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
  • H02K15/30—Manufacture of winding connections
  • H02K15/33—Connecting winding sections; Forming leads; Connecting leads to terminals
  • H02K15/35—Form-wound windings
• • 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
  • H02K15/062—Windings in slots; Salient pole windings
  • H02K15/064—Windings consisting of separate segments
• • 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
  • H02K15/30—Manufacture of winding connections
  • H02K15/33—Connecting winding sections; Forming leads; Connecting leads to terminals
  • H02K15/35—Form-wound windings
  • H02K15/36—Processes or apparatus for simultaneously twisting two or more open ends of hairpins after their insertion into the machine
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
  • H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
• • 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

Definitions

• the present invention relates to rotating electrical machines and more particularly to the stators of such machines. It relates in particular to a process for manufacturing the stator, with a set of corresponding tools.
• the invention relates more particularly to synchronous or asynchronous alternating current machines. It relates in particular to traction or propulsion machines for electric (Battery Electric Vehicle) and/or hybrid (Hybrid Electric Vehicle - Plug-in Hybrid Electric Vehicle) motor vehicles, such as individual cars, vans, trucks or buses.
• the invention also applies to rotating electrical machines for industrial and/or energy production applications, in particular naval, aeronautical or wind turbine applications.
• the tools In applications JP 2013/172575 and JP 2020/110025, the tools have vertical fingers of different lengths.
• the invention aims to meet all or part of these needs and it achieves this, according to one of its aspects, thanks to a method for manufacturing a stator for a rotating electrical machine, comprising the following steps:
• stator mass in particular comprising a stack of magnetic laminations, the stator mass comprising notches made between teeth, electrical conductors being housed in the notches, at least some of the electrical conductors, or even a majority of the electrical conductors , being in the shape of a U-shaped or I-shaped hairpin, each comprising inner and outer legs, which extend in particular axially respectively in first A and second R notches, at least one of the inner and outer legs of the electrical conductors extending out of the notches by a portion of welding,
• the subject of the invention is in particular, independently or in combination with the foregoing, a method for manufacturing a stator for a rotating electrical machine, comprising the following steps:
• stator mass in particular comprising a stack of magnetic laminations, the stator mass comprising notches made between teeth, electrical conductors being housed in the notches, at least some of the electrical conductors, or even a majority of the electrical conductors , being in the shape of a U-shaped or I-shaped hairpin, each comprising inner and outer legs, which extend in particular axially respectively in first A and second R notches, at least one of the inner and outer legs of the electrical conductors extending out of the notches by a portion of welding, (b) circumferentially offset the outer legs of the electrical conductors one-half tooth pitch from the inner legs, and
• the subject of the invention is in particular, independently or in combination with the foregoing, a method for manufacturing a stator for a rotating electrical machine, comprising the following steps:
• stator mass in particular comprising a stack of magnetic laminations, the stator mass comprising notches made between teeth, electrical conductors being housed in the notches, at least some of the electrical conductors, or even a majority of the electrical conductors , being in the shape of a U-shaped or I-shaped hairpin, each comprising inner and outer legs, which extend in particular axially respectively in first A and second R notches, at least one of the inner and outer legs of the electrical conductors extending out of the notches by a portion of welding,
• the method according to the invention makes it possible to obtain the desired inclination of the electrical conductors outside the stator mass, on the side of the welding portions thereof, with different inclinations for different electrical conductors.
• the method according to the invention makes it possible to radially shift certain electrical conductors, in particular those of phase input and/or output. Such a configuration facilitates their connection to an electrical connector of the machine.
• the method according to the invention advantageously makes it possible to carry out these operations without changing the workstation for the stator, or changing the tooling, or changing the orientation of the stator in the workstation.
• the manufacturing process is facilitated and simplified.
• the angular position of each electrical conductor can be more easily controlled.
• the number of types of electrical conductors to be introduced into the stator mass can be reduced thereby, which can facilitate the storage of the electrical conductors before their insertion into the stator mass.
• the deformation of the electrical conductors in the circumferential plane and outside the circumferential plane can be carried out at the same workstation, with the same tools. The size of the workstation can be reduced.
• the method according to the invention can also make it possible to easily add an insulator between the inner and outer legs of the electrical conductors, which can in particular be useful during the rise in voltage of the stator.
• step (b) of circumferential offset of the outer legs of the electrical conductors by a half tooth pitch relative to the inner legs the outer legs of the electric conductors can be deformed by a half tooth pitch relative to the inner legs, or alternatively deforming the inner legs relative to the outer legs.
• the step (b) of circumferential shifting of the inner legs or the outer legs of the electrical conductors, in particular the outer legs of the electrical conductors, by a half tooth pitch may comprise a step (bl) of positioning two inner crowns and external positioning of electrical conductors.
• the two inner and outer positioning rings can be placed against the stator mass, just above the stack of laminations thereof.
• the two inner and outer positioning rings may comprise, as described below, mobile fingers extending radially, which are each mobile along a radial axis of the stator. During step (bl) of positioning the positioning crowns, the mobile fingers can be in the retracted position in the positioning crowns.
• a step (b2) the mobile fingers are taken out, which can each be placed between two consecutive electrical conductors.
• the movable fingers of the outer positioning ring are placed between the outer legs of the electrical conductors and the movable fingers of the inner positioning ring are placed between the inner electrical conductors.
• the movable fingers may or may not come into contact with the electrical conductors, especially depending on the winding. Be that as it may, the aim is to prevent an electrical conductor from slipping between two mobile fingers inside and outside.
• the movable fingers slide like pistons.
• a step (b3) the positioning rings are moved in translation along the longitudinal axis of the stator, in particular away from the stator mass, in particular upwards.
• the positioning rings can be moved towards the ends of the welding portions.
• the mobile fingers play the role of combs which make it possible to properly align the electrical conductors.
• a step (b4) the outer positioning crown is rotated through a given angle around the longitudinal axis of the stator.
• the angle can be equal to half a tooth pitch.
• the mobile fingers make it possible to twist the outer legs by half a dental step with respect to the inner legs.
• step (c) of radial offset movable phase fingers of the inner positioning ring can be removed, which are in particular configured to have a longer radial stroke than other movable fingers of the inner positioning ring.
• the radial offset preferably takes place away from the longitudinal axis of the stator.
• phase input and/or output conductors make it possible to shift certain electrical conductors called phase input and/or output conductors outwards and place them on a third layer, in particular an outermost layer.
• the outward radial offset can be more or less accentuated.
• the inclination of the outer legs can have a curved part with a large radius of curvature or a smaller radius of curvature, which then causes the curved part to be closer to the sheet metal package.
• the length of the welding portions of the outer legs of the electrical phase input and/or output conductors may be different, in particular greater, than the length of the welding portions of the outer legs of the other electrical conductors. Alternatively, the lengths may be equal.
• the movable phase fingers are configured to push out the phase input and/or output electrical conductors.
• they can be configured to pull these outwards.
• they may comprise pliers or another gripping tool.
• This embodiment variant can in particular be implemented with phase input and/or output electrical conductors protruding longitudinally from the other electrical conductors, being longer than the latter.
• step (c) of radial offset mobile phase fingers can be removed from the outer positioning ring, which are in particular configured to have a longer radial travel than other mobile fingers of the outer ring of positioning.
• the radial offset in this case takes place closer to the longitudinal axis of the stator.
• phase input and/or output conductors make it possible to shift certain electrical conductors called phase input and/or output conductors inwards and place them on a third layer, in particular an innermost layer.
• the radial inward offset can be more or less accentuated.
