# US 9,882,458 B2 · Method for producing a stator winding of an electric machine, in particular an AC generator

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- Number: US 9,882,458 B2
- Document ID: US9882458B2
- Status: Granted
- Kind: B2
- Application number: 13/990,811
- Filed: 2011-12-01
- Published: 2014-02-06
- Granted: 2018-01-30
- Earliest claimed: 2010-12-01
- Assignees: SEG Automotive Germany GmbH
- Applicants: Gert Wolf; Klaus Herbold; Gerlinde Weber; Christoph Schwarzkopf; Eberhard Rau; Alexander Mueller; Helmut Kreuzer; Kurt Reutlinger
- Inventors: Gert Wolf; Klaus Herbold; Gerlinde Weber; Christoph Schwarzkopf; Eberhard Rau; Alexander Mueller; Helmut Kreuzer; Kurt Reutlinger
- Web page: https://patentgrep.com/patent/US9882458B2

## CPC

- H02K 15/085: by laying conductors into slotted stators
- H02K 1/243: {of the claw-pole type}
- H02K 3/12: arranged in slots
- H02K 3/28: Layout of windings or of connections between windings (windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32)
- H02K 15/04: of windings prior to their mounting into the machines (insulating windings H02K15/10, H02K15/12)
- H02K 15/043: winding flat conductive wires or sheets
- H02K 15/066: inserted perpendicularly to the axis of the slots or inter-polar channels
- H02K 19/22: having windings each turn of which co-operates alternately with poles of opposite polarity, e.g. heteropolar generators
- H02K 15/0431: {Concentrated windings}
- H02K 15/0433: {of the wave winding type}
- H02K 2213/03: Machines characterised by numerical values, ranges, mathematical expressions or similar information
- Y10T 29/49009: Dynamoelectric machine
- 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

Method for producing a stator winding (18) of an electric machine (10), in particular an AC generator, wherein the stator winding (18) has at least n phase windings (120, 121, 122, 123, 124), and one phase winding (120, 121, 122, 123, 124) has a plurality of directly successive wound coils (82) with coil sides (88) and coil side connectors (91), wherein the coils (82) are divided into first coils (82.1) and second coils (82.2), with a forming tool (100), in which slots (105, 106; 105′, 106′) are provided which are suitable for accommodating the coils (82), wherein a first coil (82.1) is arranged in a slot (105; 105′), and a second coil (82.2) is arranged in another slot (105; 105′), characterized in that n−1 slots (105, 106; 105′, 106′) are arranged between the first coil (82.1) and the second coil (82.2).

## Claims

### Claim 1

A method for producing a stator winding (18) of an electrical machine (10), the method comprising:
providing a number (n) of phase windings (120, 121, 122, 123, 124), each one of the phase windings having a plurality of partial phase windings (120a, 121a, 122a, 123a, 124a; 120b, 121b, 122b, 123b, 124b; 120c, 121c, 122c, 123c, 124c; 120d, 121d, 122d, 123d, 124d), each one of the plurality of partial phase windings (120a, 121a, 122a, 123a, 124a; 120b, 121b, 122b, 123b, 124b; 120c, 121c, 122c, 123c, 124c; 120d, 121d, 122d, 123d, 124d) having a plurality of directly successive wound coils (82), the plurality of directly successive wound coils (82) including at least a first coil (82.1) and a second coil (82.2), each one of the first and second coils (82.1, 82.2) having respective coil sides (88) and coil side connectors (91);
providing a shaping tool (100) with a lower part (101) including slots (105) and an upper part (102) including slots (106), said slots of the respective lower and upper parts (101, 102) being situated opposite one another, such that the slot pairs (105, 106) situated opposite one another form respective common spaces, each of the common spaces being adapted to receive one of the plurality of directly successive wound coils (82);
positioning a first coil (82.1a) from a first one of the plurality of partial phase windings (120a), including all the coil sides (88.1a, 88.2a, 88.3a, 88.4a) thereof, in one of the common spaces formed by a first one of the slot pairs (105, 106);
positioning a second coil (82.2a) from the first one of the plurality of partial phase windings (120a), including all the coil sides (88.1a, 88.2a, 88.3a, 88.4a) thereof, in another one of the common spaces formed by a second one of the slot pairs (105, 106) such that the number of slots (105, 106) between the first coil (82.1a) and the second coil (82.2a) of the first one of the plurality of partial phase windings (120a) is one less than the number (n) of phase windings of the stator winding (18);
positioning an other first coil (82.1b) from an additional one of the plurality of partial phase windings (120b), including all the coil sides (88.1b, 88.2b, 88.3b, 88.4b) thereof, into the one of the common spaces formed by the first one of the slot pairs (105, 106) alongside the first coil (82.1a) of the first one of the plurality of partial phase windings (120a); and
displacing the upper part (102) relative to the lower part (101).

### Claim 2 (depends on 1)

The method as claimed in claim 1, further comprising winding each coil (82) of one of the plurality of partial phase windings (120a, 121a, 122a, 123a, 124a; 120b, 121b, 122b, 123b, 124b; 120c, 121c, 122c, 123c, 124c; 120d, 121d, 122d, 123d, 124d) with an even number of turns (85), or winding each coil (82) of the one of the plurality of partial phase windings (120a, 121a, 122a, 123a, 124a; 120b, 121b, 122b, 123b, 124b; 120c, 121c, 122c, 123c, 124c; 120d, 121d, 122d, 123d, 124d) with an odd number of turns (85).

