conductors radially superimposed in the slots of the stator.

In one embodiment, said layer closest to an axis of the stator has deformation traces applied in a radial direction.

In one embodiment, each notch edge (28) covered with an insulator having an insertion clearance (J) with an end of a section of a given segment structure (38), increasing the width to each of the edges of the notch, the conductor layer (37) closest to the stator axis (15) of the enamel-covered segment structure (38) subsequent to its deformation is greater than audit insertion game. According to this embodiment, following its deformation, the segment structure layer closest to the axis of the machine will extend ortho radially to each of the two edges of the notch. The insertion set and the deformation are chosen such that the increase of the width of the layer closest to the axis of the machine towards each of the two edges corresponds to the insertion play, for example the insertion game. is greater than increasing the width to each of the two edges. In other words, the total increase in the width of the segment structure layer closest to the axis of the machine is greater than twice the insertion gap. This results in a tightening of the layer closest to the axis of the machine between the two edges of the notch. According to one embodiment, a ratio between a notch width covered with a notch insulator L1 and a segment structure width covered with enamel L2 is between 0.9 and 2.

During the deformation of the layer closest to a stator axis of the conductor segment structures, the width L2 of the enamel-covered segment structure will increase. This increase allows its maintenance in the notch. The ratio between the notch width and the width of the conductor between 0.9 and 2 allows on the one hand, the introduction of the segment structure in the notch and on the other hand ensures a good maintenance of the structure of segment after its introduction into the notch and its deformation.

In one embodiment, each notched edge covered with an insulator having an insertion clearance with one end of a section of a given segment structure, the notch width is equal to the sum of the structural width. segment and double the insertion set, said double of the insertion set being less than 0.3mm. For example, said double of the game is greater than a negative game of -0.2mm and less than a positive game of + 0.3mm.

A positive clearance corresponds to a width L1 greater than the width L2, that is to say to a non-zero space between the edge of a notch covered with its insulator and the segment structure while a negative clearance corresponds to a null space between the edge of a notch covered with its insulation. More specifically, in the case of a negative clearance the width L2 is greater than the width L1 so that the segment structure is tightly mounted in the notch. In other words, in the case of a positive game, the sum between the double of the positive game and the width of the segment structure is equal to the width of the notch covered with its insulation. Similarly, in the case of a negative game, the sum between the double of the negative clearance and the width of the segment structure is equal to the slot width covered with its insulation. However, the considered width of the segment structure is that before insertion.

However, the notch width and the width of the segment structure are measured in a radial ortho direction. Notch width does not not include the toothache, if any. In the case where the notch has tooth roots, the notch width is measured just below the tooth roots.

The choice of a double value of the insertion clearance less than 0.3 mm ensures, after the deformation extending over the entire axial length of the layer closest to the stator axis, conductor segment structures, a maintenance optimal segment structures in the notches. Indeed, the increase of the width L2 of the segment structure covered with enamel will increase towards each of the two edges by a value corresponding to this game, for example the increase towards each of the two edges is greater than 0, 3 mm, so that a tightening of the layer closest to the axis of the machine between the two edges of the notch is obtained.

According to another embodiment, the notches are trapeziums and are each provided with edges whose directions converge towards the axis of the stator.

In other words, each of the notches have two edges that define its shape, these two edges are not parallel and each have a direction. The stator defines an axial center passing through which is traversed by the axis of the stator. In this case, the directions of each of these two edges defining the shape of the notch are such that when approaching the axial center as defined, the distance between the two straight lines superimposed on the two edges decreases, from so that both edges converge. For example, the direction of each of these two edges is substantially radial. According to one embodiment, in the case of a trapezoid notch, for each notch is defined:

a notch entry set equal to the insertion set;

-a notch bottom set, the double bottom notch clearance being less than + 0.5mm. In the case of a trapezoid notch, the width of the notch varies as one moves radially along the edges of the notch. So we have a variation of the clearance between the width of the notch and an end of a section of a given segment structure, depending in particular on the bottom of the notch or at the entrance of the notch.

One can first define a notch entry set that corresponds to the difference between the width of the notch at its input and the segment structure width covered with its email.

Secondly, a notch bottom set which corresponds to the difference between the width of the notch at its bottom and the width of the segment structure covered with its email can be defined secondly. However, as already mentioned above the notch width and the width of the segment structure are measured in a radial ortho direction. Notch width does not include toe feet, if any. In the case where the notch has tooth roots, the notch width is measured just below the tooth roots. This difference between the play at the bottom of the notch and notch entry due to the trapezoid notch allows during the radial insertion, a better hold of the notch insulation. Indeed, at the beginning of the insertion, the segment structure sees the notch entry play and pulls a little on the notch insulation, and then when the segment structure arrives in the middle of the notch it sees a game with the edges of the notch that increases, it no longer pulls on the insulation. This is advantageous because at the beginning of the insertion is in the range of elasticity of the insulator while in the insertion medium, the pulling may cause the rupture of the insulation.

To maintain the notch of the conductor layer closest to the axis of the machine, it is necessary for the deformation to be such that the final width after deformation of said layer is greater than the input width of the machine. notch. All that is required is that the expansion of material following the deformation towards each of the two edges is greater than the entry game. That is, the total increase due to deformation of the width of the segment structure layer closest to the axis of the machine is greater than twice the insertion clearance. The invention will be better understood on reading the description which follows and the examination of the figures which accompany it. These figures are given for illustrative but not limiting of the invention.

Figure 1 is a partial perspective view of the interior of a stator in which the conductors of a phase winding are arranged in accordance with the invention;

Figure 2 shows a top view of the stator body of Figure 1;

Figure 3 is a detailed top view of the shape of the teeth of the stator of Figure 1; FIG. 4 shows a detailed top view of the external indexing means of the stator of FIG. 1;

FIG. 5 represents a linear development of two conductive wires forming a phase winding showing the relative radial position of the two conductors relative to one another on the circumference of the stator; Figure 6 is a perspective view of the stator according to the present invention provided with its winding;

Figure 7 shows a partial perspective view of the regular and irregular parts of the stator winding according to the present invention;

Figure 8 is a partial perspective view of the irregular portion of the stator winding shown alone;

Figure 9 is a schematic perspective view of an installation for producing a winding sheet according to the present invention;

Figure 10 is a perspective view on a larger scale of the installation shown in Figure 9;

Figures 11a and 11b are respectively perspective and side views of a first type of storer used with the installation of Figures 9 and 10; Figures 12a and 12b are respectively perspective and side views of a second type of storer used with the installation of Figures 9 and 10;

Figure 13 is a perspective view of a storager assembly of Figures 1 1 and 12;

Figure 14 is a longitudinal detailed sectional view of the assembly of Figure 13 showing a portion of the winding sheet located between the storers;

Figures 15a and 15b respectively show top and side views of the winding sheet obtained with the installation of Figures 9 and 10;

Figures 16a and 16b are respectively perspective and side views of a modular comb used for the transfer of the winding sheet to an annular pin; Figures 17 to 20 show perspective views of the various elements making up the modular comb of Figures 16a and 16b;

Figure 21 is a perspective view of the tool for performing a first step of shaping the winding bun on the transfer comb; Fig. 22 is a schematic representation of the annular pin about which the coil ply is wound prior to expansion transfer to the stator body;

FIG. 23 is a schematic representation of an installation for implementing the first step of transferring the conductors of the winding sheet to the annular pin of FIG. 22;

Figure 24a schematically shows the step of placing a continuous slot insulator within the stator slots according to the present invention; Figure 24b schematically shows the step of cutting the notch insulation after insertion of the winding conductors into the stator slots according to the present invention;

Figures 25a and 25b are respectively perspective and top views of a stator according to the present invention provided with notch insulators made according to a second embodiment;

Figures 26a and 26b show the step of placing the stator around the annular spindle to perform the transfer of the coil by expanding the annular pin to the stator; Figures 27a and 27b are schematic representations of the extraction blades respectively shown in initial position and approaching the final position in which the coil has been transferred to the stator body;

Figure 28 is a perspective view of the tool for performing the step of shaping the buns after the realization of the wound stator;

Figures 29a to 29c show alternative embodiments of a punch for performing the deformation step of the inner layer of conductors for their maintenance inside the stator;

Figure 30 is a detailed top view of a stator according to the present invention provided with foldable tooth stands;

Figures 31a and 31b show in top view two embodiments of the collapsible teeth of the stator according to the present invention;

FIG. 32 represents a step of stamping the segment structures of the conductors of the winding sheet; FIGS. 33 and 34 show two alternative embodiments of the tooling enabling continuous wire stamping according to the method of the invention;

FIG. 35a is a perspective view of the wire obtained at the end of the stamping step made with one of the tools of FIGS. 33 and 34; Fig. 35b is a perspective view of a portion of a phase winding die wire provided with two segment structures and a loop structure;

Figure 36 is a top view of two sub-plies intended to be nested with each other to obtain the winding ply according to the present invention;

FIG. 37a is a perspective view of a wound stator provided with an interconnector providing a delta coupling of the phase windings of the electric machine; FIGS. 37b and 37c show respectively the diagram of the connections inside the interconnector of FIG. 37a between the terminals of the interconnector and the inputs and the outputs of the phase windings, as well as the corresponding electrical diagram;

FIG. 38a is a perspective view of a wound stator provided with an interconnector forming a star coupling of the phase windings of the electric machine;

FIGS. 38b and 38c show respectively the diagram of the connections inside the interconnector of FIG. 38a between the terminals of the interconnector and the inputs and outputs of the phase windings, as well as the corresponding electrical diagram;

Figure 39 shows an alternative embodiment of the connection between a tab of an interconnector of Figures 37a and 38a and an end of a phase winding;

Figure 40 shows the influence on the height of the loop structures of the transfer phenomenon of the annular pin to the stator;

Figs. 41a-41b-43a-43b are perspective and side views of a wound stator according to the present invention having different winding winding configurations; Figures 44a and 44b show top views of a stator made in two parts having a central core (Figure 44a) and a bolt reported to be fixed around the central core (Figure 44b);

Figures 45a and 45b show the steps of placing by bending a planar yoke around the central core wound;

Figure 46 shows a step of producing the cylinder head around the central core from a flat sheet wound around the central core;

Figures 47a to 47d show alternative embodiments of the interlocking between the outer ends of the teeth of the central core and the inner periphery of the bolt reported;

Figures 48a and 48b are partial perspective views showing the possible variants of embodiment of the connection areas between the teeth of the central core;

Figure 49 shows a perspective view of a flat stator to be arched after placement of the winding sheet;

Figure 50 shows a perspective view of a curved stator without winding provided with a package of sheets whose sheets have been heat sealed;

Figure 51 shows a line of two half-packs of flat sheets having a side sheet pressed against one of their faces; Figure 52 is a perspective view of the stator obtained after assembly and bending of the two half-packs of Figure 51 without the winding;

Figure 53 is a detailed perspective view of one of the axial ends of the stator teeth having a rim sheet;

FIG. 54 is a perspective view of a stator represented without its winding obtained from a flat stator having at least one weld made in the bottom of a notch;

Figure 55 is a detailed perspective view of a weld made in the bottom of a notch; FIG. 56 represents a view from above of the stator of FIG. 54 showing the relative angular positioning of the welds;

Figure 57 is a detailed perspective view of the stator with a recess in each of the notches to facilitate the bending step; Figure 58 shows an alternative embodiment of the winding using two son in hand by phase winding.