• the inclination of the inner legs can have a curved part with a large radius of curvature or a smaller radius of curvature, which then causes the curved part to be closer to the sheet metal package.
• the length of the welding portions of the inner legs of the electrical phase input and/or output conductors may be different, in particular greater, than the length of the welding portions of the inner legs of the other electrical conductors. Alternatively, the lengths may be equal.
• the movable phase fingers are configured to push the phase input and/or output electrical conductors inward.
• the method may include the following additional step (d):
• the welding portions of the inner legs of the electrical conductors can be deformed at a first pitch PL. At least part of the welding portions of the outer legs of the electrical conductors can be deformed at a second pitch P2. All weld portions of the outer legs of the radially offset electrical conductors can be deformed in step (c). The other welding portions of the outer legs of the electrical conductors can be deformed at a third pitch P3.
• the third pitch P3 can be lower than the first and second pitch PI and P2.
• step (d) of circumferential deformation may comprise a step (d1) of positioning a third deformation crown, which may be crenellated, possibly comprising as many slots as notches to the stator.
• This third deformation crown can deform in particular the welding portions of the inner legs of the electrical conductors at a first pitch PL
• it comprises 63 slots, for a stator comprising 63 slots and 6 poles.
• This third deformation crown makes it possible to deform the 63 welding portions of the inner legs of the electrical conductors at a first pitch PI.
• Step (d) of circumferential deformation may include a step (d2) of positioning a first deformation crown, which may include at least one window to receive a leg of a second deformation crown.
• the first deformation ring may be crenellated, possibly comprising a number of slots equal to the number of slots in the stator from which the number of slots of the second deformation ring described below is deduced.
• This first deformation ring can deform in particular at least part of the welding portions of the outer legs of the electrical conductors at a second pitch P2, as well as all the welding portions of the outer legs of the electrical conductors offset radially in step (c ).
• this first deformation crown makes it possible to deform 42 welding portions of the outer legs of the electrical conductors at a second pitch P2.
• the first deformation crown may also include notches which also make it possible to deform all the welding portions of the outer legs of the electrical conductors radially offset in step (c), in particular six notches for six welding portions radially offset in step (vs).
• the position of said notches may depend on the winding diagram of the stator.
• step (d) of circumferential deformation may include a step (d3) of positioning a second deformation crown.
• the second deformation crown can be configured to be nested in the first deformation crown, being in particular configured to move therein, in particular in rotation.
• the second deformation crown may in particular comprise lugs each received in a window of the first deformation crown, in particular four windows and four lugs.
• the legs can move in the windows when the second deformation ring rotates in the first deformation ring.
• This second deformation crown can deform in particular the other welding portions of the outer legs of the electrical conductors at a third pitch P3.
• the second deformation crown comprises 15 slots distributed over 4 legs, for a stator comprising 63 slots and 6 poles. This second deformation crown makes it possible to deform the other welding portions of the outer legs of the electrical conductors at a third pitch P3.
• Step (d) of circumferential deformation may include a step (d4) of repositioning against the stator mass of the inner and outer positioning rings, with in particular a helical movement of the outer positioning ring.
• the outer positioning crown can descend in a helix in order to follow the inclination of certain electrical conductors called phase input and/or output conductors which are placed on a third layer, in particular the outermost layer.
• the inner positioning crown can descend parallel to the longitudinal axis of the stator.
• the movable fingers of the inner and outer positioning rings can be in the retracted position.
• the movable fingers can be placed in a position of grip with the electrical conductors.
• This movement provides protection for the insulators at the slot exit during the next step.
• the maintenance of the insulators at the exit of the notch to support them during step (d) of circumferential deformation is improved.
• Step (d) of circumferential deformation may include a step (d5) of simultaneous rotation of at least two of the first, second and third deformation crowns, with at least two different pitches.
• the second deformation crown can be rotated relative to the first deformation crown.
• the first and second deformation rings can be rotated in a first direction, but not at the same pitch, while the third deformation ring can be rotated in a second direction opposite to the first direction.
• the welding portions of the phase input and/or output electrical conductors are radially aligned with welding portions of other electrical conductors.
• the deformation crowns can be removed, then the inner and outer positioning crowns are also removed.
• the outer positioning ring may advantageously include notches to receive certain phase input and/or output electrical conductors, in particular six notches, which makes it possible to prevent its withdrawal movement from being prevented by the electrical conductors of phase input and/or output.
• the rotation of the first, second and third deformation crowns is simultaneous for the three deformation crowns.
• the rotation of the three deformation crowns may not be simultaneous. It can take place successively.
• the rotation of the first deformation crown may precede the rotation of the other deformation crowns. It may or may not precede the radial shift in step (c).
• step (c) of radial offset can take place before step (b) of circumferential offset.
• the positioning rings may not be configured to allow the circumferential offset.
• the radial offset can be carried out as described below, by means of claws.
• phase input and/or output electrical conductors are pushed outwards.
• they can be pulled outwards, for example by means of pliers or another gripping tool, such as independent claws.
• Said claws can be configured to allow the outward deformation of these welding portions.
• This embodiment variant can in particular be implemented with phase input and/or output electrical conductors protruding longitudinally from the other electrical conductors, being longer than the latter.
• phase input and/or output electrical conductors can be pushed inwards.
• the inner legs of the electrical conductors are shifted circumferentially by half a tooth pitch with respect to the outer legs, then the inner legs of certain electrical conductors are shifted radially inwards, in particular the inner legs of the electrical conductors of phase entry and/or exit, in particular six interior legs.
• Such a configuration can make it possible to generally improve the accessibility of the tool assembly.
• this configuration can make it possible to avoid using an inner crown with mobile fingers because accessibility from the outside is complete.
• this configuration makes it possible to obtain greater compactness, and thus a reduction in materials necessary for the connector, when you want to position the phase connector on a large diameter stator.
• At least one electrical conductor, or even a majority of the electrical conductors, introduced into the notches, are U-shaped hairpin. They can be shaped into a hairpin prior to their introduction into the notches. All the electrical conductors in the shape of a U-shaped hairpin can be shaped, simultaneously or successively, then introduced into the stator mass simultaneously or successively.
• Shaping may include a first step of assembling the strands of the same electrical conductor.
• the same U-shaped electrical conductor can be placed in two different, non-consecutive slots in the stator mass of the stator. If an electrical conductor is U-shaped, it can be welded to two other electrical conductors on the same side of the machine.
• the invention also relates to a set of tools, in particular for the manufacture of a stator of a rotating electrical machine, for the implementation of the method as described above.
• the invention also relates, independently or in combination with the foregoing, to a set of tools, in particular for the manufacture of a stator for a rotating electrical machine, in particular for the implementation of the method as described above, which comprises: a plurality of deformation crowns, in particular three deformation crowns, including a second deformation crown which is configured to be nested in a first deformation crown, being in particular configured to move therein, in particular in rotation.
• the first deformation crown may comprise at least one window to receive a leg of the second deformation crown.
• the first deformation crown may in particular comprise four windows.
• the second deformation crown may in particular comprise four legs.
• the window(s) of the first deformation ring may have a longer circumferential extent than the lug(s) of the second deformation ring, which may allow the movement, in particular in rotation, of the second deformation ring in the first ring of deformation.
• the plurality of deformation crowns may include a third deformation crown, which may include regular slots, all regularly distributed over its circumference.
• the crowns of deformation are generally circular in shape. In particular, they are not carried out in independent sectors.
• the deformation crowns can be manufactured for example by machining or by molding, or even by additive manufacturing, known as 3D printing.
• the deformation crowns can each comprise longitudinal slots to receive the welding portions of the electrical conductors.
• Each welding portion of an electrical conductor can be received in a crenel of one of the deformation crowns.
