Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/06—Embedding prefabricated windings in the machines
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/04—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
  • H02K15/043—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines winding flat conductive wires or sheets
  • H02K15/0432—Distributed windings
  • H02K15/0433—Distributed windings of the wave winding type
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K3/00—Details of windings
  • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
  • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49002—Electrical device making
  • Y10T29/49009—Dynamoelectric machine

Definitions

• the invention generally relates to methods for manufacturing stators of polyphase rotating electrical machines, such as alternators or alternator starters of motor vehicles. More precisely, the invention relates, according to a first aspect, to a method of manufacturing a stator of a polyphase rotating electrical machine, such as an alternator or a motor starter - alternator, this stator comprising a pack of sheets pierced centrally by a boring and having an axis of symmetry, axially through notches formed in the bundle of sheets around the bore, and a corrugated coil comprising a plurality of phase windings each formed of at least one electrically conductive continuous wire shaped in succession. crenellations having a plurality of branches extending in a series of notches and a plurality of link segments connecting the branches.
• the stators formed by this method have on both sides of the pack of sheets of buns very dense, offering a strong resistance to the circulation of air.
• the buns are unsymmetrical, one of the buns having an axial height greater than that of the other bun, which is also unfavorable for the circulation of the cooling air in these buns.
• the filling rate of the notches that is to say the ratio between the section of the bare conductive wire, usually copper, and the complete section of the notch in which is mounted a notch insulation intervening between the edges of the notches and the wires are limited to 50% because the positioning of the branches in the notches is poorly controlled during the transfer of the phase windings of the insertion tool to the notches.
• the efforts required to insert the conductive son in the notches are very important. The inserted phase last must indeed push the phases inserted previously. Efforts are poorly transmitted from one phase to another. Under certain conditions, this can affect the quality of the product.
• the present invention aims to overcome the defects mentioned above.
• the method of the invention is essentially characterized in that it comprises at least a first step during which the winding wires are simultaneously arranged on a false rotor and during this same operation are shaped in crenellations, the false rotor having on a radially outer face a plurality of radial slots in which are arranged the branches of the windings, and a second step in which the dummy rotor is used for the transfer of the winding in the laminations or for the constitution of the stator.
• the second step can be carried out by placing the false rotor in the center of the sheet bundle and forcing the branches of the windings radially in the notches from the inside to the outside.
• the radial slots may extend in respective radial planes regularly distributed around an axis of symmetry of the false rotor, the false rotor further comprising a plurality of blades disposed in the radial slots, and displacement means blades radially from the inside to the outside in the radial slots, the branches of the windings being inserted into the radial slots at the first step on a radially outer side of the blades, the blades being moved radially outwards. in the second step so as to transfer the branches of the radial slots in the notches.
• the stator can be constituted in the second step by fixing a cylindrical jacket around the false rotor.
• the radial slots may be equal in number to the number of notches.
• each radial slot may have a circumferential width corresponding to the section of the wire, so that the branches are all aligned radially in the slot.
• the first step can be carried out by depositing the winding wires in a first group of consecutive radial slots, from a first axial side of the false rotor to a second axial side opposite the first bending the wires of the second axial side of the false rotor to form connecting segments, depositing the wires in a second group of consecutive axial slots located next to the first, from the second axial side to the first axial side, folding the wires of the first axial side to constitute others connecting segments, and so on until a complete first revolution of the dummy rotor has been completed and a first layer of wires has been formed, all the radial slots being occupied by a branch of a wire and then performing in the same way one or more other turns to form one or more other layers of wires in the radial slots.
• each group of radial slots may comprise a number of slots equal to the number of wires used to constitute the winding in the first stage.
• the branches of a given thread may occupy a set of radial slots which is specific to this wire, and in the other layer or layers, the branches of this same wire. can occupy the same set of radial slots.
• the branches of a given thread can occupy a set of radial slots which is specific to this wire, and in at least one other layer, the branches of this same wire can occupy another set of slots radial.
• said other set of radial slots may be shifted one slot relative to said set of radial slots.
• the branches of a given thread in the first layer, can occupy a first set of radial slots which is specific to this thread, in at least a second layer, the branches of this same thread can occupying a second set of radial slots different from the first set, and, in at least a third layer, the branches of the same set may occupy a third set of radial slots different from the first and second sets.
• the son of the phase windings can be arranged in the same sequence in all groups of slots, in a determined layer of the coil.
• the son of the phase windings can be arranged according to the same first sequence determined in all groups of slots, and in at least one other layer, the son can be arranged in a second sequence.
• the winding may comprise an even number of wires, said second sequence being obtained from the first sequence by swapping the neighboring wires in pairs.
• the number of layers wound according to the first sequence may be equal to the number of layers wound according to the second sequence.
• the wires of the phase windings may be arranged according to the same first sequence determined in certain groups of slots, and according to a second sequence determined in other groups of slots.
• the son used to constitute the winding in the first step can be cut, generally in their middle, after the first step.
• the first step can be carried out by winding an even number of wires each having an input end and an output end, these wires being united in pairs after the first step by electrically connecting them to each other. input ends of the wires of the same pair and the output ends of the wires of the same pair.
• the portions of the wires constituting the connecting segments between a first group of radial slots and a second group following the first group in the winding order may comprise mutually parallel first segments forming a beam plate emerging from the first group of radial slots in a direction inclined relative to the axis of the false rotor to an axial vertex of the connecting segments, and mutually parallel second segments and forming a flat bundle extending the first segments from said vertex to the second group of radial slots, oblique to the axis of the false rotor, such that the first and second segments bundle each other in a substantially triangular area at the top of the link segments.
• the second segments may extend from a radially outer side of the first segments into the triangular overlap area.
