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US 2009/0260218 A1Published application
Method for manufacturing a stator for inner-rotor type rotary electric machines
AssigneeDenso Corporation
InventorsAkito Akimoto, Masaomi Dobashi
Life of this patent
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Abstract
A tapered cage coil is prepared, having a small-diameter top coil end 101 and a large-diameter base coil end. The tapered cage coil is axially inserted into a stator core. Then, the tapered cage coil is radially expanded to thrust slot-accommodated portions of the coil into slots of the stator core. This can eliminate the necessity of deforming the base coil end to thereby facilitate the manufacturing procedures. At the same time, possible spring back can be mitigated.
Claims8
A method for manufacturing a stator for an inner-rotor type rotary electric machine comprising:
- a stator core having an inner peripheral surface in which a number of slots are circumferentially provided at a predetermined pitch;
- and a tapered cage coil consisting of a distributed-winding coil having a number of slot-accommodated portions to be accommodated in the slots, the slot-accommodated portions being arranged at a predetermined circumferential pitch and positioned being radially apart from the axis by a predetermined distance, the tapered cage coil having a top coil end and a base coil end each of which is made up of a group of coil end portions, each coil end portion connecting two adjacent slot-accommodated portions to be radially projected from two adjacent slots which are distanced from each other by an electrical angle of “π”, wherein the method comprises steps of:
- preparing the tapered cage coil that includes the top coil end having a diameter smaller than that of the inner peripheral surface of the stator core, the base coil end having a diameter larger than that of the inner peripheral surface of the stator core, and the slot-accommodated portions which are provided being inclined from the top coil end to the base coil end so that a distance from the axis is increased toward the base coil end;
- starting axial insertion of the tapered cage coil into the stator core, with the top coil end being inserted first;
- individually inserting the slot-accommodated portions, during the axial insertion, into the slots from respective openings of the slots;
- stopping the axial insertion after the top coil end has projected from an end face of the stator core;
- and
- thrusting the slot-accommodated portions into the slots by axially compressing the top coil end while the slot-accommodated portions are plastically deformed in the axially outward direction, to shape the tapered cage coil into a completed form of the tapered cage coil.
5 more elements
Dependencies are inferred from the claim text.