• Each slot can receive a single weld portion of an electrical conductor.
• the lug(s) of the second deformation ring may be serrated.
• each deformation ring may include a different number of slots.
• a deformation crown in particular the third deformation crown, may comprise as many slots as there are notches in the stator.
• a deformation crown in particular the second deformation crown, may comprise a number of slots less than the number of notches in the stator, being for example equal to 15.
• a deformation crown in particular the first deformation crown, may comprise a number of slots equal to the number of notches of the stator from which the number of slots of the second deformation crown is deduced.
• All the slots of the first deformation crown can have the same circumferential width and/or the same height along the longitudinal axis of the stator and/or the same radial depth.
• All the slots of the second deformation crown can have the same circumferential width and/or the same height along the longitudinal axis of the stator and/or the same radial depth.
• All the slots of the third deformation crown can have the same circumferential width and/or the same height along the longitudinal axis of the stator and/or the same radial depth.
• the assembly may include at least one outer ring for positioning the electrical conductors, the outer ring for positioning comprising a plurality of movable fingers.
• the movable fingers extend radially, they are each movable along a radial axis of the stator.
• the outer positioning crown may comprise as many movable fingers as there are teeth on the stator.
• the movable fingers can be of conical shape, in particular with a chamfered and/or radiated end.
• the movable fingers are movable between a retracted position and a grip position with the electrical conductors. They can slide like pistons in the outer positioning crown.
• the movable fingers In the retracted position, the movable fingers do not interfere with the movement of the outer positioning ring relative to the stator.
• the outer positioning crown can be movable in translation along the longitudinal axis of the stator.
• the movable fingers are each engaged between two consecutive electrical conductors. They can facilitate their alignment, in particular during a movement in translation along the longitudinal axis of the stator of the outer positioning crown. In addition, they can allow their deformation by twisting, in particular over a circumferential distance of half a tooth pitch.
• all of the movable fingers of the outer positioning crown may be identical to one another.
• the outer positioning ring may include notches to receive certain phase input and/or output electrical conductors, in particular six notches.
• notches can allow the placement of the phase input and/or output electrical conductors on a third layer, in particular the outermost layer.
• the outer positioning ring has six notches each capable of receiving an electrical phase input and/or output conductor.
• Some or all of the movable fingers of the outer positioning ring may each comprise a shoulder, which may make it possible to wedge the electrical conductors.
• the mobile fingers present at the aforementioned notches may comprise such a shoulder.
• the shoulder can allow the maintenance of the electrical conductors, as well as the maintenance of an insulator of said electrical conductor.
• the shoulders can help to maintain any insulators placed on the electrical conductors and allow their protection.
• the assembly may include at least one inner ring for positioning the electrical conductors, the inner ring for positioning comprising a plurality of movable fingers.
• the movable fingers extend radially, they are each movable along a radial axis of the stator.
• the inner positioning crown may comprise as many movable fingers as there are teeth on the stator.
• the mobile fingers can be cylindrical, in particular with a chamfered and/or radiated end.
• the movable fingers are movable between a retracted position and a grip position with the electrical conductors. They can slide like pistons in the inner positioning crown.
• the movable fingers In the retracted position, the movable fingers do not interfere with the movement of the inner positioning ring relative to the stator.
• the inner positioning crown can be movable in translation along the longitudinal axis of the stator.
• the movable fingers are each engaged between two consecutive electrical conductors. They can make it possible to promote their alignment, in particular during a movement in translation along the longitudinal axis of the stator of the inner positioning ring gear. In addition, they can allow their deformation by twisting, in particular over a circumferential distance of half a tooth pitch.
• the inner crown may have a disc shape.
• the movable fingers of the inner positioning crown may comprise phase movable fingers configured to have a longer radial travel than the other movable fingers, in particular four or six.
• phase input and/or output conductors These mobile phase fingers make it possible to shift certain electrical conductors, called phase input and/or output conductors, outwards or inwards and place them on a third layer, in particular the outermost layer.
• the inner positioning crown may comprise movable fingers with two possible radial strokes, a shorter one for most of them, and a longer one for some of them, in particular six of them.
• the assembly can be configured such that the outer positioning crown and the inner positioning crown can be moved from top to bottom and from bottom to top relative to the stator, along a longitudinal axis of the latter.
• the assembly can be configured such that the outer positioning crown and the inner positioning crown can be moved in rotation with respect to each other.
• one of the two crowns can be moved in rotation relative to the other and relative to the stator, while the other crown can remain fixed relative to the stator.
• the tooling set features simple shaped crowns, which are configured to have simple kinematics.
• the assembly may be devoid of an inner positioning crown. It may only include an outer positioning crown.
• Another subject of the invention is a stator for a rotating electrical machine obtained by implementing the method as described above.
• a further subject of the invention is a stator for a rotating electrical machine, comprising a stator mass comprising notches made between teeth, electrical conductors being housed in the notches, at least some of the electrical conductors, even a majority of the electrical conductors, being in the shape of a U-shaped or I-shaped hairpin, each comprising inner and outer legs extending axially respectively in first A and second R notches, at least one of the inner legs and exterior of the electrical conductors extending outside the notches by a welding portion inclined with respect to a plane perpendicular to a longitudinal axis of the stator to come overhanging the stator mass circumferentially at the level of a notch or a tooth, this notch or tooth being separated from the first A or from the second R notch respectively by a number NI and/or N2 of teeth, at least a part of the electrical conductors each having a welding portion which is the innermost with respect to the longitudinal axis of the
• a further subject of the invention is a stator for a rotating electric machine, in particular obtained by implementing the method as described above, which comprises a stator mass comprising notches formed between teeth , electrical conductors being housed in the notches, at least some of the electrical conductors, or even a majority of the electrical conductors, being in the shape of a U-shaped or I-shaped hairpin, each comprising inner and outer legs extending axially in particular respectively in first A and second R notches, at least one of the inner and outer legs of the electrical conductors extending outside the notches by a welding portion inclined with respect to a plane perpendicular to a longitudinal axis of the stator to come overhanging the mass stator circumferentially at the level of a notch or a tooth, this notch or tooth being in particular separated from the first A or from the second R notch respectively by a number NI and/or N2 of teeth, at least some of the electrical conductors each having a welding
• Each welding portion of the phase input electrical conductors may be radially aligned with welding portions of other electrical conductors.
• the welding portions of the phase input electrical conductors may not be offset by half a tooth with respect to the welding portions of other electrical conductors.
• the electrical conductor welding portions may be arranged in several layers with respect to the longitudinal axis of the stator, in particular in three layers, at least two layers comprising a different number of electrical conductor welding portions.
• each layer of electrical conductor welding portions is concentric around the longitudinal axis of the stator.
• each layer may have a different number of electrical conductor solder portions.
• a layer in particular the innermost layer, can comprise as many welding portions as slots in the stator.
• a layer in particular the outermost layer, may comprise a number of welding portions equal to twice the number of phases of the winding of the stator, for example six in the case where the winding is three-phase.
• a layer in particular an intermediate layer placed between the innermost layer and the outermost layer, may comprise a number of welding portions equal to the number of notches of the stator from which double the number of phases of the stator winding, for example six in the case where the winding is three-phase.
• the electrical conductor welding portions are well aligned with each other, which can facilitate the welding of the electrical conductors and simplify the manufacture of the stator.
• the number of layers can for example be different from 4.
• the numbers NI and N2 can be equal or different.
• the first A and second R notches are separated by a number Nd of teeth.
• the number Nd of teeth is preferably the same for all of the U-shaped hairpin electrical conductors of the stator.