• the triangular overlapping zones of a determined layer can be inserted between the triangular overlapping areas of the preceding layer, without covering them, even partially.
• the notches of the stator may have a circumferential width corresponding to the section of the wire, all the branches being aligned in the same notch.
• the branches can be locked in the notches by deformation of the section of at least some branches.
• the deformation operation of the section of the branches can be performed after insertion of the branches in the radial slots of the false rotor and / or after insertion of the branches in the notches of the stator.
• the invention relates to a stator of a polyphase rotating electrical machine, such as an alternator or a motor starter-alternator, this stator comprising a pack of sheets centrally perforated by a bore and having an axis of symmetry, axially through notches formed in the bundle of sheets around the bore and each having a plurality of radially distributed reception positions on several levels, and a corrugated coil comprising a plurality of phase windings each formed of at least one electrically conductive continuous wire formed in succession of crenellations having a plurality of branches arranged at receiving positions in a series of notches and a plurality of connecting segments connecting the branches, characterized in each wire is wound spirally around the bore and forms a plurality of turns each corresponding to one turn of the bore, the branches of the same turn being all arranged in receiving positions of the same level.
• the winding can be wound in such a way that the wires of the windings pass through a first group of consecutive notches, from a first axial side of the stator to a second axial side opposite the first, and then are bent from the second axial side.
• the stator to form connecting segments then pass into a second group of consecutive notches located next to the first, from the second axial side to the first axial side, and then folded from the first axial side to form other segments.
• the branches of the first layer occupying the radially outer receiving positions of all the notches, the son being wound in the same way on one or more other towers and constituting one or more other layers whose branches occupy radially innermost receiving positions are in the notches.
• the portions of the wires constituting the connecting segments between a first group of notches and a second group of notches following the first in the winding order may comprise mutually parallel first segments forming a flat beam emerging from the first group.
• the second segments may extend from a radially outer side of the first segments into the triangular overlap area.
• the triangular overlapping zones of a given layer can be inserted between the triangular overlapping areas of the previous layer, without covering them, even partially.
• the first and / or second segments coming from the same end of a given notch may form a radial alignment of a circumferential side of the notch, or two radial V alignments of the two circumferential sides of the notch.
• the connecting segments linking a first group of notches to a second group of notches are relatively long, so that their first and second segments are mutually separated and define between them. a plurality of radial air passages.
• the connecting segments connecting a first group of notches to a second group of notches are relatively short, such that their first and second segments are mutually joined or mutually slightly spaced apart. .
• the notches of the stator may have a circumferential width corresponding to the section of the wire, all the branches being aligned in the same notch.
• the branches can be locked in the notches by deformation of the section of at least some branches.
• the thread may have a round section.
• FIG. 1 is a developed view of a wire of a phase winding formed in a succession of slots
• - Figure 2 is a partial view of a stator according to the invention, in section in a plane perpendicular to its axis of symmetry
• Figure 3 is a view of 4A is a perspective view of the dummy rotor used in the first embodiment of the invention, shown at the end of the first step, once the phase windings have been completed.
• FIG. 5A is a simplified perspective view of one end of the stator of FIG.
• FIG. 6 is a view similar to that of FIG. deformation of the wires in the notches of the stator.
• FIGS. 9A to 9F are developed representations of different winding sequences of the wires of the phase windings on the false rotor of FIGS. 4A and 4B, corresponding to different variants of FIG.
• FIGS. Figs. 11A to 9F are schematic diagrams showing in a developed manner the respective circumferential positions of the connecting segments of two successive layers of the coiled winding according to FIGS. Figs. 11A to 9F
• Fig. 11 is a schematic representation in radial section of a portion of the coil after placement in the stator, showing that it is possible to vary the inclination of the bun.
• FIG. 12 is a block diagram showing the means for making wire crossings on the machine of FIGS. 13 to 17,
• FIG. 13 is a general view of the machine for winding the wires of the phase windings on the false rotor. in the first step,
• FIG. 14 is a front perspective view of the machine of FIG. 13, the handling means of the false rotors not being shown;
• FIG. 14 is a front perspective view of the machine of FIG. 13, the handling means of the false rotors not being shown;
• FIG. 13 is a front perspective view of the machine of FIG. 13, the handling means of the
• FIG. 15 is a longitudinal sectional view of the machine of FIG. 13, considered according to the incidence of the arrows XV of FIG. 13, the false rotor being represented in the center of the wire guide means, gripped by the displacement means;
• FIG. 16 is an enlarged view of part of the means; wire guide of FIG. 14, considered in the longitudinal direction before,
• FIG. 17 is a sectional view of the wire guide means, considered according to the incidence of the arrows XVII of FIG. 14,
• FIGS. 18A. 18G are partial schematic representations of certain elements of the FIG. 13, illustrating a part of the winding sequence of the wires of the phase windings on the false rotor,
• FIG. 19 is an exploded partial view, in section, of a stator obtained according to a second embodiment of the invention. , seen in a plane perpendicular to the axis of symmetry of the stator, and
• FIG. 20 is an axial sectional view of the stator of FIG. 19, with the jacket and the false
• Embodiments of the invention aims to manufacture stators 1 of polyphase rotating electrical machine, more particularly stators of alternators or alternator starters of motor vehicles.
• the stator 1 comprises a bundle of annular plates 10 centrally perforated by a bore 12 and having an axis of axial symmetry 13, axial notches 30 formed in the bundle of sheets 10 evenly distributed around the bore 12, and a corrugated coil 6 ( Figures 2 and 3).
• the notches 30 are separated from each other by axial ribs 35 called teeth.
• notches 30 pass axially through the bundle of sheets 10 because they extend over the entire axial length of the bundle of sheets 10, and are open at the two opposite axial ends thereof.
