# US 2009/0260219 A1 · Method of manufacturing coil for stator incorporated in rotary electric machine

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- Number: US 2009/0260219 A1
- Document ID: US20090260219A1
- Status: Published application
- Kind: A1
- Application number: 12/427,210
- Filed: 2009-04-21
- Published: 2009-10-22
- Earliest claimed: 2008-04-21
- Assignees: Denso Corporation
- Inventors: Masahiro TAKADA; Akito Akimoto; Atsuo Ishizuka
- Web page: https://patentgrep.com/patent/US20090260219A1

## CPC

- H02K 15/0433: {of the wave winding type}
- H02K 15/066: inserted perpendicularly to the axis of the slots or inter-polar channels
- Y10T 29/49009: Dynamoelectric machine
- Y10T 29/49071: by winding or coiling
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method is provided for manufacturing a stator coil for a rotary electric machine, which is formed by winding up a plurality of phase wires. The method includes a shaping step for shaping a plurality of shaped wire members from electrically conductive wires, an integrating step for integrating the plurality of shaped wire members with each other to form an integrated body, and a winding-up step for winding the integrated body about a core member to form a wound body. At the winding-up step, curve forming is performed by plastically deforming turn portions of the integrated body into a curved shape, during conveyance of feeding the integrated body to the core member.

## Claims

### Claim 1

A method for manufacturing a stator coil loaded on a rotary electric machine, the stator coil being wound with a plurality of phase windings, comprising:
i) a shaping step of shaping a plurality of shaped wire members from electrically conductive wires,
the shaped wire members each having a plurality of linear portions extending parallel to each other and being juxtaposed in a longitudinal direction of the integrated body, and a plurality of turn portions for connecting the adjacent linear portions with each other alternately at one end side and at the other end side of the linear portions, and
the shaped wire members each having a plurality of linear superposition portions in the longitudinal direction of the integrated body, the linear superposition portions each being formed by superposing the linear portions with each other;
ii) an integrating step of integrating a plurality of the shaped wire members to form an integrated body; and
iii) a winding-up step of winding up the integrated body about a core member to form a wound body,
the wound body having a plurality of linear stack portions in a circumferential direction of the wound body, the linear stack portions each being formed by stacking a plurality of the linear superposition portions in a radial direction,
wherein the winding-up step comprises a process of performing curve forming by plastically deforming the turn portions of the integrated body into a curved shape during conveyance of feeding the integrated body to the core member.

### Claim 2 (depends on 1)

The method for manufacturing a stator coil according to claim 1, wherein, at the winding-up step, a relationship of R≦r is established between a curvature radius R at the time of performing curve forming with plastic deformation during the conveyance of feeding the integrated body to the core member at the winding-up step, and a winding radius r used in winding the turn portions of the integrated body about the core member.

### Claim 3 (depends on 2)

The method for manufacturing a stator coil according to claim 2, wherein, at the winding-up step, a relationship of R<r is established between the curvature radius R and the winding radius r.

### Claim 4 (depends on 3)

The method for manufacturing a stator coil according to claim 3, wherein, at the winding-up step, the integrated body is wound about the core member by a plurality of number of turns to obtain the wound body, the curvature radius R being changed in accordance with the winding radius that changes with each turn.

### Claim 5 (depends on 4)

The method for manufacturing a stator coil according to claim 4, wherein the curve forming is performed by sandwiching the turn portions of the integrated body between a convex tool having a convex curve-forming face and a concave tool having a concave curve-forming face.

### Claim 6 (depends on 5)

The method for manufacturing a stator coil according to claim 5, wherein the turn portions are sandwiched between the convex curve-forming face and the concave curve-forming face, with an elastically deformable convex pressing plate for covering the convex curve-forming face being interposed between the convex curve-forming face and the return portions, and an elastically deformable concave pressing plate for covering the concave curve-forming face being interposed between the concave curve-forming face and the return portions.

### Claim 7 (depends on 6)

The method for manufacturing a stator coil according to claim 6, wherein:
at least one of the convex tool and the concave tool has an alignment pin that can be inserted into a gap formed between the linear superposition portions adjacent to each other in the integrated body; and
the turn portions are sandwiched between the convex curve-forming face and the concave curve-forming face, with the insertion of the alignment pin into the gap.

### Claim 8 (depends on 1)

The method for manufacturing a stator coil according to claim 1, wherein the curve forming is performed by sandwiching the turn portions of the integrated body between a first metal roller disposed inside a curve to be formed, and an elastic roller disposed outside the curve to be formed, for the application of a pressure.

### Claim 9 (depends on 1)

The method for manufacturing a stator coil according to claim 1, wherein the curve forming is performed by sandwiching the turn portions of the integrated body between a first metal roller disposed inside a curve to be formed, and second and third metal rollers disposed outside the curve to be formed, for the application of a pressure.

### Claim 10 (depends on 7)

The method for manufacturing a stator coil according to claim 7, wherein, at the winding-up step, preliminary alignment members are inserted into and withdrawn from respective gaps formed between the linear superposition portions adjacent to each other in the integrated body, during the conveyance of feeding the integrated body to the core member.

### Claim 11 (depends on 8)

The method for manufacturing a stator coil according to claim 8, wherein, at the winding-up step, preliminary alignment members are inserted into and withdrawn from respective gaps formed between the linear superposition portions adjacent to each other in the integrated body, during the conveyance of feeding the integrated body to the core member.

### Claim 12 (depends on 9)

The method for manufacturing a stator coil according to claim 9, wherein, at the winding-up step, preliminary alignment members are inserted into and withdrawn from respective gaps formed between the linear superposition portions adjacent to each other in the integrated body, during the conveyance of feeding the integrated body to the core member.

### Claim 13 (depends on 1)

The method for manufacturing a stator coil according to claim 1, wherein, at the winding-up step, the integrated body is wound about the core member by a plurality of turns to provide the wound body, and the curvature radius R is changed in accordance with the winding radius that changes with each turn.

### Claim 14 (depends on 13)

The method for manufacturing a stator coil according to claim 13, wherein the curve forming is performed by sandwiching the turn portions of the integrated body between a convex tool having a convex curve-forming face and a concave tool having a concave curve-forming face, for the application of a pressure.

### Claim 15 (depends on 14)

The method for manufacturing a stator coil according to claim 14, wherein the turn portions are sandwiched between the convex curve-forming face and the concave curve-forming face, with the interposition of an elastically deformable convex pressing plate for covering the convex curve-forming face between the convex curve-forming face and the turn portions, and the interposition of an elastically deformable concave pressing plate for covering the concave curve-forming face between the concave curve-forming face and the turn portions.

### Claim 16 (depends on 15)

The method for manufacturing a stator coil according to claim 15, wherein:
at least one of the concave tool and the convex tool has an alignment pin that can be inserted into a gap formed between the linear superposition portions adjacent to each other in the integrated body; and
the turn portions are sandwiched between the convex curve-forming face and the concave curve-forming face, with the insertion of the alignment pin into the gap.

### Claim 17 (depends on 16)

The method for manufacturing a stator coil according to claim 16, wherein, at the winding-up step, preliminary alignment members are inserted into and withdrawn from respective gaps formed between the linear superposition portions adjacent to each other in the integrated body, during the conveyance of feeding the integrated body to the core member.

### Claim 18 (depends on 1)

The method for manufacturing a stator coil according to claim 1, wherein, at the winding-up step, preliminary alignment members are inserted into and withdrawn from respective gaps formed between the linear superposition portions adjacent to each other in the integrated body, during the conveyance of feeding the integrated body to the core member.