• the invention makes it possible to reduce the height of the buns on the side opposite the welds, which is advantageous for minimizing the size of the machine and the quantity of material, especially copper, necessary for electrical conductors.
• the rotor shaft can be shorter, the casing can be shorter, the integration of the machine into its environment of use can be facilitated. Finally, the overall mass of the machine can be minimized.
• the spacing between each of the chignons is more regular, which can make it possible to minimize the risks of contact between them, and thus to make it possible to eliminate the step of covering them with an insulator.
• the invention makes it possible to reduce the number of pin shapes to be used in the same stator.
• the manufacture of the stator can be accelerated, with fewer manufacturing steps.
• the manufacture, the space required and the tools to be used are simplified.
• the invention makes it possible to free up space on either side of the pins at the notch exit, which can make it possible to position the connections there to the other phases or to an inverter, in particular on the side of the cylinder head of the stator.
• the spacing between the pins at the notch exit can be, in one embodiment, constant or substantially constant. This can facilitate the realization of the welds on the one hand, and the cooling of the electrical conductors on the other hand.
• N 1 can vary from Nd/2 - 0.5 to Nd teeth
• N2 can vary from 0 to Nd/2 + 1.5 teeth.
• NI is equal to Nd or Nd+1 and N2 is equal to 0 or 1.
• N1 and N2 are equal or nearly equal.
• NI and N2 can each be equal to one of Nd/2 or Nd/2 + 0.5 or Nd/2 - 0.5 or Nd/2 +/- 1 or Nd/2 + 1.5.
• outer and inner legs of an electrical conductor can be referred to as 'first and second legs'.
• the welding portion of the second leg of the electrical conductor is aligned therewith.
• N2 which is zero.
• each of the first and second legs of the electrical conductors which can be extended outside the slots by a welding portion inclined with respect to a plane perpendicular to a longitudinal axis of the stator to come overhanging of the stator mass circumferentially at the level of a notch or a tooth, this notch being separated from the first A or the second R notch respectively by a number NI and N2 of teeth, the numbers NI and N2 possibly being equal or different.
• each of the first and second legs of the electrical conductors may be oriented away from each other, which may in particular be the case when the winding is corrugated. As a variant, they can be oriented in the same direction, which can in particular be the case when the winding is in series.
• a stator for a rotating electric machine comprising a stator mass comprising notches, electrical conductors housed in the notches, at least some of the electrical conductors, or even a majority of the electrical conductors, being in the shape of a U-shaped hairpin, each comprising first and second legs extending axially respectively in first A and second R notches, the first A and second R notches being separated by a number Np of notches.
• the number Np of notches is the same for all the U-shaped electrical conductors of the stator pin.
• At least one of the first and second legs of the electrical conductors can be extended outside the slots by a welding portion inclined with respect to a plane perpendicular to a longitudinal axis of the stator to come overhanging the stator mass circumferentially at the level of a notch , this notch being separated from the first A or the second R notch respectively by a number NI and/or N2 of teeth.
• the numbers NI and N2 can be equal or different.
• N 1 can vary from Np/2 - 0.5 to Np notches
• N2 can vary from 0 to Np/2 + 0.5 notches.
• NI is equal to Np and N2 is equal to 0.
• NI and N2 are equal, being equal to Np/2 or Np/2 + 0.5 or Np/2 - 0.5.
• the welding portion of the second leg of the electrical conductor is aligned therewith.
• N2 which is zero.
• each of the first and second legs of the electrical conductors which can be extended outside the slots by a welding portion inclined with respect to a plane perpendicular to a longitudinal axis of the stator to come overhanging of the stator mass circumferentially at the level of a notch, this notch being separated from the first A or the second R notch respectively by a number NI and N2 of teeth, the numbers NI and N2 possibly being equal or different.
• At least some of the electrical conductors each have a welding portion that is innermost with respect to the longitudinal axis of the stator, or even a majority, better all the electrical conductors each have a welding portion that is innermost with respect to the axis longitudinal of the stator.
• At least some of the electrical conductors each have a welding portion that is the outermost with respect to the longitudinal axis of the stator, or even a majority, better all the electrical conductors each have a welding portion that is the outermost with respect to the axis longitudinal of the stator.
• the inner portions are disposed closer to the rotor than the outer portions.
• the innermost welding portions are inclined with the same inclination with respect to the plane perpendicular to the longitudinal axis of the stator. These innermost weld portions all extend parallel to each other. As regards the outermost welding portions, they are not necessarily all inclined with the same inclination with respect to the plane perpendicular to the longitudinal axis of the stator. They can be inclined with at least two, or even three or four, different inclinations with respect to the plane perpendicular to the longitudinal axis of the stator.
• the outermost welding portions of the electrical conductors are inclined with at least two, or even three or four, different inclinations with respect to the plane perpendicular to the longitudinal axis of the stator.
• the first leg can be arranged closer to the rotor than the second leg.
• the second leg can be arranged closer to the yoke of the stator than the first leg.
• first leg may be disposed closer to the yoke of the stator than the second leg, and the second leg may be disposed closer to the rotor than the first leg.
• At least some of the electrical conductors may have a second leg extending out of the notch by a welding portion extending in the same radial plane as the second leg, or even being aligned therewith.
• the manufacture of the stator is facilitated, insofar as the operations of inclining the pins can be simplified and accelerated.
• this configuration only one of the legs of the electrical conductor is inclined, so that it is thus possible to limit the deformations and the stresses on the electrical conductors. In particular, it is thus possible to reduce the risks of electrical contact between the phases of the winding of the stator.
• only the first leg of the electrical conductors has an angled solder portion.
• the welding portion of the second leg can be aligned with the second leg, extending in the extension thereof and being straight therewith.
• the first leg can be disposed closer to the rotor than the second leg.
• the first angled leg may be disposed closer to the yoke of the stator than the second leg.
• At least a part of the electrical conductors may have a second leg extending out of the notch by a welding portion forming a recess relative to the notch, while extending in the same radial plane as the second leg.
• the offset of the electrical conductor can make it possible to reach the metallic elements of a phase connector.
• the metal elements can be arranged radially externally with respect to the electrical conductors to which they are connected.
• At least a portion of the electrical conductors may have a second leg extending out of the notch by a circumferentially extending solder portion. At least a portion of the electrical conductors may have a second leg extending out of the notch by a solder portion extending out of a circumferential surface.
• the stator may include two electrical conductors per slot.
• the electrical conductors can form a distributed winding.
• the winding can be corrugated or in series. Electrical conductors can form a fractional winding.
• the winding can be full pitch. In one embodiment, the winding may have a shortened pitch.
• the electrical conductors housed in the slots can form a multi-phase winding having at least a first phase a and a second phase b, an input electrical conductor A of the first phase a being located in a first slot (slot number 1) , one or more electrical conductors of the second phase b being located in a second notch (slot number 2), the second notch immediately following the first notch when moving circumferentially around the axis of rotation of the machine, in the direction of flow of the electric current around the axis of rotation of the machine
• the input electrical conductor of the first phase is in this case located in a first notch just before a second notch receiving one or more electrical conductors of the second phase, when moving circumferentially around the axis of rotation of the machine , in the direction of flow of the electric current around the axis of rotation of the machine.
• the electrical input conductor of the first phase is located opposite the usual position, namely a position in which the first notch receiving the electrical input conductor of the first phase is immediately followed by a second notch. receiving one or more electrical conductors of the same first phase, when moving circumferentially around the axis of rotation of the machine, in the direction of circulation of the electric current around the axis of rotation of the machine.
• the entry notch of a first phase can be followed by a notch housing electrical conductors of a second phase different from the first.