Identical, similar or similar elements retain the same reference from one figure to another.

FIG. 1 shows a partial view of a stator 15 of a rotating electrical machine which mainly comprises a body 16 in which are mounted a plurality of phase windings E1-E6 forming a winding 17 clearly visible in FIG. 6. A single winding E1 has been shown in Figure 1 for ease of understanding.

The rotating machine is for example an alternator or an alternator-starter. This machine is preferably intended to be implemented in a motor vehicle. It is recalled that an alternator-starter is a rotating electrical machine capable of reversibly working, firstly, as an electric generator in alternator function, and secondly as an electric motor, in particular for starting the engine of the motor vehicle .

As shown in FIG. 2, the stator body 16 has an annular cylindrical shape with an X axis and consists of an axial stack of plane sheets. The body 16 of stator 15 is delimited radially by an inner cylindrical face 20 and by an outer cylindrical face 21. The body 16 is moreover defined axially by a radial face of lower axial end 22 and by a radial face of upper axial end 23.

The body 16 has teeth 25 angularly distributed regularly over an inner circumference of a yoke 26. These teeth 25 delimit two by two notches 28. The yoke 26 corresponds to the full outer annular portion of the body 16 which extends between the bottom of the notches 28 and the outer periphery of the stator 15. The notches 28 open axially into the radial faces of the lower axial end 22 and upper 23 of the body 16. The notches 28 are open radially in the internal cylindrical face of the body 16. In a variant, the notches 28 are open in the outer cylindrical face of the body 16. The notches 28 of the stator 15 are preferably with parallel edges, that is to say that the inner faces facing each other of the notches 28 are parallel, one to the other. report to the other. The notches 28 are for example 36, 48, 60, 72, 84, or 96. In the exemplary embodiment, the stator 15 has 96 notches. They are angularly distributed regularly around the axis X of the body 16.

To form the winding 17 of the stator 15, several phase windings E1-E6 are mounted in the body 16. In this case, the "hexaphase" stator comprises six E1-E6 phase windings. The invention is however applicable to stators 15 comprising a different number of phase windings, and in particular to "three-phase" stators comprising three E1-E3 phase windings, or five-phase stators comprising five E1-E5 phase windings. or heptaphased with seven E1 -E7 phase windings. The body 16 of the stator 15 then comprises for example thirty-six or forty-eight notches 28. Preferably, as is clearly visible in FIG. 3, the stator 15 does not have a toothed root on the side of the free ends of the teeth 25. In addition, wedges 31 located at the free ends of the teeth 25 preferably have a rounded shape along a radius R, said input radius. This input radius R is between 0.15 mm and half a width of a tooth 25. The realization of this radius makes it easier to insert the various layers of conductors 37 inside the notches 28 by the end of the notches 28 open on the inner side of the stator 15. To obtain the rounded shape in the corners 31, a step is made to cut the sheets of the body 16 along the radius R and a compaction step of the body 16 of the stator.

In addition, as can be seen in FIG. 4, external indexing means 32 provided on an outer periphery of the yoke 26 allow angular positioning under control during the various steps of embodiment of the wound stator 15 described in more detail below. These indexing means 32 are in particular used at the time of placing the stator 15 around the annular pin 105 before the transfer of the coil 17 to the notches 28 of the stator 15. These indexing means 32 are also used when the installation of a notch insulation.

These external indexing means 32 take the form of recesses 33 intended to cooperate with rods 34 of an external tool. The recesses 33 present in this case a V-shaped section, while the rods 34 have a round section. In a variant, the external indexing means 32 take the form of pins protruding from the outer periphery of the yoke 26 intended to cooperate with recesses formed in the external tool.

Each conductor 37 belonging to a phase winding E1-E6 comprises a series of segment structures 38 which are received in a series of associated notches 28. Each conductor 37 also comprises loop structures 39 which interconnect the consecutive segment structures 38 of a given winding E1-E6, and which extend alternately in projection relative to the upper axial end face 23 and in protruding from the lower axial end face 22. A set of loop structures 39 arranged at an axial end of the stator body 16 constitutes a winding bun 163.

To optimize the filling of notches 28, each conductor 37 may have a rectangular or square cross section whose width is substantially equal to the width of a notch 28. In one embodiment, the conductors 37 have a rectangular or square section over their entire length. Alternatively, the segment structures 38 have a square or rectangular section; while loop structures 39 connecting two adjacent segment structures 38 have a round section. To obtain such a configuration, the conductors 37 may undergo a stamping step described hereinafter with reference to FIGS. 32 to 34. The conductors 37 are preferably made of copper covered with enamel. Alternatively, the conductors 37 may be made of aluminum. As shown in FIG. 3, a ratio between a slot width L1 covered with slot insulator 145 and a width L2 of segment structure 38 covered with enamel measured in a direction perpendicular to the internal faces of the slot is defined. notch 28, or in an ortho-radial direction (ratio L1 / L2). This ratio is between 0.9 and 2 in order to maximize the filling of the notches 28 by the conductors 37, optimizing the size of the conductor 37 that can be inserted into the notch relative to the width of the notch 28.

Each notch being covered with an insulator, and each notch edge covered with the insulator preferably having a clearance J with an end opposite a section of a given segment structure 38, the notch width L1 is equal to the sum of the width of the segment structure 38 and the doubling of the set J, said doubling of the set J being greater than a negative set of -0.2mm and less than a positive set of + 0.3mm. The notches 28 of a series of notches receive the segment structures 38 of the conductors 37 constituting a phase winding E1-E6. Each series of notches 28 is associated with one of the six phase windings. Two consecutive notches 28 of a series of notches are separated by notches 28 adjacent each corresponding to another series of notches 28 associated with one of the other five phase windings. Thus, for a hexaphase stator 15 as is the case in FIG. 1, five adjacent notches 28 are left free between two notches 28 of each series. In other words, the conductors 37 of one winding are inserted into a notch on six adjacent notches 28. Thus, for a stator 15 having K phase windings, the segment structures 38 are received in a notch on K adjacent notches 28.

The phase windings E1-E6 define a radial stack of C1-C8 concentric layers, as can be seen in FIG. 3 or in FIGS. 41b, 42b or 43b. A so-called "outer" layer is located on the side of the yoke 26 with respect to an inner layer; while a so-called "internal" layer is located on the X axis side of the stator 15 with respect to the outer layer. There is shown here a stator 15 comprising eight concentric layers C1-C8 conductor 37. However, it is clear that the winding 17 may comprise less than or more than eight layers of conductors 37, and in particular six or four layers of conductor 37 radially superimposed as shown in Figure 5.

More generally, as explained in more detail below, the winding 17 is formed from a coil ply 52 of interlaced conductors wound on N / 2 turns of stator 15, N being the number of layers of conductors 37 desired in the wound stator, N being greater than or equal to two. The number N of conductor layers 37 is preferably four, six, or eight. As can be seen in FIG. 5 on which is represented a series of notches 28 associated with a given phase winding, here the phase winding E1, the successive segment structures 38 of the same conductor 37 are positioned alternately in an inner layer and an outer layer on the majority of the circumference of the stator 15. Thus, for a pair of conductors 37a, 37b from the same wire 44 folded as is explained in more detail below and occupying the layers C1 and C2, each conductor 37a, 37b is generally sinusoidal in shape and consecutively comprises a lower loop structure 39 which extends below the lower face 22 of the body 16, a segment structure 38 which is received in a notch associated, an upper loop structure 39 which extends above the upper face 23 of the body 16, or an upper loop structure 39 which extends above the upper face 23 of the body 1 6, a segment structure 38 which is received in an associated notch, a lower loop structure 39 which extends below the lower face 22 of the body 16.

When in a notch 28 of the series, the segment structure 38 of the conductor 37a is in the layer C1, the segment structure 38 of the conductor 37b is in the layer C2. On the other hand, when the segment structure 38 of the conductor 37a is in the layer C2 of the successive notch 28 of the series, the segment structure 38 of the conductor 37b is in the layer C1. In all cases, the two segment structures 38 are superimposed radially on each other in each notch 28. This alternation in the layers is also found in the layers C3 and C4 of the winding 17. In each notch 28 of the stator 15, there is thus a single column of segment structures 38 stacked radially on each other.

Moreover, for two adjacent notches 28 of a series of notches associated with a phase winding E1-E6, the winding 17 has two loop structures 39 located on either side of the stator 15 connecting segment structures 38. one of the notches 28 adjacent to those of the other.

Thus, the loop structure 39 of one of the conductors 37a which connects the segment structures 38 received in the two adjacent notches 28 mentioned above is arranged axially above the upper face of the body 16, while the loop structure 39 of the other conductor 37b which connects the segment structures 38 received in the two aforementioned adjacent notches 28 is arranged axially below the underside of the body 16.

In addition, for two adjacent notches 28 of a series associated with a given phase winding E1-E6, the loop structure 39 of the conductor 37a connects a segment structure 38 belonging to an inner layer to a segment structure 38 belonging to an outer layer; while the loop structure 39 of the other conductor 37b connects a segment structure 38 belonging to an outer layer to a segment structure 38 belonging to an inner layer. The relationship is reversed for the next two adjacent notches 28.