• the coil 6 comprises a plurality of phase windings 70 typically each consisting of at least one electrically conductive continuous wire 60
• the wire is for example of round copper section covered with an insulator such as enamel of any diameter, typically between 1, 5 and 2, 12 mm.
• a notch insulation visible in Figure 2 is interposed between the son and the edge of the notches.
• each phase winding 70 comprises a succession of substantially rectilinear branches 71, arranged parallel to each other, connected by segments of link 72. More precisely, each branch 71 has an end connected by a connecting segment 72 to the end of the preceding branch 71 situated on the same side, and an opposite end connected by another link segment at the end of the next branch on the same side.
• the notches 30 each provide a plurality of receiving positions 36 of the side branches 71 stepped radially on several levels ( Figure 2).
• Each winding 70 is disposed on the stator so that the side branches 71 are arranged at receiving positions 36 in a series of notches 30 of the stator 1, the connecting segments 72 forming buns 40 and 40 'respectively. a first and a second axial side of the stator 1.
• the notches 30 are generally divided into several series, each series being exclusively associated with a given winding 70 and receiving exclusively the branches of this winding.
• the notches 30 of the same series are evenly distributed around the stator 1, the positions of the series of notches 30 associated with the different windings being deduced from each other by an angular offset of a notch, as shown in FIG. 9A.
• the same phase winding can be distributed in two series of notches, as will be seen later.
• the son or wires 60 of each winding 70 are each spirally wound around the bore 12 and thus form a plurality of turns 73 each corresponding to a turn of bore 12. These turns 73 are coaxial with the axis of symmetry 13 of the stator .
• the turns 73 of the various wires 60 are superposed radially in a predetermined order, and are arranged in the notches 30 in a concentric manner, the first inserted turns 73 being arranged radially on the outside, and the last inserted turns 73 being arranged radially. inside the plate package 10.
• the method comprises at least a first step in which the wires 60 of the phase windings 70 are arranged simultaneously on a false rotor 80 and are during this same operation shaped in slots, and a second step during which the false rotor 80 is used for the transfer of the winding 6 in the sheet package 10 (first embodiment) or for the constitution of the stator 1
• a substantially cylindrical false rotor 80 having on a radially outer face 85 a plurality of radial slots 84 in which are arranged the branches 71 of the windings 70 ( Figures 7 and 8).
• the radial slots 84 are equal in number to the number of notches 30 and are regularly distributed around the false rotor 80. They extend over the entire axial length of the false rotor and are open radially outwards and at both axial ends of the rotor. false rotor 80.
• each radial slot 84 has a circumferential width corresponding to the section of the wire, so that the branches 71 are all aligned radially in the slot 84 and occupy a plurality of radial positions distributed radially on several levels.
• the first step is carried out using a winding machine 90 which will be described later, according to a winding sequence of which several variants are shown in FIGS. 9A to 9F, by simultaneously depositing the wires 60 of the different windings 70 in a first group of radial slots 84 consecutive, from a first axial side of the false rotor 80 to a second axial side opposite the first, by folding the wires 60 of the second axial side of the false rotor 80 to form connecting segments 72, by depositing the wires 60 in a second group of consecutive axial slots 84 located next to the first, from the second axial side to the first axial side, by folding the wires 60 of the first axial side to form further connecting segments 72, and so on until to have made a first full revolution of the false rotor 80 and to have constituted a first layer of son 60.
• All the radial slots 84 are then occupied by a branch 71 of a wire 60, this branch occupying the innermost radial position in the slot (first line, detail B of FIGS. 9A to 9F).
• One or more other turns are made in the same manner to form one or more other layers of wires 60 in the radial slots 84.
• FIGS. 9A to 9F clearly show that each group of radial slots 84 comprises a number of slots equal to the number of wires used to carry out the winding operation, this number being equal to the number of windings of phase 70 or different of it, as we will see later.
• FIG. 9A corresponds to an exemplary embodiment in which 6 wires are used to make the winding, the radial slots having 6 radial positions, the winding operation being carried out in 6 turns, and the stator thus produced comprising 6 phase windings of each 6 turns, denoted x, u, z, w, y and v ( 1 wire per phase).
• the inputs 62 of the wires of the phase windings are denoted x1, ul, z1, w1, y1 and v1, and their respective outputs 63 x2, u2, z2, w2, y2 and v2.
• the winding sequence is such that the radial slots 84 are divided into several assemblies exclusively associated with a winding 70 (see details A and C).
• the branches 71 of a determined phase winding 70 occupy a set of radial slots 84 which is specific to this winding, and in the other layers, the branches 71 of this same phase winding 70 occupy the same set of radial slots 84.
• the wires 60 of the phase windings 70 are arranged in the same sequence in all the groups of slots 84, in a determined layer of the winding 6, and this sequence is the same in all the layers of the winding 6.
• the slots 84 associated with a given phase winding 70 are distributed regularly around the false rotor and are spaced apart by 6 slots (for example: slots
• FIG. 9B also corresponds to an exemplary embodiment in which 6 wires are used to carry out the winding, the radial slots having 6 radial positions, the winding operation being carried out in 6 turns, and the stator thus produced comprising 6 phase windings. each of 6 turns (1 wire per phase).
• the branches 71 of the same phase winding 70 are distributed in two sets of radial slots 84.
• the branches 71 of a determined phase winding 70 occupy a first set of radial slots which is specific to this winding, and, in the last two layers, the branches 71 of this same winding.
• phase 70 occupy another set of radial slots.
• This other set of radial slots 84 is here shifted one slot relative to said first set of radial slots, to the right in the representation of Figure 9B.
• This offset could also be a slit to the left.