• the implementation of the invention makes it possible to reduce the tooth pitch of the electrical conductors which are used to connect the various winding paths which progresses in the same direction around the axis of rotation of the machine, and the average length of each phase thanks to better interweaving of the subsets of electrical conductors constituting the winding, measured circumferentially around the axis of rotation of the machine. Shortening the average length of a phase improves linear resistance and thermal performance, and reduces the mass of copper required.
• a first phase output electrical conductor may be located in a first notch, one or more second phase electrical conductors being located in a second notch, the second notch immediately following the first notch when moving circumferentially around of the axis of rotation of the machine, in the direction of circulation of the electric current around the axis of rotation of the machine.
• the output electrical conductor of the first phase can be located in a first notch just before a second notch receiving one or more electrical conductors of the second phase, when one moves circumferentially around the axis of rotation of the machine, in the direction of flow of electric current around the axis of rotation of the machine.
• the electrical output conductor of the first phase is located opposite the usual position, namely a position in which the first notch receiving the electrical output conductor of the first phase is immediately followed by a second notch receiving a or more electric conductors of the same first phase, when moving circumferentially around the axis of rotation of the machine, in the direction of circulation of the electric current around the axis of rotation of the machine.
• the exit notch of a first phase can be followed by a notch housing electrical conductors of a second phase different from the first.
• the phase inputs can be offset by an angle of 30°, 60°, 90 or an angle of 120° for example.
• the second notch may include one or more electrical conductors of the same phase only.
• the first entry slot of a first phase may comprise one or more electrical conductors of the first phase only.
• the first entry notch of a first phase may comprise one or more electrical conductors of the first phase and one or more electrical conductors of the second phase.
• the electrical conductor(s) of the first phase can be placed on the side of the cylinder head or alternatively on the air gap side.
• the electrical conductor or conductors of the second phase can be placed on the air gap side or, alternatively, on the yoke side.
• the phase inputs and outputs can be placed on the yoke side or alternatively on the air gap side.
• At least one first electrical conductor housed in a first notch can be electrically connected to a second electric conductor housed in a second notch, at the exit from said notches.
• the stator may comprise a phase connector comprising metallic elements connected to electrical conductors of the stator.
• the metal elements can be arranged radially externally or internally with respect to the electrical conductors to which they are connected.
• the metal elements connected to conductors of the stator windings can be held by an insulating support.
• the phase connector may have lugs for connection to a power supply bus. The machine can thus be connected to an inverter, electrically connected to the connection tabs of the connector.
• Electrical conductors at least, see a majority of electrical conductors, can be pin-shaped, U-shaped or I-shaped.
• the pin can be U-shaped ("U-pin” in English) or straight, being in form of I (“I-pin” in English).
• all electrical conductors are U-shaped.
• all electrical conductors are I-shaped.
• the hairpin and flat electrical conductors increase the filling factor of the slot, making the machine more compact. Thanks to a high filling coefficient, heat exchanges between the electrical conductors and the stator mass are improved, which makes it possible to reduce the temperature of the electrical conductors inside the slots.
• stator can be facilitated thanks to the electrical conductors in the form of pins.
• the pins do not require having open notches, we can have closed notches which allow the pins to be held and we can therefore eliminate the step of inserting the stator wedges.
• Electrical conductors extend axially in the slots.
• the electrical conductors can be introduced into the corresponding slots by one or both axial ends of the machine.
• An I-shaped electrical conductor has two axial ends each placed at one of the axial ends of the stator. It passes through a single notch, and can be welded at each of its axial ends to two other electrical conductors, at the axial ends of the stator.
• the stator may for example comprise 6, 10, 12, 14, 18, 22 or 26 I-shaped electrical conductors, the other electrical conductors all being able to be U-shaped.
• the stator may be devoid of an I-shaped electrical conductor.
• a U-shaped electrical conductor has two axial ends both placed at one of the axial ends of the stator. These two axial ends are defined by the two legs of the U. It passes through two different notches, and can be welded at each of its axial ends to two other electrical conductors, at the same axial side of the stator. The bottom of the U, i.e. the side of the U forming the bun or coil head, is placed on the other axial side of the stator.
• At least a portion of the electrical conductors, or even a majority of the electrical conductors, may be U-shaped hairpin.
• the size of the electrical conductors at the level of the coil heads is reduced. This facilitates the interweaving of electrical conductors.
• the winding can be devoid of a U-shaped hairpin with a width different from Np.
• the width of a U-pin is equal to the number of tooth pitches + 1.
• the width of a U-pin is defined by the number of notches separating the first and second legs of the U-pin, including the two notches housing the two legs of the U-shaped hairpin considered.
• the first and second legs can be separated by a number of notches comprised between 3 and 20, better still between 6 and 16, being for example 6.7, 8, 9 or 10 or 11 notches.
• each electrical conductor may comprise one or more strands (“wire” or “strand” in English).
• strand we mean the most basic unit for electrical conduction.
• a strand can be of round cross section, we can then speak of a 'thread', or flat.
• the flat strands can be shaped into pins, for example U or I.
• Each strand is coated with an insulating enamel.
• each notch can comprise several conductors and/or several strands makes it possible to minimize the losses by induced currents, or AC Joule losses, which evolve with the square of the supply frequency, which is particularly advantageous at high frequency and when the running speed is high. Heat transfer to the cold source is also facilitated. It is thus possible to obtain better performance at high speed.
• each electrical conductor may comprise several pins, each forming a strand, as explained above. All the strands of the same electrical conductor can be electrically connected to each other at the exit from the notch. The strands electrically connected to each other are placed in short circuit. The number of strands electrically connected together can be greater than or equal to 2, being for example between 2 and 12, being for example 3, 4, 6 or 8 strands.
• Several strands can form the same electrical conductor.
• the same electric current of the same phase circulates in all the strands of the same electrical conductor.
• All the strands of the same electrical conductor can be electrically connected to each other, in particular at the exit from the notch.
• All the strands of the same electrical conductor can be electrically connected to each other at each of their two axial ends, in particular at the exit from the notch. They can be electrically connected in parallel.
• each electrical conductor has a single strand. In another embodiment, each electrical conductor has three strands.
• a notch can therefore accommodate two strands, or as a variant six strands, for example, distributed between the two electrical conductors.
• a slot has four electrical conductors. Each electrical conductor may comprise two strands. The notch then houses eight strands, distributed between the four electrical conductors.
• the strands can be positioned in the notch so that their circumferential dimension around the axis of rotation of the machine is greater than their radial dimension. Such a configuration allows a reduction in losses by eddy currents in the strands.
• a strand can have a width comprised between 1 and 5 mmm, being for example of the order of 2.5 or 3 mm.
• the width of a strand is defined as its dimension in the circumferential direction around the axis of rotation of the machine.
• a strand can have a height comprised between 1 and 5 mm, being for example of the order of 1.6 or 1.8 mm.
• the height of a strand is defined as its thickness in the radial dimension.
• Electrical conductors can be made of copper or aluminum.
• Winding A winding is made up of a number of phases m shifted in space in such a way that when they are supplied by a multi-phase current system, they produce a rotating field.
• the electrical conductors can form a single winding, in particular with whole or fractional pitch.
• single winding it is meant that the electrical conductors are electrically connected together in the stator, and that the connections between the phases are made in the stator, and not outside the stator, for example in a terminal box. .
• the electrical conductors can form a distributed winding.
• the winding is not concentrated or wound on tooth.
• the winding can be full pitch.
• Each notch only houses electrical conductors of the same phase and/or the width of an electrical conductor is equal to the number of notches divided by the number of poles.
• the winding can be shortened.