The coil 17 also has a discontinuity. Indeed, as shown in FIG. 7 and in FIG. 5, the winding 17 comprises a so-called "regular" portion 46 in which, for each phase winding E1-E6, segment structures 38 are connected each via two loop structures 39, with two adjacent segment structures 38 located in two different notches 28. The winding 17 also comprises a so-called "irregular" portion 47 situated in FIG. 7 on the side of the outer periphery of the stator 15, in which, for each phase winding E1-E6, at least one segment 38 is connected via two loop structures 39 to two segment structures 38 superimposed radially relative to each other in the same notch 28. As can be seen in Figure 5, the winding E1 thus presents in the leftmost notch 28 is a segment structure 38 connected via two loop structures 39 to two segment structures 38 superimposed radially relative to each other in the right adjacent notch 28. Alternatively, the irregular portion 47 is located on the side of the inner periphery of the stator 15.

Preferably, as shown in FIG. 8, in the irregular winding portion 47, the E1-E6 phase windings each comprise at least one loop structure 39 having radial adjustments 50, so that these loop structures 39 which connect segment structures 38 lying in identical conductor layers do not overlap. These radial adjustments 50 are defined by portions of a conductor 37 extending radially with respect to the axis of the stator 15 so as to avoid the loop structures 39 of the other phase windings connecting segment structures 38 located in the same layer.

It should be noted that for the first phase winding E1 located at one end of the series of notches 28 associated with the different phases, the loop structure 39 which connects two segment structures 38 positioned in the same layer does not require be configured to avoid the loop structures 39 of the other phase windings. As a result, this loop structure 39 is devoid of radial adjustment 50.

In addition, if a first type of loop structure 39 is defined which provides a connection of consecutive segment structures 38 received in the notches 28 situated in the same layer C1-C8 of conductors 37, and a second type of loop structure 39 ensuring a link of consecutive segment structures 38 received in the notches 28 located in C1-C8 layers of different conductors 37, the coil 17 is made so that less than 10 percent of all the loop structures 39 are of the first type loop structures 39. By implementing segment structures 38 which change layers in a large proportion, the stresses on the wires 44 of the winding bunches 163 are thus limited at the time of a change of revolution of the winding ply 52 around the stator 15 as this is explained below. In addition, by virtue of the predominant front-rear alternation of the winding, the number of radial adjustments 50 is limited because of the parallel positioning of the successive loop structures 39 associated with the E1-E6 phase windings in the direction of the winding. transition from one C1-C8 layer to another. As can be seen in FIG. 6, the loop structures 39 form stationary blades which are inclined in a direction D1 around the X axis of the stator 15 in accordance with a direction of a cooling fluid. With respect to a radial position of the blades, these blades are inclined in a direction corresponding to the direction of rotation of the rotor. This thus improves the flow of cooling fluid, generally air, inside the electric machine to optimize its cooling. The loop structures 39 are inclined to be substantially parallel in pairs for adjacent segment structures 39. A circulation of the cooling fluid is ensured by blades fixed to a rotor oriented substantially radially with respect to the axis of the stator 15.

In addition, such a configuration allows each bun 163 winding 17 to be of generally limited height. The height of each winding bun is thus less than 33% of a height of the body 16 of the stator 15, which saves copper in the buns for the same performance of the machine, since only copper present in the notches makes it possible to generate the current of the electric machine. The bunches of the winding 17 are preferably positioned exclusively inside an outer periphery of the stator 15, to facilitate the integration of the machine in the under-hood environment of the vehicle.

FIGS. 9 and 10 show an installation 51 making it possible to form a winding sheet 52 clearly visible in FIGS. 14, 15a, and 15b used for producing the hexaphase stator 15 according to the invention. This installation 51 comprises a winding unit 54 extending in a longitudinal direction Y and a feed unit 55 of the conductors 37 extending substantially transversely with respect to the winding unit 54.

More specifically, the feed unit 55 of the conductors 37 comprises a guide head 57 of conductors 37 secured to a movable support 58 in translation along the Y axis relative to a fixed frame 59. The displacement of the movable support 58 and the guide head 57 is effected by means of a referenced operating device 60.

Furthermore, the winding unit 51 comprises a winding unit 54 intended to successively receive storages 61 described in more detail below. The winding unit 54 is rotatable with the storer 61 which it carries around the Y axis relative to a stationary frame 64 of annular shape. The winding unit 54 is also configured to translate the storages 61 in translation to a storage unit 65. The winding unit 54 further comprises on its two opposite longitudinal lateral edges keys 66 intended to ensure the maintenance of the conductors 37 during the rotation of the winding unit 54 relative to the feed unit 55 of the conductors 37. The keys 66 also have a variable spacing in order to be able to vary a height of the layers of conductors during the realization of the winding sheet.

The winding process is based on the use of the storages 61 shown in FIGS. 11a, 11b, 12a and 12b and intended to be put in place successively on the winding unit 54. Each storer 61 consists of a generally parallelepipedal element of longitudinal orientation. Each storer 61 has transverse notches 69 arranged on two stages 70, 71 which open transversely into the lateral faces of storer 61. These notches 69 delimited two by two by teeth 72 are distributed longitudinally at a constant pitch along the storer 61. In the embodiment of FIGS. 11a and 11b, each storer 61 has a low floor 70 provided with small teeth 72 and a high floor 71 provided with large teeth 72, that is to say teeth 72 higher than the small teeth 72 of the low floor 70. The large teeth 72 may include lateral notches 74 on the side of their longitudinal ends to allow the passage of These notches 69 are intended to receive the segment structures 38 of the winding ply 52.

The low stage 70 comprises a number of successive notches 69 equal to the number of phases, here six notches 69. The high stage 71 has a number of notches 69 equal to the number of phases minus one, here five notches 69. These storages 61 comprise so-called double interlocking forms, for interlocking in series and in parallel the storages 61 between them. For this purpose, each storer 61 has at one of its longitudinal ends a tongue shape 76 intended to cooperate with a recess 77 of complementary shape of an adjacent storer 61 positioned in series.

In addition, because of the staged configuration of storers 61, two storages 61 can cooperate with each other by positioning them facing each other. The positioning is performed so that the teeth 72 of the lower stage 70 of a first storer 61 are located next to the teeth 72 of the upper stage 71 of a second storer 61, and the teeth 72 of the high floor 71 of the first storer 61 are located next to the teeth 72 of the low floor 70 of the second storer 61. These storages 61, between which the winding ply 52 is positioned, can thus guide and hold the conductors of the ply 52. In addition, another embodiment of the storages 61 shown in FIGS. 12a and 12b may also be used. a low stage 70 without tooth 72. These storages 61 also allowing double interlocking will be used in a level 80 compensation zone of the winding ply 52, in order to limit the stresses in the conductors of the ply 52 during the winding of the web 52 around the stator. This is explained in more detail below. The various steps of the winding process based on the use of a single wire 44 by E1-E6 phase winding are described below, ie six wires for a hexaphase winding. Those skilled in the art will be able to adapt the winding to a five-phase or heptaphased embodiment. The son 44 may each come from a container not shown in which is placed a coil of wire 44.

More specifically, the method comprises a pre-training step of moving, relative to the conductor bundle 37, the winding unit 54 so as to obtain a bundle of conductors 37 having for each phase winding E1-E6 at minus two loop structures 39 and at least three segment structures 38. Two of said segment structures 38 are positioned so as to be arranged in the same slot 28 of the stator 15. The two loop structures 39 respectively connect the two segment 38 superimposed on the third segment structure 38. The two segment structures 38 are positioned facing each other on either side of the winding unit 54. This step corresponds to obtaining the irregular portion 47 of the winding.

This preforming step makes it possible to split the number of conductors 37 with respect to the initial number of wires 44, so that the bundle of conductors 37 feeding the winding unit 54 following this step is equal to 12 as can be seen in Figure 10.

A forming step is then performed consisting of moving the winding unit 54 relative to the conductor bundle 37 so as to form, on a storage unit 61, a portion of each of the phase windings E1 - E6 each comprising two conductors 37. having at least one loop structure 39 and at least two segment structures 38, said loop structure 39 connecting the two segment structures 38. The step of forming the E1-E6 phase windings is performed so that segment 38 of two conductors 37 constituting the same phase winding E1-E6 (that is to say from the same wire 44) are positioned alternately in a lower layer and an upper layer of the Winding sheet 52. This step corresponds to obtaining the regular winding portion 46.

For this purpose, after setting up a storer 61 on the winding unit 54 facing the guide head 57, the operating device 60 is actuated so as to translate the guide head 57 and the associated bundle of conductors 37 with respect to the winding unit 54. The displacement of the bundle of conductors 37 is effected in the opposite direction of the storage unit 65 along the arrow F1 and following a pitch P corresponding to the number of phases, here a step of six notches 69. A key 66 is placed on the opposite side of the guide head 57 to maintain the voltage of the conductor bundle 37 during winding. The winding step of turning the winding unit 54 with respect to the conductor bundle 37 by 180 degrees along the arrow F2 is then carried out. This unwinds the bundle of son 44, which has the effect of filling the storer 61.

Then the feed unit 55 of conductors 37 and the initial storer 61 are translated together in the direction of the storing unit of the winding 65 according to the pitch P corresponding to the number of phases, here a step of six notches. This translation is thus performed along the arrow F3. A new storer 61 is positioned so that the notches 69 of the upper stage 71 of the new storer 61 are located opposite the notches 69 of the lower stage 70 of the previous storer 61 and that the notches 69 of the lower stage 70 the new storer 61 receives the conductors 37 during the next winding. The preceding steps are repeated until a winding sheet 52 covering a stator circumference 15 is obtained.

The method further includes a compensation step of compensating for a change in level of the web 52 when a winding of the web 52 covers a stator circumference 15. For this purpose, the formation of the plurality of E1 phase windings -E6 being performed by turning the winding unit 54 in the direction given by the arrow F2, when the sheet 52 has reached a length substantially equal to the circumference of the stator 15, the compensation step is carried out consisting of performing a step of forming said plurality of E1-E6 phase windings by rotating in an opposite direction F2 ' said given direction (ie a direction of rotation opposite the arrow F2), so as to form at least one loop structure 39 and at least two segment structures 38 for each phase winding E1-E6. Once the compensation step has been completed, the phase windings E1-E6 are continued around the winding unit 54 by rotating in said given direction along the arrow F2.

