US 2026/0246350 A1 · METHOD AND APPARATUS FOR MANUFACTURING A STATOR FOR ELECTRIC MOTORS

Abstract

A method and an apparatus for manufacturing a star yoke stator for electric motors with distributed winding, as well as a stator achieved with the method described, are described. A two-component stator is provided with a central star-shaped element provided with radial stator teeth and stator slots interposed between the teeth, and a yoke into which the star is inserted with the windings included in the stator slots. The assembly method provides for positioning the star on a rotating spindle and for inserting the linear portions of coils of wire, previously formed on a winding tool and preferably pressed and carburized, into the stator slots, so that to keep the arrangement of the wires in order. The windings are completed by alternating the movements of inserting coils into the stator slots and of rotating the star. The yoke can be coupled to the star in a final step, whenever the yoke is made in one piece, or can be constructed around the star by coupling sectors of the yoke as the windings are completed. An apparatus configured for implementing the method described is further described. The invention further concerns a stator directly obtained with the method described and an electric motor integrating the stator. Greater filling coefficient, greater efficiency, less leakage currents and reduced stator height are achieved.

Claims30

Dependent claims

A method of manufacturing a two-component stator with distributed winding, named star yoke stator,

the stator comprising:
an outer body, named yoke, and
a body inside the yoke, named star, having an inner cylindrical surface defining a housing volume of the rotor of an electric motor and a plurality of radial stator teeth jutting out from the cylindrical surface towards the yoke and between which there are stator slots intended to accommodate windings of a conducting wire,
the method comprising:
making coils of conducting wire, wherein one or more conducting wires are wound on a winding tool so that to form at least one coil comprising at least one linear portion which in turn comprises a plurality of individual linear portions of conducting wire and which is adapted to be inserted into one of said stator slots;
supporting the star on a rotation axis with at least one first stator slot accessible to a manipulator of the coils;
inserting, by means of the manipulator, a first linear portion of the coil into the at least one first stator slot and restraining a second linear portion of the coil;
rotating the star about said rotation axis by an angle, thus deforming the coil at the portions comprised between the linear portions, and making at least one second stator slot accessible to the manipulator;
inserting, by means of the manipulator, a second linear portion of the coil into the at least one second stator slot;
repeating steps D, E and F until completing the winding of the star, thus having inserted a linear portion of a coil into each stator slot;
constraining the star to the yoke.

8 more elements

An apparatus (500, 600) for making a star yoke stator,

the stator comprising:
an outer body, named yoke, and
a body inside the yoke, named star, having an inner cylindrical surface defining a housing volume of the rotor of an electric motor and a plurality of radial stator teeth jutting out from the cylindrical surface towards the yoke and between which there are stator slots intended to accommodate windings of a conducting wire,
the apparatus (500, 600) comprising:
at least one winding tool configured to carry out step A, wherein one or more conducting wires are wound on the winding tool so that to form coils comprising at least one linear portion which in turn comprises a plurality of individual linear portions of conducting wire and which is adapted to be inserted into one of said stator slots;
a spindle (501, 601) rotatable about a rotation axis and lockable in a plurality of angular positions, configured to:
support the star with at least one first stator slot of the star accessible to a manipulator of the coils, and to
rotate the star by an angle corresponding to making at least one second stator slot accessible to the manipulator of the coils, possibly deforming the coil at the portions comprised between the linear portions during step E,
a manipulator of the coils, which is configured to carry out step D by inserting a first linear portion of the coil into the corresponding stator slot and restraining a second linear portion of the same coil, and to carry out step F by inserting a second linear portion of the coil into the corresponding stator slot,
wherein the spindle is susceptible to intermittent rotations alternated with the movements of the manipulator for inserting linear portions of the coil.

7 more elements

Dependencies are inferred from the claim text.

Method and apparatus for manufacturing a stator for electric motors

Life of this patent

Method and apparatus for manufacturing a stator for electric motors

Life of this patent

Abstract

Claims30