• Notches can accommodate electrical conductors of different phases.
• at least one notch accommodates a first phase electrical conductor and a second phase electrical conductor and/or the width of the majority of the electrical conductors is less than the number of notches divided by the number of poles .
• the winding is in the whole or fractional invention.
• the winding can be full-pitch with or without shortening, or in a fractional variant.
• the electrical conductors form a fractional winding.
• the number of notches of the stator can be between 18 and 96, better still between 30 and 84, being for example 18, 24, 27, 30, 36, 42, 45, 48, 54, 60, 63, 72, 78 , 81, 92, 96, better being 60 or 63.
• the number of poles of the stator can be between 2 and 24, or even between 4 and 12, being for example 6 or 8.
• the combination number of notches/number of poles of the stator can be chosen from the combinations of the following list, which is not exhaustive: 30/4, 42/4, 45/6, 48/8, 63/6, 60/8, 78/8, 84/8.
• [Table 1] invention if the number of phases is different, being for example two, the machine then comprising a two-phase winding, or being for example 5, 6, 79, 11 or 13.
• the winding is polyphase.
• the series connection of the electrical conductors can be done in so-called wavy winding or in so-called series winding.
• wavy winding means a winding in which the electrical conductors of the same phase and of the same pole are electrically connected to each other so that, for one winding path, the electric current of the phase circulates in the electrical conductors by rotating around the axis of rotation of the machine, always in one direction.
• the electrical conductors of the same phase and of the same pole do not overlap when observed perpendicular to the axis of rotation of the machine.
• series winding is meant a winding in which the electrical conductors of the same phase of the same pole are electrically connected to each other so that the electric current of the phase flows in the electrical conductors. rotating around the axis of rotation of the machine alternately in one direction then in the other. For a winding track, the electrical conductors of the same phase and of the same pole overlap when observed perpendicular to the axis of rotation of the machine.
• the winding may comprise a single winding path or several winding paths.
• an "electrical conductor” the current of the same phase flows by way of winding.
• winding path is meant all of the electrical conductors of the machine which are traversed by the same electric current of the same phase.
• These electrical conductors can be connected together in series or in parallel or in series-parallel. In the case where there is a single channel, the electrical conductors are connected in series. In the case where there are several channels, the electrical conductors of each channel are connected in series, and the channels are connected in parallel.
• At least one first electrical conductor housed in a first notch can be electrically connected to a second electric conductor housed in a second notch, at the exit from said notches.
• electrically connected we mean any type of electrical connection, in particular by welding, with different possible welding methods, in particular laser, induction, friction, ultrasound, vibration, or soldering, or by mechanical tightening, in particular by crimping, screwing or riveting for example.
• the welding step can be implemented by means of a heat source, in particular a laser or an electric arc, for example an electric arc produced by means of a tungsten electrode.
• the welding process using a tungsten electrode can be TIG welding (in English “Tungsten Inert Gas”). In this welding process, the electric arc is produced from a tungsten electrode and a plasma.
• a heat source makes it possible to achieve fusion of the free ends of the strands without degrading the assembly of the strands of the conductor(s).
• a single heat source can be used to perform the same weld.
• several heat sources can be used to produce the same weld.
• the first and second electrical conductors can be electrically connected at the output of the notches, that is to say that the electrical connection is formed on the electrical conductors just after they emerge from the two notches, at an axial end of the stator mass.
• the electrical connection can be made in a plane perpendicular to the axis of rotation of the machine.
• the plane of the electrical connection can be separated from the stator mass by approximately 30 to 70 mm, better still by approximately 40 to 60 mm.
• the electrical conductors can be arranged in the slots in a distributed manner.
• distributed it should be understood that the outgoing and return electrical conductors are each housed in different and non-consecutive slots. At least one of the electrical conductors can pass successively through two non-consecutive notches.
• the electrical conductors can be arranged in a row in the notches.
• row it is meant that the electrical conductors are not arranged in the loose slots but in an orderly manner. They are stacked in the notches in a non-random manner, being for example arranged in a row of electrical conductors aligned in the radial direction.
• the electrical conductors may be in cross section of generally rectangular shape, in particular with rounded edges.
• the circumferential dimension of an electrical conductor may correspond substantially to the width of a notch.
• a notch may not have only one electrical conductor across its width.
• the width of the notch is measured in its circumferential dimension around the axis of rotation of the machine.
• Electrical conductors can be adjacent to each other by their long sides, otherwise called the flat.
• the optimization of the stack can make it possible to arrange in the notches a greater quantity of electrical conductors.
• the stator may include a sensor for measuring the temperature of the electrical conductors, for example a thermocouple.
• the sensor can be arranged in the notch, or alternatively at the welding portions.
• At least one tooth preferably all of the teeth, may be generally trapezoidal in cross-section. At least one tooth, better all the teeth, can have divergent edges when moving away from the axis of rotation of the machine.
• the stator mass can be produced by stacking sheets.
• the teeth are interconnected by material bridges, and on the opposite side by a yoke.
• the closed notches can be made entirely by cutting in the sheets.
• Each sheet of the stack of sheets can be monobloc.
• Each sheet is for example cut from a sheet of magnetic steel or sheet containing magnetic steel, for example steel 0.1 to 1.5 mm thick.
• the sheets can be coated with an electrically insulating varnish on their opposite faces before they are assembled within the stack. Electrical insulation can still be obtained by heat treatment of the sheets, if necessary.
• stator mass can be made from compacted or agglomerated magnetic powder.
• Another subject of the invention is a rotating electrical machine, such as a synchronous motor or a synchronous generator, comprising a stator as defined previously.
• the machine can be synchronous or asynchronous.
• the machine can be reluctance. It can constitute a synchronous motor.
• the maximum speed of rotation of the machine can be high, being for example greater than 10,000 rpm, better still greater than 12,000 rpm, being for example of the order of 14,000 rpm to 15,000 rpm. min, or even 20,000 rpm or 25,000 rpm.
• the maximum speed of rotation of the machine may be less than 100,000 rpm, or even 60,000 rpm, or even even less than 40,000 rpm, better still less than 30,000 rpm.
• the rotating electrical machine may include a rotor.
• the rotor can be permanent magnets, with surface or buried magnets.
• the rotor can be flux concentrating. He may comprise one or more layers of magnets arranged in an I, U or V. Alternatively, it may be a wound or squirrel cage rotor, or a variable reluctance rotor.
• the diameter of the rotor can be less than 400 mm, better still less than 300 mm, and greater than 50 mm, better still greater than 70 mm, being for example between 100 and 200 mm.
• the rotor may comprise a rotor mass extending along the axis of rotation and arranged around a shaft.
• the shaft may include torque transmission means for driving the rotor mass in rotation.
• the rotor can be cantilevered or not.
• the machine can be inserted alone into a casing or inserted into a gearbox casing. In this case, it is inserted in a casing which also houses a gearbox.
• Figure 1 is a perspective view, schematic and partial, of a stator made in accordance with the invention.
• Figure la is a perspective view, schematic and partial, of the stator of Figure 1.
• FIG 2 illustrates the manufacturing process for the stator of Figure 1.
• FIG 3 illustrates the manufacturing process for the stator of Figure 1.
• FIG 4 illustrates the manufacturing process for the stator of Figure 1.
• FIG 5 illustrates the manufacturing process for the stator of Figure 1.
• FIG 6 Figure 6 illustrates the manufacturing process for the stator of Figure 1.
• Figure 6a illustrates the manufacturing process for the stator of Figure 1.
• Figure 6b illustrates the manufacturing process for the stator of Figure 1.
• Figure 6c illustrates the manufacturing process for the stator of Figure 1.