Indeed, it is specified that when the sheet 52 is wound around the stator 15, there is a radial offset at the time of changing the layer after a stator circumference. Indeed, the ply 52 must then be superimposed on a ply layer of the previous winding. The compensation step thus makes it possible to produce level compensation zones 80 visible in FIGS. 14 and 15b accompanying the radial offset of the sheet 52 at the location of a turn change. For this purpose, the zones 80 have a difference in level which has a shape complementary to the difference in level which exists at the place of a change of revolution of the ply around the stator 15. The height difference of the ply of coil 52 corresponds to a height of a layer of conductors 37 of the winding ply 52. The compensation step followed by the forming step thus makes it possible to obtain a height offset of two layers of conductors 37. the mechanical stresses on the conductors 37 of the ply 52 at the place of a layer change. Since it is desired to obtain eight layers of conductors 37 and the layer 52 comprises two layers of conductors 37, the layer 52 has a number of compensation zones 80 equal to the number of desired C1 -C8 conductor layers divided by two minus one, that is 8 / 2-1 = 3.

The preceding steps are repeated so as to obtain the winding ply 52 visible in FIGS. 15a and 15b positioned inside an assembly 81 of storages shown in FIGS. 13 and 14. It should be noted that there are two ways to produce a web 52 according to the invention consisting either of the method described above, or of a method requiring a reversal of the rotational directions F2 and F2 'respectively at the time of the step of training and at the time of the compensation stage.

The resulting ply 52 comprises two layers of conductors, and at one of its ends an irregular portion 47 and at its other end the inputs 11 -16 and the phase outputs 01 -06, the part of the ply which carries these inputs and outputs being called later in the document connections part 73.

The sheet 52 is put in place on a modular transfer comb 83 visible in FIGS. 16a and 16b having notches 84 delimited in pairs by teeth 85. The notches 84 of the comb 83 have dimensions similar to those of the stator 15. The comb 83 is mounted to move in translation on a rail 86. For this purpose, the comb 83 comprises in its lower part a cavity 87 extending longitudinally intended to cooperate with the rail 86.

More specifically, the modular comb 83 is composed of two end portions 88 and 89, as well as a plurality of central portions 90 and intermediate portions 91 of change of layer.

More specifically, the parts 88 and 89 respectively visible in Figures 17 and 20 are substantially identical. These portions 88 and 89 are intended to receive respectively the irregular portion 47 and the connection portion 73. Moreover, the central portions 90 are intended to receive the portions of the ply 52 corresponding to a circumference of the stator 15 (see FIG. ), while the intermediate portions 91 are intended to receive the compensation zones 80 (see FIG. The central portions 90 and the intermediate layer change portions 91 abut each other alternately. The modular comb 83 will thus be able to adapt to the configuration of the winding 17 of the stator 15, in particular to the number of layers C1-C8 and to the circumference of the stator 15, by simply modifying the dimensions and the number of central parts 90 and intermediate parts 91. The notches 84 located at a junction 95 between two portions 88-91 preferably have an opening greater than the other notches 84. In addition, each portion 88-91 of the comb 83 preferably has longitudinal grooves 98, the occurrence of two to allow the passage of sloping surface guides 107 for the transfer of the winding ply 52 to an annular pin 105, as described more specifically below.

The coil ply 52 has two layers of conductors 37 superimposed on each other. There is thus a lower layer of conductor 37 located on the bottom side of the notches 84 of the comb and an upper layer located on the side of the opening of the notches 84 of the comb.

As can be seen in FIG. 19, each conductor 37 of the ply 52 obtained forms longitudinal corrugations successively comprising a segment structure 38 which is received in an associated notch, a loop structure 39 which extends -vis the lower side face of the comb 83, a consecutive segment structure 38 which is received in a subsequent associated notch 84, a loop structure 39 which extends opposite the upper side face of the comb 83 The loop structures 39 are arranged alternately on either side of the comb 83, that is to say that they are offset longitudinally by a step equivalent to the distance between two consecutive segment structures 38.

In a manner similar to that of the body 16 of the stator 15, the notches 84 of the comb are associated in series with the conductors 37 of a phase winding E1-E6. Thus, the notches 84 of a series of notches 84 receive the segment structures 38 of the conductors 37 constituting a phase winding E1-E6. Each series of notches 84 is associated with one of the six phase windings E1-E6. Thus, two consecutive notches 84 of the same series of notches 84 are separated by notches each of which belongs to one of the other series of notches 84. The notches 84 of each set of notches associated with a phase winding E1-E6 are thus distributed on the transfer comb 83 at a constant pitch equal to the number of phases, that is to say here with a pitch of six notches 84. In other words, the segment structures 38 are inserted into the notches 84 of the comb with a polar pitch equal to the pole pitch of the stator 15.

In a phase winding E1-E6, the successive segment structures 38 of the same conductor 37 are alternately positioned in an inner layer and an outer layer on the majority of the length of the comb 83. Thus, for a pair of conductors 37a , 37b from the same wire 44 and in a given notch of the series, the segment structure 38 of the conductor 37a is in the layer C1, while the segment structure 38 of the conductor 37b is in the layer C2. The segment structure 38 of the conductor 37a is in the layer C2 of the successive notch of the series, while the segment structure 38 of the conductor 37b is in the layer C1. In all cases, the two segment structures 38 are superimposed on each other in each notch 84. Moreover, for two notches 84 adjacent a series of notches associated with a phase winding E1-E6, the winding ply 52 has two loop structures 39 located on either side of the comb 83 connecting segment structures 38 located in said adjacent slots 84. Thus, the loop structure 39 of one of the conductors 37a which connects the segment structures 38 received in the two adjacent notches 84 mentioned above is arranged axially above the upper face of the body 16, while the loop structure 39 the other conductor 37b which connects the segment structures 38 received in the two adjacent slots 84 mentioned above, is arranged axially below the lower face of the body 16. The relationship is reversed for the two adjacent adjacent notches 84.

In addition, for two adjacent slots 84 of the series associated with a phase winding E1-E6, the loop structure 39 of the conductor 37a connects a segment structure 38 belonging to the lower layer of the web 52 to a segment structure 38. belonging to an upper layer of the ply 52; while the loop structure 39 of the other conductor 37b connects a segment structure 38 belonging to an upper layer of the web 52 to a segment structure 38 belonging to a lower layer of the web 52. The relationship is reversed for the next two notches 84 next.

The coil ply 52 also has a discontinuity. Indeed, the sheet 52 comprises a so-called "regular" part in which the segment structures 38 of each phase winding E1-E6 are each connected, via loop structures 39, to two segment structures 38 located in two notches 84 different. The sheet 52 also comprises a so-called "irregular" portion obtained at the end of the pre-forming step in which at least one segment structure 38 of each E1-E6 phase winding is connected to two superposed segment structures 38. axially with respect to one another in the same notch 84. Furthermore, the compensation zones 80 previously described are located in the intermediate portions 91 of the comb 83.

The number of notches 84 of the comb 83 corresponding to the length of the coil ply 52 is determined as a function of the number of conductor layers 37 of each phase winding E1-E6, and as a function of the number of notches 28 of the body 16, so that the web 52 allows to form an integer number of layers of conductors. In the case where it is desired to form eight layers of conductors 37 on a body 16 comprising 96 notches, the comb 83 has 96x4 + 6 = 390 notches. The number 6 corresponds to the 6 notches of the irregular part 47 in the case of a hexaphase stator. In other words, the length of the winding ply 52 is substantially equal to N / 2 times the circumference of the stator 15, where N is the number of desired conductor layers 37 in the wound stator. N is greater than or equal to two.

Preferably, a step is also performed to press the windings 17 by means of a shaping tool 100 shown in FIG. This shaping tool 100 comprises for this purpose two clamping plates 101 between which are positioned the loop structures 39 projecting from one side of the comb 83 before controlled crushing of said loop structures 39 between the two plates 101 following a axial direction. Thus, the thickness of the ply 52 is reduced in order to obtain the desired bun dimension. The modular comb 83 also allows to maintain the spacing of the conductors 37 during the shaping of the bun.

After the setting of the winding ply 52 on the transfer comb 83 and the step of shaping the buns, the method of producing the wound stator 15 comprises a step of transferring the conductors 37 of the ply 52 located in the notches 84 of the comb 83 to the annular spindle 105. This step generally consists in winding the ply 52 of conductors 37 around the annular pin 105 to form the layers of the phase windings E1-E6. This winding of the ply 52 can be made starting from one of the two ends of the ply 52, namely the irregular part 47 or the connection part 73.

FIGS. 22 and 23 show the various elements that make it possible to implement this step, consisting of an annular pin 105, a guide casing 106 of the annular pin 105 moving relative to the transfer comb 83, and two longitudinal guides 107.

As can be seen in more detail in FIG. 22, the annular spindle 105 is an element of revolution of main axis Z which comprises notches 109 made in the outer cylindrical face of the annular spindle 105 and opening axially into the faces of the axial end of the annular pin 105.

The distance between the outer radial ends of two adjacent notches 109 of the annular spindle 105 is equal to the distance between two adjacent notches 84 of the transfer comb 83. The number of notches 109 of the annular spindle 105 is equal to the number of notches. notches 28 of the stator body 16, that is to say here the annular pin 105 has 96 notches.

The annular spindle 105 further comprises a central hub 1 12 which is fixed to the inner cylindrical face of the annular spindle 105. This hub 1 12 is provided with a central opening 1 13 allowing the passage of a shaft (not shown) to allow the rotational drive of the annular pin 105 about its axis Z. The casing 106 comprises a coaxial bore 1 14 at the annular pin 105 and in which the annular pin 105 is received free to rotate about its axis Z. The bore 1 14 of the casing 106 is opening into the lower face of the casing 106, to allow the transfer of the conductors 37 to the annular pin 105.

The guides 107 are intended to be received in the longitudinal grooves 98 of the transfer comb 83. Thus, the transfer comb 83 is longitudinally guided without clearance during this step of transferring the winding ply 52 around the annular pin 105. Each guide 107 has a ramp-shaped upper face, the inclination of which is determined so that each upper face is able to bear under the segment structures 38 of the conductors 37, so as to gradually drive the conductors 37 towards the top, for their transfer to the annular pin 105. According to the embodiment shown in Figure 23, the upper face of each guide 107 is flat and is inclined relative to a horizontal plane. However, it will be understood that the shape of the upper face of each guide 107 may be different, for example, the upper face may be convex curved upwards, concave open upwards, or it may form two inclined planes according to different angles.