• the electrical currents flowing through the phase windings 70 resulting from the winding sequence of FIG. 9B are out of phase with the electrical currents flowing through the phase windings 70 resulting from the winding sequence of FIG. 9A.
• FIG. 9C still corresponds to an exemplary embodiment in which 6 wires are used to make the winding, the radial slots having 6 radial positions, the winding operation being carried out in 6 turns, and the stator thus produced having 6 phase windings each of 6 turns (1 wire per phase).
• the branches 71 of a phase winding 70 are distributed in three sets of radial slots 84.
• the branches 71 of a determined phase winding occupy a first set of radial slots 84 which is suitable for this winding
• the branches 71 of the same phase winding 70 occupy a second set of radial slots 84 different from the first set
• the branches 71 of the same winding occupy a third set of radial slots 84 different from the first and second sets.
• the second set of slots is shifted one slot to the right in Fig. 9C relative to the first, and the third set of slots is shifted one slot to the right in Fig. 9C relative to the second.
• the electrical currents flowing through the phase windings 70 resulting from the winding sequence of FIG. 9C are out of phase with the currents flowing through the phase windings 70 resulting from the winding sequence of FIG. 9A or sequence 9B.
• FIG. 9D always corresponds to an exemplary embodiment in which 6 wires are used to make the winding, the radial slots having 6 radial positions, the winding operation being carried out in 6 turns.
• the wires of the phase windings are arranged according to the same first sequence determined in all the groups of slots of the first three layers, and are arranged in a second sequence in the other three layers.
• Said second sequence is obtained from the first sequence by dividing the son into several pairs of mutually neighboring son, and by permuting the neighboring son in pairs, between the third and fourth layers (points a2, b2, c2, d2, e2, f2).
• a stator Since the number of layers wound in the first sequence is equal to the number of layers wound according to the second sequence, a stator is obtained with three phase windings of 6 turns, each having two parallel wires.
• the branches 71 of the first wire of a pair are arranged at the first three layers in a first set of radial slots 84, and are arranged at the last three layers in a second set of radial slots 84 offset by a slot relative to to the first set.
• the branches 71 of the second wire of the same pair are arranged at the first three layers in the second set of radial slots 84, and are arranged at the last three layers in the first set of radial slots 84.
• the first and second wires are therefore traversed by electrical currents which are in phase, and therefore constitute the same phase winding with two parallel wires.
• the winding sequence of FIG. 9D could include an offset of a notch of the type described with respect to FIG. 9C.
• FIG. 9E always corresponds to an exemplary embodiment in which 6 wires are used to make the winding, the radial slots having 6 radial positions, the winding operation being carried out in 6 turns.
• the wires 60 of the phase windings 70 are cut in their middle after the first step, between the third layer and the fourth layer.
• the first half of wire 60 includes a first end (input or output x1, ul, z2, w2, y1, v1) and extends over the first three layers to a second end (input or output a21, b21, c21 , d21, e21, f21) in a set of radial slots specific to the corresponding phase winding.
• the second half of wire 60 comprises a third end (input or output a22, b22, c22, d22, e22, f22) and extends over the last three layers to a second output end, in the same set of slots radial than the first half of wire.
• the second and third ends are created when the wire 60 is cut.
• FIG. 9F corresponds to an exemplary embodiment in which 6 wires are used to carry out the winding, the radial slots having 6 radial positions, the winding operation being carried out in 6 turns.
• the winding sequence shown in FIG. 9F combines certain characteristics of the sequences of FIGS. 9D and 9E.
• each wire is cut between the third layer and the fourth layer.
• the first half of the wires occupying the first three layers are distributed in pairs and undergo pairwise pairs in the middle of the second layer.
• the second halves of yarns occupying the last three layers undergo even-numbered crosses in the middle of the fifth layer, the second halves of yarns being distributed in the same pairs as the first half-yarns, so that each yarn returns to its original position.
• first two ends of the two wires of the same pair and the two third ends of the two wires of the same pair are electrically connected, ie four mutually connected ends.
• the two second ends of the two wires of the same pair and the two fourth ends of the two wires of the same pair are electrically connected, that is to say four mutually connected ends.
• FIGS. 9A, 9B, 9C and 9E each make it possible to obtain six phase windings offset by 30 °, capable of being connected three by three in a star or in a triangle.
• FIGS. 9D and 9F each make it possible to obtain three phase shunts offset by 60 °, capable of being connected in a star or in a triangle. Formation and layout of link segments 72
• the portions of the wires 60 constituting the connecting segments 72 between a first group of radial slots 84 and a second group following the first in the winding order comprise first mutually parallel first segments 721 forming a flat bundle emerging from the first group of radial slots 84 in a direction inclined with respect to the axis of the false rotor 80 to an axial vertex 723 of the link 72, and second segments 722 mutually parallel and forming a flat beam extending the first segments 721 from said apex 723 to the second group of radial slots 84, obliquely to the axis of the false rotor 80, so that the beams of first and second segments 721/722 overlap each other in a substantially triangular zone 724 at the top of the connecting segments 72.
• the flat bundles may also extend each in a plane substantially perpendicular to the slots from which the segments are derived (for the first segments 721) or perpendicular to the slots to which the segments are directed (for the second segments 722).
• Figs. 10A / B show the first two turns of the winding sequence of a plurality of wires 60 on the false rotor 80, for example six wires in the embodiments of Figs. 9A-9F.
• the wires 60 are not shown individually, but in the form of a band developing in a slot around the false rotor, this band materializing the traj and son. This indicates that the wires 60 are wound simultaneously and are kept mutually parallel in a flat beam during the entire winding operation, as can be seen in Figures 9A to 9F.
• Each vertical portion numbered of the band corresponds to the passage of the beam in a group of radial slots.