• FIG 7a Figure 7a illustrates the manufacturing process for the stator of Figure 1.
• FIG 7b Figure 7b illustrates the manufacturing process for the stator of Figure 1.
• Figure 7c illustrates the manufacturing process for the stator of Figure 1.
• FIG 8 Figure 8 illustrates the manufacturing process for the stator of Figure 1.
• Figure 8a is a perspective view of a deformation crown used in the manufacturing process for the stator of Figure 1.
• FIG 9 illustrates the manufacturing process for the stator of Figure 1.
• Figure 9a is a perspective view of a deformation crown used in the manufacturing process of the stator of Figure 1.
• Figure 10 illustrates the manufacturing process for the stator of Figure 1.
• Figure 10a is a perspective view of a deformation crown used in the manufacturing process for the stator of Figure 1.
• FIG 11 Figure 11 illustrates the manufacturing process for the stator of Figure 1.
• Figure 1 la illustrates the method of manufacturing the stator of Figure 1.
• Figure 11b illustrates the manufacturing process for the stator of Figure 1.
• Figure 12a illustrates an alternative embodiment of the method.
• Figure 12b illustrates this alternative embodiment of the method.
• Figure 12c illustrates this alternative embodiment of the method.
• Figure 13 is a perspective view, schematic and partial, of an alternative embodiment.
• stator 2 of a rotating electrical machine 1 also comprising a rotor, not shown.
• the stator makes it possible to generate a rotating magnetic field for driving the rotating rotor, in the context of a synchronous or asynchronous motor, and in the case of an alternator, the rotation of the rotor induces an electromotive force in the electrical conductors of the stator.
• the stator 2 comprises electrical conductors 22, which are arranged in notches 21 formed between teeth 23 of a stator mass 25.
• the notches 21 are closed.
• the notches 21 are closed on the air gap side by bridges of material 27, each connecting two consecutive teeth of the stator mass 25, and on the opposite side by a yoke 29.
• the latter and the teeth 23 are integral .
• the electrical conductors 22 may for the most part be pin-shaped, namely U-shaped, and extending axially into the notches.
• all the electrical conductors 22 of the stator 2 are identical, being all U-shaped hairpins, with the same pitch Np for all the electrical conductors of the stator which are U-shaped hairpins.
• U-shaped pin-shaped electrical conductor has first 22e and second 22f legs extending axially respectively in first A and second R notches.
• the first A and second R notches are separated by a number Np of notches and by a number Nd of teeth.
• the number Np of notches is the same for all the U-shaped electrical conductors of the stator pin.
• Np is 11.
• the number Nd of teeth is the same for all U-shaped electrical conductors of the stator pin.
• Nd is 10.
• the first legs 22e are interior and the second legs 22f are exterior.
• a first electrical conductor housed in a first notch is electrically connected to a second electrical conductor housed in a second notch, at the output of said notches.
• the first and second notches are non-consecutive. In the example shown, they are separated by 12 other notches and 11 teeth. Alternatively, the first and second notches are separated by 3, 4, 5, 6, 7, 8, 9, 10, 11 or 13 other notches, for example, and by 2, 3, 4, 5, 6, 7, 8, 9, 10, 12 or 13 teeth.
• the electrical conductors are arranged in the slots in a distributed manner, and they form a distributed winding, which in the example described is fractional.
• the number of slots is 63.
• the number of stator poles is 6.
• the number of slots/number of stator poles combination is 63/6.
• the electrical conductors 22 are made of copper or aluminum, or any other enamelled conductive material or coated with any other suitable insulating coating.
• the electrical conductors 22 are arranged in a row in the notches 21, according to a row of aligned electrical conductors.
• the electrical conductors may have a generally rectangular cross-section, in particular with rounded corners. In the example described, they are radially superimposed in a single row.
• the circumferential dimension of an electrical conductor corresponds substantially to the width of a notch. Thus, the notch has only one electrical conductor across its width. It may include several electrical conductors in its radial dimension. It has two in the example described.
• the hairpin electrical conductors each have first 22nd and second 22f legs which extend out of the notches by a welding portion 22b inclined with respect to a plane perpendicular to a longitudinal axis of the stator to come overhanging the stator mass circumferentially at the level of a notch, this notch being separated from the first A or the second R notch respectively by a number NI and/or N2 of teeth.
• the innermost welding portion 22b relative to the longitudinal axis of the stator which is arranged closer to the rotor, is inclined with the same inclination relative to the plane perpendicular to the longitudinal axis of the stator as the other innermost welding portions.
• the outermost welding portion with respect to the longitudinal axis of the stator which is arranged farther from the rotor, is inclined with an inclination which may be different with respect to the plane perpendicular to the longitudinal axis of the stator than the other outermost welding portions.
• the outermost weld portions are not necessarily all inclined with the same inclination relative to the plane perpendicular to the longitudinal axis of the stator. They can be inclined with at least two, or even three or four, different inclinations with respect to the plane perpendicular to the longitudinal axis of the stator.
• some electrical conductors have a second outer leg 22f extending out of the notch by a welding portion 22b forming a recess relative to the notch, while extending in the same radial plane as the second leg.
• This welding portion 22b is radially even further from the axis of rotation of the machine. This offset of the electrical conductor makes it possible to reach the metal elements of the machine phase connector. These are the phase input and/or output electrical conductors.
• At least one welding portion of an electrical phase input and/or output conductor is radially aligned with welding portions of other electrical conductors.
• Each welding portion of the phase input electrical conductors is in particular aligned radially with welding portions of other electrical conductors.
• the electrical conductor welding portions are arranged in three layers with respect to the longitudinal axis of the stator, each layer comprising a different number of electrical conductor welding portions.
• the different layers of electrical conductor welding portions are concentric around the longitudinal axis of the stator.
• the innermost layer Int comprises as many welding portions as slots in the stator.
• the outermost layer Ext comprises a number of welding portions equal to twice the number of phases of the stator winding, here six with a three-phase winding.
• the intermediate layer Cen placed between the innermost layer and the outermost layer comprises a number of welding portions equal to the number of notches of the stator from which we deduce twice the number of phases of the stator winding, here six with the three-phase winding.
• the welding portions 22b of electrical conductors are well aligned with each other, which can facilitate the welding of the electrical conductors 22 and simplify the manufacture of the stator.
• a stator mass 25 is provided, as can be seen in FIG. electrical conductors 22 being housed in the notches 21. All the electrical conductors are in the shape of a U-shaped hairpin, each comprising inner 22e and outer 22f legs, which in particular extend axially respectively in first A and second R notches. At least one of the inner 22e and outer 22f legs of the electrical conductors 22 is extended outside the notches by a welding portion.
• a second step (b) we will circumferentially shift the outer legs of the electrical conductors by half a tooth pitch with respect to the inner legs.
• the second step (b) can be broken down into several sub-steps (bl) to (b4).
• Step (b) of circumferential shifting of the outer legs of the electrical conductors by half a tooth pitch includes a step (bl) of positioning two inner 31 and outer 32 crowns for positioning the electrical conductors 22.
• the two inner crowns 31 and outer 32 for positioning are placed against the stator mass 25, just above the stack of laminations thereof, as shown in FIG. 2.
• the inner ring 31 has the shape of a disc.
• the two inner 31 and outer 32 positioning rings comprise, as described below, movable fingers 33 and 34 respectively, which extend radially and which are each movable along a radial axis of the stator.
• the mobile fingers are in the retracted position in the positioning crowns.
• a step (b2) the movable fingers 33 and 34 are taken out, each of which is placed between two consecutive electrical conductors 22, sliding like pistons, as shown in FIG. 3.