More specifically, the transfer step consists of rolling the annular pin 105 on the upper face of the transfer comb 83 so that the notches 109 of the annular pin 105 come successively in facing relation with the notches 84 of the comb transfer 83 and without slip of the annular pin 105 relative to the transfer comb 83. To do this, one of the two ends of the ply 52 is positioned near the pin 105 which receives first either the irregular portion 47 or the connecting part 73.

During the rolling of the annular pin 105, the comb 83 mounted on the rail 86 moves relative to the guides 107 in a manner synchronized with the rotation of the annular pin 105. The upper face of each guide 107 then leans towards the high against segment structures 38 conductors 37 which are located at the lower end of each notch 84 of the transfer comb 83. Thus, the upper faces of the guides 107 allow simultaneous transfer of the segment structures 38 and the loop structures 39 of the conductors 37 forming the two layers of the winding ply 52.

As indicated previously, the annular pin 105 has a number of notches 109 which is equal to the number of notches 28 of the stator body 16 and the transfer comb 83 has a number of notches 84 which is greater than the number of notches. Notches 28 of the body 16. Consequently, the annular pin 105 makes several turns around its axis Z as it rolls on the upper face of the transfer comb 83, and the sheet 52 with its two layers of conductors 37 are wound around of the pin 105, forming coaxial spirals.

Since the annular pin 105 performs several turns around its Z axis, each of the notches 109 successively receives the segment structures 38 that were received in a plurality of notches 84 of the transfer comb 83. In this case, the annular pin 105 performs four turns to the irregular portion 47 near its Z axis, so that each notch 109 of the pin 105 receives eight segment structures 38 (two per turns). This results in a winding with eight layers of conductors 37.

In addition, the width of each notch 109 of the annular spindle 105 is substantially equal to the width of each of the conductors 37. Therefore, the segment structures 38 of the conductors 37 are superimposed radially in the notches 109 of the next annular spindle 105. a single column.

In the case where the wire 44 used is a round section wire, prior to the transfer of the sheet 52 to the pin 105, a stamping step of the segment structures 38 shown in FIG. 32 is carried out. For this purpose, the sheet winding 52 is put in place on a stamping comb 1 19 having notches 120 delimited in pairs by spacers 121 issuing from a magnetic plate 1 18. The spacers 121 are preferably profiled on the free end side, so that each notch 120 has a flared end to facilitate the insertion of the segment structures 38 inside the notches 120 of the comb 1 19. Lower wedges 122 reported have been previously positioned at the bottom of the notches 120 of the comb before the insertion of the segment structures 38.

Top shims 123 added are placed above the segment structures 38. A width of the lower shims 122 and 123 upper corresponds to a desired width of the conductors 37 after stamping. The upper shims 123 have a shape complementary to the notches 120 of the comb 1 19.

An upper plate 125 then crushes the segment structures 38 between the lower wedges 122 and the upper wedges 123. For this purpose, clamping means 129 provide a connection between the plates 1 18 and 125 towards each other, which has the effect of transforming the initial round section of the segment structures 38 of the web 52 into a square or rectangular section.

The use of the insert blocks 122, 123 makes it possible to control the deformation of the segment structures 38 and to facilitate the take-off of the conductors 37 of the matrix following the ascent of the upper plate 123.

It is also noted that such a configuration makes it possible to maximize the filling of the notches 28 of the stator 15 while facilitating the formation of coil windings in which the round section of the conductors facilitates folding to form the winding wave 17. In a variant, only the lower shims 122 are used, the segment structures 38 then being compressed between teeth of the upper plate 125 and the lower shims 122.

As a variant, the stamping step is carried out on a winding sheet 52 comprising a single layer of conductors 37 or a single conductor 37 per notch of the comb 19. Since the winding 17 is made from copper wires 44, the method comprises a step of heating at least 150 degrees Celsius, for example 280 degrees Celsius, of the winding 17 before stamping to limit the macroscopic deformation of the copper. The method may also include an annealing step after stamping so that the copper returns to its initial macroscopic structure.

Alternatively, the winding is made from aluminum son. As a variant, the stamping step could also be implemented directly in the transfer comb 83. Alternatively, the stamping step is performed before the step of forming the winding sheet 52. The stamping can then be performed by a set 135 of rotary rollers between which passes a linear conductor 37. The assembly 135 of rollers comprises for this purpose, a first pair of vertical rollers 136 of horizontal axis and a second pair of horizontal rollers 137 of vertical axis. The rollers 136, 137 of each pair are positioned opposite each other while being slightly offset between them to allow the rolling of the conductor 37.

The length of the stamped portions and the length of the non-stamped portions depend on the dimensions of the stator 15, in particular the length of the notches 28 and the distance between two successive notches 28 of a series of notches associated with a phase winding. E1-E6.

Thus, the rollers 136, 137 will be in the stamping position along the length of the notches 28, as shown in FIG. 33. The rollers 136, 137 will then be moved away from the lead 37 along the length of the buns corresponding to the length between two successive notches 28. The conductor 37 shown in FIG. 35a is then obtained which comprises stamped parts corresponding to the segment structures 38 and non-stamped parts corresponding to the loop structures 39. The driver 37 can therefore be shaped into the winding sheet 52 according to FIG. 35b with two parallel segment structures 38 interconnected by a loop structure 39. In the embodiment of FIG. 34, stamping is performed by pressing using a device 141 provided with two radially movable symmetrical jaws 141 and a crushing element 142 making it possible to deform the conductor 37 on four sides. The two jaws 141 form a slight angle between them so as to facilitate an exit of the segment structures 38 of the conductor 37 after stamping.

Forging may also be performed on a bundle of conductors 37 in parallel using the comb 1 19 as described above or by means of a series of sets 135 of rotating rollers or devices 141. As indicated above, it will be possible to perform a heating step and optionally an annealing step before and after the stamping step and / or the step of shaping the buns.

Moreover, as can be seen in FIG. 24a, the method comprises a step of placing a continuous slot insulator 145 inside the notches 28 of the stator 15. For this purpose, the pins 34 cooperate. with the recesses 33 of the external indexing means 32 so as to position a notch 28 of the stator 15 in front of the continuous notch insulation 145. A shim 146 moved radially from the inside to the outside of the stator 15 ensures then a plating of the notch insulation 145 against the inner walls of each notch 28. The notch insulation 145 thus covers the inner faces vis-à-vis the notch 28 and the bottom of the notch 28 corresponding to the portion of the inner periphery of the yoke 26 extending between two consecutive teeth 25. The operation is repeated by positioning a new notch 28 in front of the slot insulator 145 until all the notches 28 are covered by the continuous slot insulator 145.

Indeed, once the notch insulator 145 placed inside the notches 28, a transfer step of the winding 17 is carried out from the annular pin 105 to the body 16 of the stator 15, as shown on Figures 26a and 26b. The external indexing means 32 make it possible to ensure precise positioning of the annular pin 105 around the body 16 of the stator 15. The annular pin 105 is received coaxially with the body 16, in the circular housing delimited by the internal cylindrical face. of the body 16. The diameter of the outer cylindrical face of the annular spindle 105 is generally equal to the diameter of the internal cylindrical face of the body 16.

The indexing means 32 of the stator 15 also make it possible to angularly position the stator 15 with respect to the annular pin 105 about its axis Z, so that each notch 109 of the annular pin 105 is opposite the a notch 28 of the body 16, as can be seen in Figures 26a and 26b.

The installation also comprises radial insertion blades 148 visible in FIGS. 27a and 27b, each extending in a radial plane with respect to the axis X, Z of the pin 105 and the body 16. An insertion blade 148 is associated with each notch 109 of the annular spindle 105. The blades 148 are identical and angularly distributed around the Z axis of the annular spindle 105. Here, the annular spindle 105 has 96 notches, the installation therefore comprises, 96 insertion blades. These blades 148 extend in the median radial plane of the notch 109 associated, and the thickness of each blade 148 is slightly less than the width of the notch 109 associated.

More precisely, as can be seen in FIG. 27a, at the beginning of the transfer step, each blade 148 is located radially so that the outer radial end edge of each blade is situated at the level of the most internal conductor located in pin 105.

During the implementation of the step of expansion by expansion of the conductors 37, the insertion blades 148 are displaced radially with respect to the Z axis of the annular pin 105 along the arrow F4, so that each blade 148 moves radially in the associated notch 109 outwardly of the annular pin 105 by simultaneously driving the segment structures 38, so that these segment structures 38 are moved into the associated notch 28 of the body 16, thereby forming the segment structures 38 of E1-E6 phase windings. The displacement of the blades 148 is obtained by applying an axial force along the arrow F5 (see Figure 26b) which is converted by a mechanical system into a radial force applied to the blades 148 along the arrow F4. At the end of the transfer phase, each blade 148 is located radially with respect to the Z axis of the annular pin 105, so that its outer radial end edge is located generally at the outer cylindrical face of Annular pin 105. All segment structures 38 that were received in each notch 109 of annular pin 105 migrated into an associated notch 28 of body 16.

The wound stator 15 described above is then obtained. It should be noted that the coil segment structures 38 located at the outer periphery of the pin 105 are found by translation at the outer periphery of the stator 15. Likewise, the coil segment structures 38 located at the level of the outer periphery of the pin internal periphery of the pin 105 are found by translation at the inner periphery of the stator 15.

According to a preferred embodiment, all the insertion blades 148 are driven simultaneously radially outwardly in the associated notches 109 of the annular pin 105. Thus, the transfer of all the segment structures 38 is carried out simultaneously. The width of each notch 28 of the body 16 is substantially equal to the width of each conductor 37, so that the radial stack of the conductors 37 in a single column is kept in the notches 28.

It is also noted that the use of continuous notch insulation 145 ensures proper positioning of the notch insulator 145 within the notches 28 upon insertion of the coil segment 38 structures 17 , insofar as the ends of the notch insulator 145 located on the radial open side of each notch 28 along the corners of the teeth 31 are interconnected and therefore can not be pushed towards the bottom of the notches 28 when insertion of segment structures 38.