• the second segment 722 of the rightmost wire covers the first segments 721 of all the other wires, ie five wires for a winding made of 6 wires.
• the second segment 722 of the wire situated immediately to its left covers the first segments 721 of all the wires located to the left of itself, ie four wires if the winding is made of 6 wires.
• the second segment 722 of the leftmost yarn does not overlap the first segments 721 of the other yarns.
• the link segments 72 can therefore be divided into three zones.
• the overlap zone 724 has a double thickness and an isosceles triangle shape whose axial apex 723 constitutes an edge, the opposite to this edge pointing to the radial slots.
• link segments 72 separating the groups of slots 1 and 2 and the connecting segments separating the groups of slots 3 and 4 are separated by a void space 726 of triangular shape.
• the other link segments 72 separating other groups of slots are constituted in the same manner as described above. It is clearly seen in FIG. 10B that the triangular overlapping zones 724 of a determined layer are inserted between the triangular overlapping zones 724 of the preceding layer, without covering them even partially, in the empty spaces 726 left between the segments. link 72.
• the lateral zones 725 of the connecting segments 72 of the second layer are covering the lateral zones 725 of the connecting segments of the first layer, as can be seen in FIG. 10B.
• the radial thickness of the parts of the winding intended to form the bunches of the stator 1 is uniform all around the false rotor 80.
• the parts winding intended to form the buns of the stator 1 have local radial thicknesses.
• the second segments 722 extend from one radially outer side of the first segments 721 into the triangular overlap area 724 in all link segments 72 of all layers. .
• FIGS. 4A, 7 and 8 show that the false rotor 80 comprises in this first embodiment a cylindrical portion 88 defining the radially outer face 85 in which the radial slots 84 are formed, a plurality of blades 86 arranged in the radial slots 84, and means 87 for moving the blades 86 radially from the inside to the outside in the radial slots 84.
• the blades 86 are arranged at the bottom of the radial slots 84, the branches 71 of the windings 70 fitting into these radial slots 84 on a radially outer side of the blades 86, as seen in the left half of FIG. 7.
• the insertion of the windings 70 in the notches 30 of the stator is carried out by placing the insertion tool 80 in the center of the sheet package 10 (FIG. 4B), so that each radial slot 84 located opposite a notch 30, and by forcing the branches 71 radially in the notches 30 from the inside to the outside.
• the blades 86 are displaced radially outwards by the means 87 provided for this purpose (see the right half of Figure 7 which shows the false rotor with the blades 86 substantially halfway).
• each blade 86 extends in a radial plane with respect to the axis of the false rotor 80 and comprises a central portion 861 engaged in one of the radial slots 84, and two axially extending end portions 862. the central portion 861 on both sides of the cylindrical portion 88.
• the end portions 862 of the blades 86 are delimited on a radially inner side by bevelled edges 863, so that the beveled edges
• each side of the cylindrical portion 88 has a hollow truncated cone 864, converging towards said cylindrical portion 88, coaxial with the axis of symmetry of the false rotor 80.
• the means 87 for moving the blades 86 comprise two frustoconical pushers 871 movable along the axis of symmetry of the false rotor 80, and actuators 872 for axially moving said pushers 871.
• the pushers 871 have shapes combined with those of the hollow cone frustum 864.
• the actuators 872 typically consist of cylinders each provided with an axially movable rod, the pushers being secured to the rods.
• the cylinders are able to move the rods to axially apply the pushers 871 against the beveled edges 863 forming the hollow cone truncated 864, these pushers thus soliciting the blades 86 in the direction of a spacing outwards.
• the movement of the pushers and blades is visible by comparing the left and right halves of Figure 7.
• the central portions 861 of the blades 86 then push the lateral branches 71 into the notches 30, all the phase windings 70 thus being put in place on the stator 1 in a single operation.
• the parallelism of the branches 71 is particularly well controlled throughout the various steps. These branches are held parallel in the radial slots 84 of the insertion tool 80 and then during the transfer of the tool to the notches 30.
• the actuators 872 for moving the blades 86 apart are remote and are not in the center of the tool 80. This is an important advantage because the size of the stators tends to be reduced.
• the radial insertion of the turns makes it possible to put in place the turns without torsion thereof during insertion, so that they do not deform back once insertion is complete.
• the false rotor 80 is provided with a central axis 89 secured to the cylindrical portion 88, extending axially beyond the blades 86.
• This central axis 89 serves as a guide for the pushers 871.
• the stator 1 is constituted in the second step by fixing a cylindrical jacket 20 around the false rotor 80, the latter becoming a constituent element of the stator 1.
• the cylindrical jacket 20 has an axial length equal to that of the false rotor 80 and an inside diameter slightly smaller than the outside diameter of the false rotor 80.
• the false rotor 80 as seen in FIG. 20, has a generally cylindrical shape, of constant outside diameter over its entire axial height, and is pierced axially by a cylindrical slot constituting the bore 12 of the sheet package 10, the radial slots 84 constituting the notches 30 of the sheet package 10.
• the radial slots 84 extend practically over the entire radial thickness of the false rotor, from the radially outer face 85 to the radially inner face delimiting the bore 12. These slots are closed on one inside by a thin wall under of the radial thickness of the false rotor 80, and are closed on one outside by the jacket 20.
• the false rotor does not include, in this second embodiment, movable blades 86, the branches 71 completely filling the slots 84, to the partitions closing these slots of an inner side.
• the jacket 20 is placed around the false rotor 80 by thermal expansion, this jacket 20 being first heated to a temperature such that its internal diameter becomes greater than the outer diameter of the false rotor 80, then the jacket 20 is threaded axially around the false rotor 80, finally the jacket 80 being cooled, which causes a constriction of the jacket on the false rotor 80 due to the decrease in the inside diameter of the jacket 20.