• the movable fingers 34 of the outer crown 32 positioning are placed between the outer legs 22f of the electrical conductors and the movable fingers 33 of the inner ring 31 for positioning are placed between the inner electrical conductors 22e.
• the outer positioning crown 32 comprises as many movable fingers 34 as there are teeth on the stator. They can all be identical to each other.
• the inner positioning crown 31 also comprises as many movable fingers 33 as there are stator teeth. They can all be identical to each other.
• all the movable fingers 33, 34 are each engaged between two consecutive electrical conductors. They make it possible to promote their alignment, in particular during a movement in translation along the longitudinal axis of the stator of the positioning crowns 31, 32, described below.
• a step (b3) the positioning crowns 31, 32 are moved in translation along the longitudinal axis of the stator, away from the stator mass 25, namely upwards in FIG. 4.
• the crowns positioning are moved towards the ends of the welding portions 22b.
• the movable fingers 33, 34 play the role of combs which make it possible to properly align the electrical conductors.
• a step (b4) the outer positioning crown is rotated through a given angle around the longitudinal axis of the stator, as illustrated in figure 5.
• the angle here is equal to half a tooth pitch.
• the mobile fingers make it possible to twist the outer legs 22f by half a dental step with respect to the inner legs 22e.
• the outer positioning ring 32 is moved in rotation relative to the inner positioning ring 31 and relative to the stator, while the inner positioning ring 31 remains fixed relative to the stator.
• step (c) illustrated in FIG. 6 the six outer legs 22f of the phase input and/or output electrical conductors are shifted radially outwards, and they are placed on a third layer, namely the outermost layer Ext.
• movable phase fingers 35 are taken out of the inner positioning ring 31, which are configured to have a longer radial stroke than the other movable fingers 33 of the inner positioning ring 31.
• the movable fingers of the inner positioning ring 31 thus comprise movable phase fingers 35 configured to have a longer radial stroke than the other movable fingers 33, here six movable phase fingers 35.
• the inner positioning ring thus comprises mobile with two possible radial strokes, a shorter one for most of them 33, and a longer one for some of them 35, in particular six of them.
• the outer positioning ring 32 includes notches 38 to receive the phase input and/or output electrical conductors. These notches 38 allow the placement of the phase input and/or output electrical conductors on the third outermost layer Ext.
• Some or all of the movable fingers of the outer positioning ring may each comprise a shoulder 36, as illustrated in FIG. 6a, which may make it possible to wedge the electrical conductors.
• the mobile fingers present at the aforementioned notches may comprise such a shoulder.
• the outward radial offset can be more or less accentuated.
• the inclination of the outer legs can have a curved part having a large radius of curvature, as shown in figure 6b, or a smaller radius of curvature, as shown in figure 6c, which causes the welding portion to be then closer to the sheet metal package.
• the length of the welding portions of the outer legs of the electrical phase input and/or output conductors may be greater than the length of the welding portions of the outer legs of the other electrical conductors , as illustrated in Figures 7a to 7c.
• the method then comprises the following additional step (d):
• step (d) circumferentially deform the welding portions of the electrical conductors, with at least two different pitches, in particular three different pitches.
• This step (d) can be broken down into several sub-steps (d1) to (d5) and is implemented using three deformation crowns 41,
• step (dl) the third deformation crown is first placed in position
• This third deformation ring 43 will deform in particular the welding portions of the inner legs of the electrical conductors at a first pitch PL
• the third deformation ring 43 is generally circular and crenellated, comprising in particular as many slots as notches in the stator to receive the welding portions of the electrical conductors. Slots 49 are regular, all being regularly distributed around its circumference.
• this third deformation crown makes it possible to deform the 63 welding portions of the inner legs of the electrical conductors at a first pitch PL
• a step (d2) the first deformation ring 41 is placed in position, as illustrated in FIG. 9.
• This first deformation ring 41 will deform part of the welding portions of the outer legs 22f of the electrical conductors to a second step P2, as well as all the welding portions of the outer legs of the electrical conductors radially offset in step (c).
• This first deformation crown 41 is generally circular and crenellated, comprising a number of slots 49 equal to the number of notches of the stator from which the number of slots of the second deformation crown 42 described below is deduced.
• this first deformation crown 41 makes it possible to deform 42 welding portions of the outer legs of the electrical conductors at a second pitch P2.
• the first deformation crown also includes notches 48 which also make it possible to deform all the welding portions of the outer legs of the electrical conductors offset radially in step (c), in particular six notches 48 for six welding portions offset radially at the step (c).
• the windows 45 of the first deformation ring have a longer circumferential extent than the tabs 46 of the second deformation ring 42, which can allow the rotational displacement of the second deformation crown in the first deformation crown.
• the second deformation ring 42 is placed in position, as illustrated in FIG. 10.
• This second deformation ring 42 can deform in particular the other welding portions of the outer legs of the electrical conductors at a third P3.
• the second deformation crown 42 is configured to be nested in the first deformation crown 41, and to move there in rotation.
• the second deformation crown 42 is generally circular and crenellated, comprising in particular tabs 46 each received in a window 45 of the first deformation crown 4L
• the tabs 46 can move in the windows 45 when the second deformation crown 42 moves in rotation in the first deformation ring 4L
• the legs 46 are crenellated, comprising slots 49.
• the second deformation crown comprises 15 slots 49 distributed over 4 legs 46, for a stator comprising 63 slots and 6 poles.
• a step (d4) the inner 31 and outer 32 positioning rings are put back into position against the stator mass.
• the external positioning crown 32 descends in a helix in order to follow the inclination of the phase input and/or output electrical conductors which are placed on the third outermost layer Ext.
• the inner positioning crown 31 descends parallel to the longitudinal axis of the stator. During this repositioning movement, the movable fingers of the inner and outer positioning rings are in the retracted position.
• the movable fingers can be put back into a position of grip with the electrical conductors. This movement provides protection for the insulators at the slot exit during the next step.
• a step (d5) the first, second and third deformation crowns 41, 42, 43 are driven in simultaneous rotation, with different pitches, as illustrated in FIG. 11.
• the second deformation crown is rotated with respect to the first deformation crown.
• Figure 11 shows the starting position of the first and second deformation crowns, and Figure 11b their arrival position.
• the first and second deformation ring are rotated in a first direction, but not at the same pitch, while the third deformation ring is rotated in a second direction opposite to the first direction.
• the welding portions of the inner legs of the electrical conductors are deformed at a first pitch PI.
• the third pitch P3 is lower than the first and second pitches PI and P2.
• the welding portions of the phase input and/or output electrical conductors are radially aligned with the welding portions of other electrical conductors.
• the electrical phase input and/or output conductors are pushed outwards.
• the set of tools can for this purpose comprise pliers or another gripping tool, such as independent claws 50.
• Said claws 50 can be configured to allow the outward deformation of these welding portions.
• This embodiment variant can in particular be implemented with phase input and/or output electrical conductors protruding longitudinally from the other electrical conductors, being longer than the latter.
• the electrical phase input and/or output conductors are pushed inwards. In this case, as illustrated in FIG. 13, the inner legs 22e of the electrical conductors have been circumferentially offset by half a tooth pitch with respect to the outer legs 22f, then the six inner legs 22e of the phase input and/or output electrical conductors.

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• 2022
  • 2022-10-11 WO PCT/FR2022/051911 patent/WO2023062313A1/fr not_active Ceased
  • 2022-10-11 EP EP22802208.3A patent/EP4416832A1/de active Pending
  • 2022-10-11 CN CN202280068978.4A patent/CN118202560A/zh active Pending

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