Once the winding transfer step 17 has been performed, a step is performed to cut the notch insulation 145 shown in FIG. 24b. This step aims to remove portions 149 of the notch insulation 145 extending between two successive notches 28, i.e. the portions 149 of the notch insulation 145 extending against the inner face of each tooth 25. The step of cutting the notch insulation 145 is performed by means of a mechanical tool 150 or by laser. The notch insulators thus individualized located inside each notch 28 will thus have traces of cutting along the rounded internal corners of the teeth 25 located on the X axis side of the stator 15.

Alternatively, in the embodiment shown in FIGS. 25a and 25b, individual notch insulators 195 are inserted into notches 28 of stator 15. Two consecutive slot insulators 195 are welded together to maintain notch insulators 195 inside the notches 28 during insertion of the conductors 37 of the coil 17.

For this purpose, each slot insulator 195 has walls intended to cover the internal faces of the notches 28 vis-à-vis and the bottom of the notch 28. In addition, each notch insulation 195 has fins. 196 from the walls pressed against the internal faces vis-à-vis. These fins 196 are folded and pressed against at least one radial axial end face of the body 16 of the stator. The fins 196 of each slot insulator 195 are welded with corresponding fins 196 of adjacent slot insulators 195. In other words, two adjacent fins 196 of two adjacent notch insulators 195 are welded together.

The notch insulators 195 may be welded together on one side of the stator or on both sides of the stator 15. Preferably, in order to facilitate welding, the fins 196 are superimposed on one another. Alternatively, the welding is carried out edge to edge.

A step is preferably carried out for pressing the winding bunches 163 formed by the loop structures 39 extending on either side of the stator 15 with the aid of a tool 162 shown in FIG. 28. For this purpose, the tool 162 comprises a plurality of fixed holding members 165 intended to be placed against an outer periphery of each winding bun 163. These elements 165 are positioned side-by-side in an annular shape.

A central cam 166 is then rotated so as to successively move pressing elements 167 radially in the direction of the corresponding holding element 165. The windings of the winding 163 are thus pressed by successive portion, each portion being pressed between the holding member 165 and the corresponding pressing element 167 which is then in a position called "active". The pressing elements 167 may include return means to return them from their active position to their initial position once they have been displaced by the cam 166.

Moreover, the teeth 25 of the stator 15 being devoid of tooth roots to facilitate the insertion of the segment structures 38, a deformation step, by means of a punch 170, of segment structures 38 located in the radial layer of conductors 37 closest to an axis of the stator 15. This deformation step illustrated in FIGS. 29a to 29c makes it possible to guarantee the maintenance of the segment structures 38 inside the notches 28 before carrying out the step impregnation. Indeed, the deformation by means of the punch 170 allows a creep of the material towards the internal faces of the notches 28, so that the deformed edges of the segment structures 38 bear against the internal faces of the notches 28.

According to a first implementation illustrated in FIG. 29a, three deformations 171 are distributed axially on each of the segment structures 38 situated at the inner periphery of the stator.

The deformations 171 are made so that a ratio between a length L3 of a deformation and a gap L4 between two successive deformations 171 is between 0.8 and 1.2. The extreme deformations 171 are spaced from corresponding axial ends of the segment structures 38 by at least three millimeters (see length L5). The deformations 171 are made by protuberances 172 of corresponding shape belonging to the punch.

Alternatively, as shown in Figure 29b, two deformations 171 are distributed axially on each of the segment structures 38 located at the inner periphery of the stator. Each deformation 171 is spaced from the corresponding axial ends of the segment structures 38 by at least three millimeters. For this purpose, the punch 170 has two protuberances 172 of corresponding shape. Alternatively, as shown in FIG. 29c, a single axially elongate deformation 171 is produced on each of the segment structures 38 located at the inner periphery of the stator. The deformation 171 is made so that ends of this deformation 171 are spaced from the corresponding axial ends of the segment structures 38 by at least three millimeters. For this purpose, the punch 170 has a protuberance 172 of corresponding shape.

On the final product, the segment structures 38 of the layer closest to the axis of the stator 15, or inner layer, comprises traces of deformation produced by the punch 170.

Once the coil 17 is installed on the stator 15, an impregnation step is performed consisting in pouring liquid varnish around the excitation winding 17, and more particularly around the two buns of the winding 163. The varnish which is heated can be introduced in the liquid state drop by drop in the son 44 of the coil 17. Then, the varnish is cooled by polymerizing. The varnish is for example based on epoxy resin.

In an alternative embodiment of the stator 15 shown in Figure 30, each tooth 25 has two foldable legs 174 teeth.

Before being folded, the toothed feet 174 are located along the edges of the notches 28 extend in a substantially radial plane so as to be clear of the notches 28.

The tooth roots 174 each comprise a section reduction 175 at their connection with each free end of the teeth 25. The section reduction 175 is made in the face of the tooth root 174 turned towards the notch. The tooth legs 174 preferably have a rounded end side. In the embodiment of Figure 31a, the inner face of each tooth 25 extending between the two tooth roots 174 has a protrusion 176. In the embodiment of Figure 31b, the inner face of each tooth 25 is devoid of protuberance 176. Following the step of inserting the segment structures 83 into the notches 28 by expansion of the blades 148, the teeth 174 are folded towards the interior of each notch 28 according to the arrows F6 so as to close at least partially the notches 28.

Such a configuration makes it possible to improve the magnetic performance of the electric machine while allowing easy insertion of the segment structures 38 inside the notches 28.

In the embodiment of FIG. 36, the winding ply 52 is obtained from a nesting between a first 181 and a second 182 sub-ply. The nesting of the two sub-layers is carried out so that on the one hand the first 181 and the second 182 sub-layers have inputs 11 -16 and outputs 01 -06 all located on the same side of the stator 15 and secondly that the second sub-sheet 182 is offset from the first sheet by a number of notches in the stator equal to the number of phases, in this case six. This corresponds to the axial offset D in the figure. This facilitates the making of the connections taking into account the advantageous positioning of the inputs 11 -16 and the outputs 01 -06 on the same side of the stator 15. The first 181 and the second 182 sub-layers are preferably identical. The two sub-layers 181, 182 are preferably made from the same set of wires 44. Each phase winding E1-E6 is made from a single wire 44 connecting the input li to the output Oi to i ranging from 1 to 6 in the case of a hexaphase stator.

The sub-plies 181, 182 each have a length equal to N / 2 times the circumference of the stator 15, where N is the number of desired conductor layers 37 in the coiled stator, N being greater than or equal to two. The number N of conductor layers 37 is for example equal to two, four, six or eight. Preferably, the number N of conductor layers 37 is equal to eight.

The various steps of placing the ply 52, installation of the ply 52 in the spindle 105, and transfer of the spindle winding 105 to the stator 15 are identical to those described above.

The following are described below with reference to FIGS. 37a to 37c and 38a to 38c, the different types of coupling of the phase windings E1-E6 produced in FIG. using an interconnector 185 shaped ring portion. This interconnector 185 is disposed between a bun 163 of the coil 17 and diodes (not shown) of a voltage rectifier bridge. This interconnector 185 comprises electronic terminals B1-B6 of axial orientation whose number is equal to the number of phase windings E1-E6, here equal to six.

The terminals B1-B6 are divided on the interconnector 185 according to two groups G1 and G2 each having the same number of terminals B1-B3 and B4-B6. This number of electronic terminals corresponds to the number of phases divided by two, ie three terminals per group G1, G2.

The angular difference K1 between a terminal of one of the groups G1, G2 and the corresponding terminal of the other group G1, G2 is constant. Thus, the left-most end terminal B1 of one of the groups G1 is separated from the left-most end terminal B4 of the other group G2 by the angular distance K1. The central terminal B2 of the first group G1 is separated from the central terminal B5 of the group G2 from the angular gap K1. The rightmost end terminal B3 of one of the groups G1 is separated from the rightmost end terminal B4 of the other group G2 by the angular difference K1. The angular difference K1 of the order of 125 degrees. In the embodiments of FIGS. 37a and 38a, the ends 186 of the phase windings E1-E6 corresponding to the inputs and the outputs are folded so as to be pressed against the interconnector 185 in a radial direction. These ends 186 are then welded to tabs 187 of the interconnector 185 of axial orientation. In the variant shown in Figure 39, the ends 186 extend axially and are welded to tabs 187 of the interconnector 185 of radial orientation. In all cases, the interconnector 185 has two tabs 187 per phase.

The interconnector 185 includes traces 189 electrically connecting the tabs 187 to the electronic terminals B1-B6.

It will be possible to achieve a so-called "double three-phase" triangle coupling illustrated in FIGS. 37b and 37c. Thus, the first E1, the third E3 and the fifth E5 phase windings are coupled in a triangle and the second E2, the fourth E4 and the sixth E6 phase windings on the other hand.

More specifically, the traces 189 of the interconnector 185 then provide a connection of the inputs 11, 13 of the first and third phase windings E1 and E3 with the terminal B1. Traces 189 also provide a connection of an input 15 of the fifth phase winding E5 and an output 01 of the first phase winding E1 with the second terminal B2. Traces 189 provide a connection of an output 05 of the fifth phase winding E5 and an output 03 of the third phase winding E3 with the third terminal B3.

On the other hand, the interconnector 185 has traces 189 for making corresponding connections for the phase windings E2, E4 and E6 according to FIGS. 37b and 37c. Thus, the traces 189 of the interconnector 185 then provide a connection of the inputs 12, 14 of the second and fourth phase windings E2 and E4 with the terminal B4. Traces 189 also provide a connection of an input 16 of the sixth phase winding E6 and an output 02 of the second phase winding E2 with the terminal B5. Traces 189 provide a connection of an output 04 of the fourth phase winding E4 and an output 06 of the sixth phase winding E6 with the terminal B6.

Alternatively, the coupling produced is a "double three-phase" star coupling illustrated in FIGS. 38b and 38c. The first E1, the third E3 and the fifth E5 phase windings are coupled together in a star and the second E2, the fourth E4 and the sixth E6 phase windings on the other hand.

Specifically, traces 189 provide an interconnection at a neutral point located on the interconnector 185 of the outputs of the first E1 and the fifth E5 phase winding and the input of the third E3 phase winding. A trace 189 provides a connection of the input 11 of the phase winding E1 with the terminal B1. A trace 189 provides a connection of the input 15 of the phase winding E5 with the terminal B2. A trace 189 provides a connection of the output 03 of the phase winding E3 with the terminal B3.