• the inside diameter of the jacket 20 is chosen so that the connection between the false rotor and the jacket is particularly strong.
• the step of heating the jacket is replaced by a step of cooling the false rotor 80, so as to reduce the external diameter of the false rotor sufficiently to allow the jacket 20 to be threaded on.
• This machine mainly comprises a frame 91, a magazine 92 for storing the wires 60 in coils, means 93 for guiding the wires 60 from the magazine 92 to a winding station 94, means 95 for moving the false rotor 80 axially to the winding station 94, and handling means 96 for transferring the false rotor 80 between a storage area 97 and the winding station 94.
• FIGS. 14, 16 and 17 show that the guiding means 93 comprise a vertical support plate 931 rigidly fixed to the frame 91, a front plate 932 having a shape of a half-ring rigidly fixed to a front side of the plate 933 fixed guide arms extending radially from an upper arcuate edge of 932 front plate circle, and 934 radial guide tubes mounted sliding radially on the front plate in the extension of the guide arms 933.
• the winding station 94 is located in the center of the front plate 932, the arcuate edge thereof being turned upward and centered on an axis X-X '.
• Each wire 60 extends from the magazine 92 to an outer end of one of the guide arms 933, then radially along the arm 933 to the associated tube 934, then radially inside the tube until at the winding station 94 (FIG. 16).
• Each guide arm 933 carries rollers G aligned on two opposite sides of the wire 60 to straighten this wire and make it rectilinear (FIG. 16) and means B to allow the wire 60 to move radially towards the center of the plate before 932 while by blocking the movement of the wire 60 in the opposite direction.
• the guiding means 93 still comprise
• FIG. 17 means 935 for simultaneously moving all the tubes 934, these means comprising for each tube 934 a rotary axis A parallel to the axis XX 'and passing through the front plate, a front pinion PV rotatably mounted on the front plate around the axis A and meshing with an external thread formed on the tube 934
• These means also comprise a drive member C in an arc of axis XX 'rotatable about the axis XX' relative to the front plate 932 and having an internal toothing meshing all the rear gears PR, and a motor M driving the member C in rotation through an external toothing on a radially outer face thereof.
• the motor M drives the member C in rotation about the axis XX ', in the clockwise or counterclockwise direction, the member C then driving the front gears PV in rotation with respect to the front plate, which causes the radial displacement of the guide tubes 934, inwardly or outwardly in the direction of rotation of the member C.
• the guiding means 93 still comprise
• FIG. 17 means 936 for packing the wires in the slots of the false rotor 80.
• These means 936 comprise radial blades L mounted radially on the front plate 932, each associated with a guide tube
• the guide plate PG carries a plurality of arcuate slots FA forming cams in which are engaged lugs E integral with the radial blades L, the rotation of the plate PG causing the displacement of the lugs E along the slots and the radial displacement of the blades L.
• the guide plate PG carries on its rear side an arcuate rib N having an external toothing meshing with a toothed wheel RD, which wheel is rotated by an actuator AC via the auxiliary gear wheel RA.
• the magazine 92 comprises a plurality of coils 921 of horizontal axes mounted on rotating supports 922 around respective vertical axes, the wires extending from the coils 921 to the coils 921.
• return pulleys 923 arranged in two columns, on either side of the guide means 93, then up to the radial guide arms 933 of the guide means 93.
• the means 95 for moving the false rotor 80 comprise a front unit 951 and a rear unit 952, visible in FIG. 15, arranged on both sides opposite axes of the guide means 93, and means 953/953 'for axially moving the front and rear units 951 and 952.
• the false rotor 80 at the winding station 94, is arranged so that its central axis 89 is aligned along the axis X-X '.
• the front unit 951 comprises a body 954 and a head 955 free to rotate about the axis XX 'with respect to the body 954, this head 955 being able to grip one end of the central axis 89 of the false rotor 80 and comprising means for fixing the free ends 64 of the wires 60 at predetermined angular locking positions. These locking positions are distributed around the head 955 so as to be brought into the radial extension of the guide tubes 934 by rotation of the head 955.
• the rear unit 952 includes a body 954 ', a head 955' engageable with the end of the central axis 89 opposite the front unit, and means 956 for driving said head 955 'in rotation about the XX 'axis relative to the body 954'.
• the means 953 for moving the front unit are disengageable, so that, once the two heads 955/955 'have gripped the false rotor 80, it is possible to move in one piece the assembly formed by the two heads 955/955 'and the false rotor 80 in axial translation, with the aid of the means 953 for moving the rear unit 952, and in rotation about the axis XX', with the aid of the means 956 for driving the head 955 'in rotation.
• the handling means 96 are capable of gripping a false rotor 80 to be wound in the storage zone 97, and to move it between this zone and a gripping position located immediately in front of the winding station, the false rotor being oriented so that its central axis 89 extends along the axis XX '.
• the front and rear units 951 and 952 come to grip the false rotor in this position.
• the front 951 and rear 952 units position the false rotor 80 again in the gripping position, and the handling means grab it to transfer it to the storage area 97, after the 951 and rear 952 units have released the false rotor 80. All elements of the machine are driven by a computer (not shown).
• the false rotor 80 is first moved axially forwardly to the position shown in broken lines in FIG. 18A, the guide tubes 934 being at the same time moved radially inwardly with the wires 60, on a length equivalent to the displacement of the false rotor 80. It follows from these joint movements that branches 71 are axially deposited at the bottom of a first group of radial slots 84. The guide tubes 934 are then raised radially (solid lines in FIG. 18B) and are then moved inwardly with the wires 60 to create the link segments 72 extending between the first group of radial slots 84 and the second group.