### Claim 3 (depends on 1)

The method as claimed in claim 1, further comprising winding one coil (82) of one of the plurality of partial phase windings (120a, 121a, 122a, 123a, 124a; 120b, 121b, 122b, 123b, 124b; 120c, 121c, 122c, 123c, 124c; 120d, 121d, 122d, 123d, 124d) with an even number of turns (85), and winding another coil (82) of the one of the plurality of partial phase windings (120a, 121a, 122a, 123a, 124a; 120b, 121b, 122b, 123b, 124b; 120c, 121c, 122c, 123c, 124c; 120d, 121d, 122d, 123d, 124d) with an odd number of turns (85).

### Claim 4 (depends on 1)

The method as claimed in claim 1, further comprising winding the first coil (82.1a) from the first one of the plurality of partial phase windings (120a) with an even number of turns (85), and winding the second coil (82.2a) from the first one of the plurality of partial phase windings (120a) with an odd number of turns (85), and arranging n−1 slots (158) between the first coil (82.1a) from the first one of the plurality of partial phase windings (120a) and the second coil (82.2a) from the first one of the plurality of partial phase windings (120a).

### Claim 5 (depends on 1)

The method as claimed in claim 1, further comprising shaping at least one of the first and second coils (82.1a, 82.2a) from the first one of the plurality of partial phase windings (120a) after winding of respective turns (85) to arrange the coil sides (88.1a, 88.2a, 88.3a, 88.4a) of the at least one of the first and second coils (82.1a, 82.2a) from the first one of the plurality of partial phase windings (120a) at least virtually on a plane.

### Claim 6 (depends on 5)

The method as claimed in claim 5, wherein the first and second coils (82.1a, 82.2a) from the first one of the plurality of partial phase windings (120a) are two directly adjacent coils having a coil connector (94.1) between them, which coil connector (94.1) is connected integrally to the first and second coils (82.1a, 82.2a) from the first one of the plurality of partial phase windings (120a), the method further comprising rotating each of the first and second coils (82.1a, 82.2a) from the first one of the plurality of partial phase windings (120a) through an amount of substantially ninety angular degrees with respect to the coil connector (94.1) between the first and second coils (82.1a, 82.2a) from the first one of the plurality of partial phase windings (120a), with the rotation directions being mutually opposite.

### Claim 7 (depends on 6)

The method as claimed in claim 6, further comprising separating the coils sides (88.1a, 88.2a, 88.3a, 88.4a) of the first coil (82.1a) from the first one of the plurality of partial phase windings (120a) into first and second groups (130, 133) by the displacement of the upper part (102) of the shaping tool (100) relative to the lower part (101) of the shaping tool (100) such that n−1 slots are arranged between the first and second groups (130, 133) after the displacement.

### Claim 8 (depends on 1)

The method as claimed in claim 1, further comprising stamping the coil sides (88.1a, 88.2a, 88.3a, 88.4a) of the first coil (82.1a) from the first one of the plurality of partial phase windings (120a) in a stamping tool (186).

### Claim 9 (depends on 8)

The method as claimed in claim 8, wherein a first subset of the coil sides (88.1a, 88.3a) of the first coil (82.1a) from the first one of the plurality of partial phase windings (120a) are stamped differently than a second subset of the coil sides (88.2a, 88.4a) of the first coil (82.1a) from the first one of the plurality of partial phase windings (120a).

### Claim 10 (depends on 8)

The method as claimed in claim 8, wherein the coil sides (88.1a, 88.2a, 88.3a, 88.4a) of the first coil (82.1a) from the first one of the plurality of partial phase windings (120a) are stamped after winding or after displacement.

### Claim 11 (depends on 8)

The method as claimed in claim 8, wherein the first coil (82.1a) from the first one of the plurality of partial phase windings (120a) is provided with a stamped junction area (149) between the coil sides (88.1a, 88.2a, 88.3a, 88.4a) and the coil side connectors (91.1a, 91.3a).

### Claim 12 (depends on 1)

The method as claimed in claim 1, wherein the first one of the plurality of partial phase windings (120a) has two successive coils (82.1a, 82.2a) and the additional one of the plurality of partial phase windings (120b) likewise has two successive coils (82.1b, 82.2b), the method further comprising situating, in the shaping tool (100), the coils (82.1b, 82.2b) of the additional one of the plurality of partial phase windings (120b) between the coils (82.1a, 82.2a) of the first one of the plurality of partial phase windings (120a).

### Claim 13 (depends on 1)

The method as claimed in claim 1, wherein the first one of the plurality of partial phase windings (120a) has two successive coils (82.1a, 82.2a) and the additional one of the plurality of partial phase windings (120b) likewise has two successive coils (82.1b, 82.2b), the method further comprising situating, in at least one of the shaping tool (100) and the stator core (17), the coils (82.1b, 82.2b) of the additional one of the plurality of partial phase windings (120b) between the coils (82.1a, 82.2a) of the first one of the plurality of partial phase windings (120a).

### Claim 14 (depends on 1)

The method as claimed in claim 1, wherein the first one of the plurality of partial phase windings (120a) has two successive coils (82.1a, 82.2a) and the additional one of the plurality of partial phase windings (120b) likewise has two successive coils (82.1b, 82.2b), the method further comprising situating, in at least one of the shaping tool (100) and the stator core (17), one coil (82.1b) of the additional one of the plurality of partial phase windings (120b) between the two successive coils (82.1a, 82.2a) of the first one of the plurality of partial phase windings (120a).

### Claim 15 (depends on 1)

The method as claimed in claim 1, further comprising connecting the first one of the plurality of partial phase windings (120a) and the additional one of the plurality of partial phase windings (120b) in series with one another or in parallel with one another.