Stator for an automobile alternator and method

An alternator for an automobile comprising:

• a housing;
• a shaft rotatingly supported by said housing;
• a rotor supported by and adapted to rotate with said shaft;
• and
• a stator fixedly disposed in said housing adjacent said rotor, said stator comprising:
• a generally cylindrical hollow stator core having an annular array of slots formed in an inner surface thereof, the slots extending radially outwardly from the inner surface and having a substantially constant width;
• and
• a plurality of continuous conductors having a cross section adapted to be radially inserted into the slots of said stator core, a width of each of said conductors being substantially equal to the width of each of the slots of said stator core.

A method of winding a stator for an automobile alternator, the method comprising the steps of:

• a) providing a stator core having an annular array of slots formed in an inner surface thereof, the slots extending radially outwardly from the inner surface and having a substantially constant width, the stator core having a first side and a second side;
• b) providing a first conductor and a second conductor representing a first phase of a winding, each of the first conductor and the second conductor having a cross section adapted to be radially inserted into the slots of the stator core, a width of each of the first conductor and the second conductor being substantially equal to the width of each of the slots of the stator core;
• c) positioning the first conductor such that a first end of the first conductor lies on a first side of the winding;
• d) positioning the second conductor such that a first end of the second conductor lies on a second side of the winding, the first conductor and the second conductor cooperating to form a first conductor layer;
• e) bending the first conductor to form a first straight portion representing the middle of the winding;
• f) bending the second conductor to be substantially parallel with and lay adjacent and on top of the first straight portion defined by the first conductor;
• g) bending the second conductor to form an end loop and form a second straight portion spaced from the first straight portion in the middle of the winding;
• h) bending the first conductor to form an end loop and be substantially parallel with and lay adjacent and on top of the second straight portion defined by the second conductor;
• i) repeating steps e) through h) for the first conductor and the second conductor to complete a first portion of the winding that completes the first layer;
• j) repeating steps e) through h) for the first conductor and the second conductor to complete a desired number of layers for the winding;
• k) terminating the first conductor such that a second end of the first conductor extends from one of the first side and the second side of the winding;
• l) terminating the second conductor such that a second end of the second conductor extends from the other of the first side and the second side of the winding;
• m) repeating steps c) through l) for a desired number of conductors to reach a desired number of phases, shifting each phase a predetermined number of straight portions away from the first straight portion of the first phase of the winding;
• and
• n) inserting the straight portions of the winding into the desired core slots of the stator core beginning with the first layer and ending with the last of the desired number of layers.