• the dummy rotor 80 rotates around the axis XX 'and undergoes a short parallel forward translation (formation of the first segments 721) and then a short backward translation (formation of second segments 722).
• the guide tubes 934 are then arranged opposite the radial slots 84 of the second group.
• the guide tubes 934 are then raised radially (solid lines in FIG. 18C) by a length corresponding to the length of the branches 71, and are then moved inward again with the threads 60 to create the branches deposited in the second radial slot group 84.
• the false rotor 80 is translated backwards.
• FIG. 18C the situation illustrated in broken lines in FIG. 18C.
• the guide tubes 934 are then raised radially (solid lines in FIG. 18D) by a length corresponding to the length of the connecting segments 72 between the second group of radial slots and the third group of radial slots, and are then moved again. inwardly with the wires 60 to create these link segments 72.
• the false rotor 80 rotates about the axis XX 'and undergoes a short parallel translation to the rear (formation of the first segments 721) and then a short translation forward (formation of the second segments 722).
• These link segments 72 are arranged on an opposite side to the link segments 72 formed at the step of Figure 18B. We are in the situation illustrated in broken lines in Figure 18D.
• FIGS. 18E to 18G illustrate the following steps, making it possible to deposit branches 71 in the third group of radial slots 84, to create connecting segments 72 extending between the third and fourth groups of slots 84 and to deposit branches 71 in the fourth group of slots 84. These operations are performed according to the procedure described with respect to FIGS. 18A to 18C.
• the winding operation continues in the same way, until it has made a complete revolution of the false rotor 80, and has constituted the first layer of threads.
• the other layers are made in the same way.
• the front plate 932 is divided into two moving parts relative to one another. to the other, as schematically illustrated in FIG. 12.
• the first part is rigidly fixed to the support plate 931 and carries the guide arms 933 and the guide tubes. 934 associated with the first, third and fifth wires, these wires being numbered in the order in which they are arranged around the winding station 94.
• the second part is rotatable about the X-X 'axis relative to the first and carries the guide arms 933 and the guide tubes 934 associated with the second, fourth and sixth son.
• the displacement of the second part can be achieved by any suitable means, for example by a motor whose shaft drives a toothed wheel meshing with teeth on the second part.
• the displacement of the second part makes it possible to bring the first wire between the second and fourth wires, the third wire between the fourth and sixth wires, and the fifth wire on the outer side of the sixth wire, thus realizing the desired two - two permutations.
• the branches 71 are locked in the notches 30 by deformation of the section of at least some branches 71. In each notch, this deformation is performed on at least the branch 71 located in the most radially outer, that is to say the closest to the opening of the notch, so as to block the other branches inside the notch.
• the deformation can be practiced equally on all the other branches of the notch.
• the branches 71 which are deformed bear against the two opposite walls of the notch 30.
• the deformation operation of the section of the branches 71 can be carried out in several ways.
• the deformation of the branches in the slots of the false rotor does not in any way prevent the transfer of these branches in the notches of the sheet package according to the first embodiment of the stator, the force exerted by the actuator to move the blades 86 of the false rotor 80 is very high and largely offsetting the resistance resulting from the support branches 71 on the sides of the radial slots.
• the locking of the branches in the notches by deformation of the wire section has the advantage of increasing the filling coefficient of the notches.
• the locking of the branches in the notches is carried out by deformation of the inner edge of each tooth 35 (toe), in a plurality of points distributed axially along the tooth root or over the entire axial length. of the tooth base.
• the locking of the branches in the notches is achieved by impregnating the son with a resin after the insertion thereof into the notches. It is possible to combine the three embodiments, and to achieve for example a deformation of the sections of the son to increase the filling coefficient of the notches and impregnation blocking.
• Such a stator comprises a corrugated coil 6 comprising a plurality of phase windings each formed of an electrically conductive wire 60 or of several wires 60 in parallel. These wires are continuous, which means that they do not consist of several sections welded end to end. On the other hand, when a phase winding comprises several parallel wires 60, the input ends of these wires are joined by welding and the output ends of these son are joined by welding.
• Each wire 60 is wound in a spiral around the bore 12 of the sheet bundle 10 and forms several turns 73 each corresponding to one turn of the bore 12, each turn 73 being incorporated in a different layer of the coil.
• the branches 71 of the same turn 73 are all arranged in receiving positions of the notches 30 of the bundle of sheets 10 located radially at the same level.
• the notches 30 of the stator have a circumferential width corresponding to the section of the wire 60, all the branches 71 being aligned radially in a row in the same notch 30.
• the coil 6 is wound so that the wires 60 of the windings pass through a first group of consecutive notches 30, from a first axial side of the stator 1 to a second axial side opposite the first, then are folded on the second axial side of the stator 1 to form connecting segments 72, then pass into a second a group of consecutive notches 30 adjacent the first, from the second axial side to the first axial side, and then folded on the first axial side to form further link segments 72, and so on a first complete turn.
• stator 1 constituting a first layer, the branches 71 of the first layer occupying the radially outer receiving positions of all the notches 30, the wires 60 being wound in the same way on one or more other turns and thus constituting one or more other layers of wires whose branches 71 occupy radially inner receiving positions 36 in the notches 30.
• the portions of the wires 60 constituting the connecting segments 72 between a first set of notches 30 and a second set of notches 30 following the first in the winding order comprise first segments. 721 mutually parallel forming a flat beam emerging from the first group of notches 30 in a direction inclined relative to the axis of the stator to an axial vertex of the connecting segments 72, and second segments 722 mutually parallel and forming a beam plate extending the first segments 721 from said vertex to the second set of notches 30, oblique to the stator axis, such that the first and second segments 721/722 overlap one another in a region substantially triangular 724 at the top of the connecting segments 722.