The interconnector 185 has traces 189 for making corresponding connections for the phase windings E2, E4 and E6 in accordance with Figures 38b and 38c. Thus traces 189 provide an interconnection at a neutral point located on the interconnector 185 of the outputs of the second E2 and the sixth E6 phase winding and the input of the fourth E4 phase winding. A trace 189 provides a connection of the input 12 of the phase winding E2 with the terminal B4. A trace 189 provides a connection of the input 16 of the phase winding E6 with the terminal B5. A trace 189 provides a connection of the output 04 of the phase winding E4 with the terminal B6.

Alternatively, it will be possible to achieve a hybrid coupling in which the phase windings of one of the groups of the group E1-E3-E5 and the group E2-E4-E6 are coupled in a star and the phase windings of the other group in triangle.

Preferably, in order to obtain that the output inputs 01 -06 11 -16 are positioned at the outer periphery of the stator, the first winding on the spindle is the irregular portion 47. It is thus avoided that the input-output wires n interfere with the rotor fan in view of the absence of a tooth root to maintain these wires in some embodiments.

The following is described below with reference to FIGS. 40 to 43, different implementations of the method making it possible to adapt the shape of the coil windings 163. It should be noted that on the transfer comb 83 as well as on the spindle 105 each conductor 37 is separated from the next by a spacing corresponding to the distance between the medium of the notch inlet N and the middle of the notch inlet N + 1, this step being invariant.

In contrast to this invariant step for a given stator, the height of the conductor layers 37 is flexible, so that it is possible to vary the height of the buns 163 on the finished stator. Moreover, the height of winding bunches 163 will vary depending on the position of the layers on the comb 83.

For a given portion of a conductor 37 of a phase winding consisting of two segment structures 38 connected by a loop structure 39, a distance A corresponding to the length of the arc of a circle between the middle of the two is defined. notch inputs 109 of the annular pin 105 which will receive the two conductors 37.

A distance B (greater than A) corresponding to the length of the arc of the circle between the middle of the two notches 28 on the positioning diameter of the conductors 37 after the transfer in the notches 28 of the stator 15 which will receive the two drivers 37.

The height of the point C will decrease away from the axis and rise closer to the axis, thus compensating for variations in distance between the segment structures 38. In other words, the segment structures 38 on a diameter (a ) are axially transferable to the notches 28 on a diameter (b) move away physically from each other.

By adapting the height of the layers of the winding 17, a pre-transfer bun height is then configured which will generate, after transfer, a different height (resulting from the sum of the resulting conductor layer heights of the winding 17 and the height lost as a result of the transfer. drivers 37).

More precisely, in order to obtain coil windings 163 whose height increases when moving from the outer periphery of the stator 15 to the X axis, the conductor layers 37 placed on the annular pin 105 have different heights the highest layers on the pin 105 are at the inner periphery, and the lower layers are at the outer periphery (the pin 105 being the image of the notches 28 of the stator 15).

After transfer, each layer loses height proportionally according to its position on the pin 105 and its final position in the stator 15. More precisely, the more the layer is in the outer layer, the more it loses the height of the bun as it transfers from the spindle to the stator.

Thus, to obtain in the stator 15, an outer layer of chignon lower than the others, it is sufficient that in the pin 105, the layers are all at the same height. It is also possible to accentuate the difference in height between the inner layer and the outer layer in the bun to provide in the pin 105 an outer layer of lesser height than the inner layer.

To obtain such an arrangement, it is necessary that the end of the ply 52 which winds first on the spindle 105 is of greater height than the remainder of the ply 52.

For this, it is used on the winding unit 51 the keys 66 whose spacing varies to vary the height of the sheet 52.

Thus, in the first case where the end of the ply 52 which first winds on the spindle 105 is the irregular part 47, the distance between the two keys decreases as the formation of the ply increases. 66.

On the other hand, in the second case where the end of the ply 52 which first winds on the spindle 102 is the connecting part, the spacing between the plies 52 increases as the formation of the ply 52 increases. two keys 66.

Indeed, as described above, the formation of the sheet 52 is always made from the irregular portion 47.

In the first case, we obtain the technical advantage that the input-output 01 -06 11 -16 are positioned at the outer periphery of the stator 15. On the contrary, in the second case, the input output 01 -06; 11-16 are positioned at the inner periphery of the stator 15.

The advantage of such a configuration is a form of bun 1 63 which matches the shape of the bearing and optimizes the size of the machine, and in particular its length. In addition, this allows a better exposure to the air flow generated by the rotor.

In order to obtain 163 flat coil windings as illustrated in FIGS. 42a and 42b, the heights of the conductor layers 37 placed on the pin 105 are different in order to compensate for only the height loss related to the transfer phenomenon of the wires. conductive layers 37 from the diameter (a) to the diameter (b).

To obtain such an arrangement, it is necessary that the end of the ply 52 which winds first on the spindle 105 is of lower height than the remainder of the ply 52.

Thus, in the first case where the end of the sheet that winds first on the pin 105 is the irregular portion 47, it increases as the formation of the sheet 52 the spacing between the two keys 66. On the contrary, in the second case where the end of the ply 52 which winds first on the pin 105 is the connecting portion, it decreases as the formation of the ply 52 the gap between the two keys 66.

In the first case, the technical advantage is obtained that the output inputs 01 -06 11 -I6 are positioned at the outer periphery of the stator.

On the contrary, in the second case, the input inputs 01 -06 11 -16 are positioned at the inner periphery of the stator.

The resultant is to obtain a height of winding buns 163 homogeneous. This makes it possible to optimize the length of the machine, and to obtain a better contact between the layers of conductors 37 in order to optimize the transfer of heat from the layer facing the rotor towards the vis-à-vis layer. -vis the landing.

In order to obtain coil windings 163 whose height decreases when moving from the outer periphery of the stator 15 to the X axis as shown in FIGS. 43a and 43b, the layers of conductors The top layers 37 on the pin 105 are at the outer periphery and the lowest conductor layers 37 are at the inner periphery. To obtain such an arrangement, it is necessary that the end of the ply 52 which winds first on the spindle 105 is of lower height than the remainder of the ply 52.

Thus, in the first case where the end of the sheet which winds first on the spindle is the irregular portion 47, as the formation of the ply 52 increases, the spacing between the two keys 66 increases. .

On the other hand, in the second case where the end of the ply 52 which winds first on the spindle is the connecting part, the gap between the two keys is gradually reduced as the ply is formed. 66. In the first case, the technical advantage is obtained that the output inputs 01 -06 11 -16 are positioned at the outer periphery of the stator.

The advantage of such a configuration is the optimization of the air flow in the machine which promotes exchanges between internal diameter and outside diameter of the machine.

In the embodiment of FIGS. 44a, 44b, 45a, 45b, the body 16 of the stator 15 is formed by two elements assembled together, namely a central core 201 intended to receive the conductors 37 as well as an attached yoke 202 for to be positioned around the central core 201. The central core 201 and the yoke 202 are sheet stacks. The central core 201 has notches 28 open on the side of its outer periphery and interconnected on the side of an inner periphery by tooth roots 203 which each extend on either side of a free end of A tooth 25. These toothed feet 203 thus define connection zones 204 between the free ends of the teeth 25. Such a configuration facilitates the insertion of the coil 17 by the open outer end of the notches 28, while being able to benefit from the feet of teeth 25 which improve the magnetic performance of the machine. As shown in FIG. 48a, the central core 201 may be solid in the connection zones 204 between two successive teeth 25. Alternatively, as shown in FIG. 48b, the central core 201 is perforated in the connection zones 204 between two successive teeth 25. Furthermore, the stack of laminations of the cylinder head 202 may extend over the entire height of the central core 201 or half of the height of the central core 201. The sheet stack of the yoke 202 may be flat before deformation by bending to a cylindrical shape for its establishment around the central core 201 (see Figure 45a). Alternatively, the yoke 26 may initially have an arcuate shape to facilitate its positioning around the central core 201 (see Figure 45b).

In another embodiment shown in FIG. 46, a flat plate 207 having a height smaller than that of the central core 201 is used so as to create a winding of this sheet 207 around the central core 201. The winding operation of the sheet 207 is repeated as many times as necessary to reach the height of the central core 201. This operation can be performed with several sheets 207 piled axially wound on several turns.

The central core 201 may be attached to the bolt 202 reported by a triangular interlocking fit (see Figure 47a), a round shape interlock (see Figure 47b), or an interlocking form of a radius (see Figure 47c). The yoke 202 or the sheet 207 then has a succession of planar zones 208 and recesses 209 of corresponding shape (triangular, round or in the form of a radius), as can be seen in Figures 45b, 46, 47a to 47c. The depressions 209 are intended to cooperate with the outer ends of the teeth 25 of complementary shape. The flat areas 208 are intended to extend between two successive teeth 25 to form the bottom notches 28. Alternatively, the yoke 202 is placed around the central core 201 without interlocking, as shown in Figure 47d.

Such a configuration of the body 16 avoids having to perform steps of transfer of the coil 17 of the pin 105 to the stator 15. Indeed, in this case, it is possible to replace the pin 105 by the central core 201 so as to directly transfer the segment structures 38 of the comb 83 to the notches 28 of the central core 201.

For this purpose, a hub 1 12 is placed in the central part of the core 201. The hub 1 12 is removably attached to the toothed feet 203. The establishment of the hub 1 12 makes it possible to rotate the central core 201 during the insertion of the segment structures 38 from the comb 83 to the notches 28 Once the coil 17 is installed inside the notches 28 of the central core 201, the outer open face of the notches 28 is closed by means of the yoke 26 according to one of the previously described techniques. The hub 1 12 can then be removed.

In an embodiment described in FIG. 49, a flat stator 15 is formed comprising a flat body 16 formed by a stack of sheets of stacked sheets. The flat body 16 is provided with a flat head 26 extending substantially in a plane and teeth 25 extending substantially perpendicularly to the breech 26. These teeth 25 delimit in pairs notches 28 preferably provided with tooth roots 215 The length L6 of the flat stator corresponds to the circumference of the stator 15 after the bending step carried out according to the arrows F7.