• the flat bundles are inscribed in a cylinder sector surface coaxial with the axis of symmetry 13 of the stator.
• the second segments 722 always extend from one radially inner side of the first segments 721 into the triangular overlap area 724.
• the triangular overlapping zones 724 of a determined layer are inserted between the triangular overlapping zones 724 of the preceding layer, without covering them, even partially. It follows that, if the winding is made from an even number of wires, the buns 40/40 'of the stator 1 have a constant radial thickness over the entire periphery of the stator. The radial thickness of the buns is the same as the radial thickness of the branches 71 aligned in the notches 30.
• the buns obtained are thus particularly compact radially, the connecting segments being however well ordered and drawing air circulation passages, as seen in Figure 3. Particularly advantageously, it is possible to modulate the cross section of the air. these passages by tilting the wires in the buns, as shown in Figure 11. It is thus possible to optimize the cooling conditions.
• length of a connecting segment 72 is meant the length of the portion of the wire constituting this segment.
• turns 73 intended to be inserted first into the notches 30, and whose branches 71 are inserted in the radially outer positions of notch bottoms 30, are shaped in the first step so that their connecting segments 72 are relatively longer than those of turns 73 whose side branches 71 occupy radially inner positions.
• all the connecting segments 72 of the same turn 73 have the same length.
• the different length between the connecting segments 72 of the different turns 73 of the same wire compensates for the fact that the successive branches 71 of an outer turn, arranged at the bottom of the notches 30, are mutually wider than the branches 71 of an inner turn, whose branches are arranged at the entrance of notches 30.
• the connecting segment 72 connecting the two outer legs 71 will be more open than the connecting segment 72 connecting the two inner legs 71. It will suffer because of its larger opening a flattening that will bring it to the same height as the linking segment 72 connecting the two inner legs 71 (see Figures 5A and 5B).
• all the segments coming from the same end of a given slot of the stator are therefore substantially radially aligned in two directions, as shown in FIG. 5B.
• the segments coming from the same axial end of a notch and forming part of the layers 1, 3 and 5 are mutually aligned and are inclined by a first circumferential side.
• the segments forming the layers 2, 4 and 6 are mutually aligned radially and are inclined by a second circumferential side opposite to the first.
• the segments of the layers 1, 3 and 5 form with the segments of the layers 2, 4 and 6 a V whose end of the notch constitutes the tip (FIG. 5A).
• all the segments coming from the same notch may be aligned on the same circumferential side of the notch.
• the relatively long connecting segments 72 are selected (right part of FIG. 5A).
• first segments 721 of these link segments 72 are mutually parallel and spaced apart (right part of Figure 5C).
• second segments 722 of these connecting segments 70 are mutually parallel and spaced apart.
• a plurality of air passages extending radially through the buns, of parallelepipedal section, is defined, as can be seen in FIG. right side of Figure 5C.
• These passages are arranged in the buns in a regular mesh, which promotes the circulation of air and the cooling of the buns. It is also possible to obtain particularly compact bunches by winding the wires so that the link segments are in place once in place on the stator.
• the buns are not crossed by any passage of air circulation.
• the lengths of the relatively short link segments 72 are selected (left-hand part of FIG. 5A).
• first segments 721 are mutually parallel and joined or very slightly apart (left part of Figure 5C).
• second segments 722 are mutually parallel and jointive or very slightly spaced apart.
• the bun in this case has a lower axial height than in the case of the bun well ventilated described above and illustrated on the right side of Figure 5C.
• This configuration is advantageous in the case of conduction cooled stators to the cylinder head.
• the stators of these alternators typically comprise a bore diameter of 80 to 120 mm, have 12 to 16 poles, a polar pitch of about 18 to 30 mm, and preferably 6 notches per pole. These features are particularly interesting because they are realistic in terms of manufacturability and performance.
• the method makes it possible to produce coils comprising two three-phase systems, mutually offset by 30 ° electrical, which are more efficient than simple three-phase systems.
• the method described above makes it possible to produce stators having a high filling rate of the notches. It is possible to achieve filling ratios of 65% (ratio between the section of the bare conductors and the section of the notch).
• the stators obtained have good thermal characteristics (good cooling of buns due to the airy structure of these buns) and acoustic, and good electrical performance.
• the method generally does not include a welding step, which reduces the cycle time and limit the risk of failure in the winding.
• the only welds that may be necessary are in small numbers, for example 6 per stator, and relate to the inputs and phase outputs (see the embodiment of Figure 9D).
• the winding machines have great flexibility and can be easily adapted according to the characteristics of the stators to be produced: diameter and axial height of the laminations, number of notches, turns, wire cross section, star or delta coupling of phase windings.

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• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Windings For Motors And Generators (AREA)
• Manufacture Of Motors, Generators (AREA)

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• 2004
  • 2004-12-20 FR FR0413611A patent/FR2879855A1/fr not_active Ceased
• 2005
  • 2005-12-12 KR KR1020077013883A patent/KR20070090934A/ko not_active Ceased
  • 2005-12-12 EP EP05826008A patent/EP1829193A1/de not_active Withdrawn
  • 2005-12-12 CN CNA2005800437972A patent/CN101084618A/zh active Pending
  • 2005-12-12 BR BRPI0518681-1A patent/BRPI0518681A2/pt not_active Application Discontinuation
  • 2005-12-12 JP JP2007546105A patent/JP2008524977A/ja active Pending
  • 2005-12-12 US US11/722,005 patent/US20090096311A1/en not_active Abandoned
  • 2005-12-12 WO PCT/FR2005/003106 patent/WO2006067298A1/fr not_active Ceased

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