In order to obtain the flat stator, a prior step of heat-sealing sheet sheets 218 is carried out between them. All sheets 218 sheet may be heat sealed together. Alternatively, a sheet on N is heat sealed, N being greater than or equal to two. The sheets 218 which are not heat sealed are assembled together and with the sheets fused together by riveting by means of a rivet (not shown) passing through the package of sheets from side to side or alternatively by welding.

The winding ply 52 previously described may be inserted into the notches 28 of the flat stator 15. Since the winding ply 52 has a length equal to an integer number M times the circumference (to the irregular part, 6 notches in the hexaphase case) of the stator 15, is set up the winding ply 52 along M times the length of the stator 15 following a way back and forth along the flat stator. Once the winding ply 52 is in place, a flat stator bending step is performed to form a generally cylindrical wound stator 15 shown in Fig. 50 without the winding 17 to improve the sharpness of the figure. The end edges 220 of the arched and wound stator are then welded together. The heat-sealing of the sheet sheets 218 thus makes it possible to limit the deformation of the sheets 218, in particular the flaring of the teeth 25, during the step of bending the stator 15.

In the embodiment of FIGS. 51 and 52, a rim plate 221 is pressed against an end face of a line 220 of half-packs 222 of sheet metal sheets. The edge plate 221 is thicker than the sheets 218 of the sheet package. The edge plate 221 has a thickness equal to at least one millimeter. The end face against which the edge plate 221 is fastened is perpendicular to a direction of longitudinal elongation D2 of the teeth 25 (a single tooth 25 has been shown in FIG. 51 to facilitate understanding).

The line 220 of half-packs 222 is then cut for example by laser in the plane P to obtain two half-packs 222 separated. Each half-packet 222 has a length L7 substantially equal to the circumference of the stator 15 and a width L8 substantially equal to half the height of the final stator. The two half-packs 222 are then assembled together according to the arrow F8, that is to say by returning one of the packets 222 cut so as to press against one another the faces of the two opposite half-packs 222. to the face carrying the edge plate 221.

A flat stator 15 is thus obtained comprising a bank plate 221 pressed against each of its ends corresponding to the axial ends of the cylindrical stator. The winding ply 52 is then placed in notches 28 of the flat stator 15 as previously described. The flat stator 15 is then arched to obtain a generally cylindrical wound stator shown in FIGS. 52 and 53 without its winding 17. The end edges 220 of the arched stator 15 are then welded together.

In a variant, two half-packs 222 are each formed in the form of half-rings comprising two edge plates 221 that are clad on either side of the axial end faces. These half-packs 222 are assembled together at their ends after setting up the winding sheet 52 inside the notches 28 of the two half-packs 222. In a variant, two edge plates 221 are clad on both sides. other of the flat stator 15 of Fig. 49 prior to the bending step.

The half-packs 222 thus constitute sub-packets assembled together to obtain the body of the stator 15. In a variant, the pack of sheets of the stator 15 is obtained by assembling more than two sub-packets. In this case, the two end packets each comprise a side plate 221. Furthermore, in order to improve the mechanical strength of the stator 15 during the arching operation of the stator 15, the stator 15 comprises at least one weld 224 made inside at least one notch 28, as shown FIGS. 54 and 55. "Welding made inside the notch" is understood to mean a weld 224 made on an inner wall of a notch 28, preferably the bottom of a notch 28. Welds 224 are made within less than a quarter of the notches 28. Two successive welds 224 are spaced apart by an angle K2 minus 30 degrees, as shown in Figure 56. For a stator 15 having 96 notches, welds are preferably made inside a notch on 12 or a notch on 6.

In the embodiment of FIG. 57, a recess 227 may be made in a bottom of each notch 28. The recess 227 is made substantially in the middle of the bottom of the notch 28. A ratio between a depth of the recess 227 and the thickness of the yoke 26 is less than 25%. Alternatively, two recesses 228 shown in broken lines in Figure 57 are formed in the bottom of each notch 28 (instead of a single notch 227). The recesses 228 are substantially symmetrical with respect to a radial median radial plane of each slot 28. These recesses 228 are then made each at a base of the teeth 25 delimiting the notch 28.

Furthermore, a ratio between a thickness L9 of the yoke 26 and an external diameter L10 of the stator 15 (see FIG. 56) is between 2.5% and 15%, in order to facilitate the cambering of the yoke 26 of the flat stator 15 towards the cylindrical shape. It should be noted that the external diameter L10 of the stator 15 corresponds to the external diameter of the yoke 26.

The heat-sealing steps, setting up edge plates 221, making welds 224 or recesses 227, 228 in the bottom of notches 28, may be performed independently or in combination. It is the same particular ratios of dimensions of the stator chosen. The configuration of the teeth 25 (with rounded corners 31) and the dimensions of the notches 28 may be identical to those described above with the conventional winding type stator 15 initially having a cylindrical shape. The continuous notch insulation 145 may also be placed in the notches of the stator 15 before insertion of the coil.

In the embodiment variant of the winding 17 shown in FIG. 58, the two conductors 37 comprise segment structures 38 which alternate as before with an inner layer and an outer layer when passing from a notch 28 to an adjacent notch of the series following a circumference of the stator. In addition, when it occupies the inner layer the segment structure 37 has an orientation D3 different from that D4 when it occupies the outer layer. The two orientations D3, D4 are preferably perpendicular to each other. In the notches 28, a cross section of each segment structure 38 is composed of two rectangles 38 'stacked radially when the segment structure 38 occupies one of a plurality of layers comprising the inner layer and the outer layer. These two rectangles 38 'are stacked orthoradially when the segment structure 38 occupies the other layer of the assembly. In this case, the rectangles 38 'are stacked radially in an inner layer and stacked orthoradially in an outer layer. A length L20 of each rectangle 38 'is equal to twice a width L21 of each rectangle 38'.

Each phase winding E1-E6 then consists of two son. In other words, the winding ply 52 is made using two son in hand by E1-E6 phase winding by rotating 90 degrees when passing from a notch 28 to the next notch of the series. .

Apart from the use of the two son in hand, the winding 17 obtained is identical to that described above, that is to say that it comprises in particular a regular portion 46 and an irregular portion 47. In addition, the structures Loop 39 have the same configuration as that described above.

The teeth 25 are here preferably free of toes.

Of course, the foregoing description has been given by way of example only and does not limit the scope of the invention of which one would not go out by replacing the details of execution by any other equivalents.

Claims

1. A wound stator (15) comprising a body (16) having a yoke (26) and teeth (25) arranged on an inner periphery of said yoke (26), said teeth (25) delimiting in pairs the notches (28). ) in which conductor segments (38) of conductors (37) of a winding (17) are inserted, characterized in that the segment structures (38) of the conductors (37) in the nearest layer of an axis of the stator (15) have traces of deformations.

2. Stator according to claim 1, characterized in that each of the segment structures (38) of the conductor layer (37) closest to the axis of the stator (15) has at least three deformation traces distributed axially.

3. Stator according to claim 2, characterized in that a ratio between a length (L3) of a deformation and a gap (L4) between two successive deformations (171) is between 0.8 and 1 .2.

4. Stator according to claim 1, characterized in that each of the segment structures (38) of the conductor layer (37) closest to the axis of the stator (15) has a single trace of axially elongated deformation.

5. Stator according to claim 4, characterized in that ends of this deformation are spaced from the axial ends of the corresponding segment structure by at least three millimeters.

6. Stator according to any one of claims 1 to 5, characterized in that the teeth (25) of the stator (15) are devoid of toe.

7. Stator according to any one of claims 1 to 6, characterized in that corners (31) at the free ends of the teeth (25) have a rounded shape.

Stator according to one of Claims 1 to 7, characterized in that the winding (17) has a plurality of phase windings (E1-E6).

9. Stator according to claim 8, characterized in that the coil (17) comprises segment structures (38) of two conductors (37) of the same phase winding (E1-E6) positioned alternately in an inner radial layer. and an outer layer of conductors (37) along a circumference of the stator (15).

10. Stator according to claim 8 or 9, characterized in that each phase winding consists of a single wire (44).

1 1. Stator according to any one of claims 8 to 10, characterized in that for two adjacent notches (28) of a series of notches (28) associated with a phase winding, the coil (17) has two loop structures (39) located on either side of the stator (15) connecting segment structures (38) located in said adjacent slots (28).

Stator according to claim 11, characterized in that said two loop structures (39) respectively connect a segment structure (38) belonging to an inner layer to a segment structure (38) belonging to an outer layer and a segment structure (38) belonging to a layer external to a segment structure (38) belonging to an inner layer.

13. Stator according to any one of claims 1 to 12, characterized in that the conductors (37) have a square or rectangular section.

14. Stator according to any one of claims 1 to 13, characterized in that the segment structures (38) intended to be inserted into the notches (28) of the stator (15) are stamped.

15. Stator according to any one of claims 1 to 14, characterized in that said coil (17) comprises four, six, or eight layers of conductors (37) radially superimposed in the notches (28) of the stator (15).

16. Stator according to any one of claims 1 to 15, characterized in that said layer closest to an axis of the stator (15) has traces of deformation (171) applied in a radial direction.

Stator according to one of the preceding claims, characterized in that each notched edge (28) covered with an insulator having an insertion clearance (J) with one end of a section of a segment structure (38) given, the increase of the width of the conductor layer (37) closest to the axis of the stator to each of the two edges of the notch following its deformation is greater than said insertion set.

18. Stator according to the preceding claim, in that a ratio between a notch width (L1) covered with a notch insulation (145) and a segment structure width (38) covered with enamel (L2 ) is between 0.9 and 2.

Stator according to any one of the preceding claims, characterized in that each notch edge (28) covered with an insulator having an insertion clearance (J) with one end of a section of a strut structure. given segment (38), the notch width (L1) is equal to the sum of the segment structure width (L2) and twice the insertion set (J), said insertion set double (J) ) being less than 0.3mm.

20. Stator according to one of the preceding claims, characterized in that the notches are trapezium (28) and are provided with edges whose directions converge towards the axis of the stator.

21. Stator according to the preceding claim when dependent on claim 19, characterized in that for each notch is defined:

a notch entry set equal to the insertion set (J);

-a notch bottom set, the double of the bottom notch clearance being less than + 0.5mm.

22. Rotating electrical machine comprising a stator according to one of the preceding claims.