U.S. patent application number 12/065971 was filed with the patent office on 2008-12-18 for equipment for producing coils of a stator of an electrical machine and method for making coils.
This patent application is currently assigned to THALES. Invention is credited to Cyril Moya.
Application Number | 20080308173 12/065971 |
Document ID | / |
Family ID | 36587085 |
Filed Date | 2008-12-18 |
United States Patent
Application |
20080308173 |
Kind Code |
A1 |
Moya; Cyril |
December 18, 2008 |
Equipment For Producing Coils of a Stator of an Electrical Machine
and Method For Making Coils
Abstract
The invention relates to equipment for producing coils of a
stator of an electrical machine and a method for producing coils.
The coil is formed by connecting arms (6) of conducting pins (4)
inserted into the slots (3) of a magnetic circuit (2) of the stator
(1). The equipment comprises a shaper (10) axisymmetric about an
axis (5), and the shaper (10) is designed to be placed inside the
free ends of the arms (6) and in contact with the magnetic circuit
(2). A series of guide-pins (12) equal in number to the slots (3)
is designed so that each penetrates into a hole of the shaper (10).
Each hole is drilled along an axis. The axes of the holes (13) meet
at a first point (14) on the axis of revolution (5) of the shaper
(10). Each guide-pin (12) is designed to separate two arms (6) of
pins (4) inserted into two adjacent slots (3) to guide the arms (6)
in a fixed direction, distinct from the direction of the arms (6)
in their slot (3). The method using the previously described
equipment includes successively carrying out the following
operations. The pins (4) are inserted according to a wiring scheme
for the coil; The first shaper (10) is put into place along the
axis of revolution (5) of the magnetic circuit (2) on the free side
of the arms (6) in contact with the magnetic circuit (2); The first
series of guide-pins (12) are put into place. Each of the arms (6)
is folded by pressing it onto a guide-pin (12) of the first
series.
Inventors: |
Moya; Cyril; (Chatou,
FR) |
Correspondence
Address: |
LOWE HAUPTMAN & BERNER, LLP
1700 DIAGONAL ROAD, SUITE 300
ALEXANDRIA
VA
22314
US
|
Assignee: |
THALES
NEUILLY SUR SEINE
FR
|
Family ID: |
36587085 |
Appl. No.: |
12/065971 |
Filed: |
September 29, 2006 |
PCT Filed: |
September 29, 2006 |
PCT NO: |
PCT/EP2006/066939 |
371 Date: |
July 21, 2008 |
Current U.S.
Class: |
140/71C |
Current CPC
Class: |
H02K 15/0056 20130101;
H02K 15/064 20130101 |
Class at
Publication: |
140/71.C |
International
Class: |
B21F 45/00 20060101
B21F045/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 30, 2005 |
FR |
0510019 |
Claims
1. Equipment for producing coils of a stator of an electrical
machine, the coil having several windings, each winding being
formed by connecting arms of conducting pins inserted into the
slots of a magnetic circuit of the stator, comprising: a shaper
axisymmetric about an axis, the shaper being designed to be placed
inside free ends of the arms and in contact with the magnetic
circuit, a first series of guide-pins equal in number to the slots
and designed so that each penetrates into a hole of the shaper,
each hole being drilled along an axis, the axes of the holes
meeting at a first point on an axis of revolution of the shaper,
each guide-pin being designed to separate two arms of pins inserted
into two adjacent slots to guide the arms in a fixed direction,
distinct from the direction of the arms in their slot.
2. The equipment as claimed in claim 1, wherein the first point is
situated a fixed distance from a bearing surface of the shaper on
the magnetic circuit and wherein the fixed distance is nonzero.
3. The equipment as claimed in claim 1, wherein it comprises a
second series of guide-pins equal in number to the slots and
designed so that each penetrates into a hole of the shaper, each
hole being drilled along an axis, the axes of the holes meeting at
a second point on the axis of revolution of the shaper, the second
point being at a distance from the first point, each guide-pin of
the second series being designed to guide the arms in a direction
parallel to the direction of the arms in their slot.
4. The equipment as claimed claim 1, the shaper comprising a
conical part designed to move the arms of the pins away from an
axis of the magnetic circuit.
5. The equipment as claimed in claim 1, comprising a second shaper
axisymmetric about an axis, the second shaper being designed to be
placed inside the bends in the pins and in contact with the
magnetic circuit, a third series of guide-pins equal in number to
the slots and designed so that each penetrates into a hole of the
second shaper, each hole being drilled along an axis, the axes of
the holes meeting at a point on the axis of revolution of the
second shaper, each guide-pin of the third series being designed to
separate two arms of pins threaded into two adjacent slots so as to
position the bends in the pin at a fixed distance from the magnetic
circuit.
6. A method for producing coils of a stator of an electrical
machine, the coil comprising several windings, each winding being
formed by connecting arms of conducting pins inserted into the
slots of a magnetic circuit of the stator, the method using the
equipment as claimed in claim 1, comprising successively carrying
out the following operations: inserting the pins into the slots
according to a wiring scheme for the coil; putting the first shaper
into place along the axis of revolution of the magnetic circuit on
the free side of the arms in contact with the magnetic circuit
putting the first series of guide-pins into place; folding each of
the arms by pressing it onto a guide-pin of the first series.
7. The method as claimed in claim 6, using equipment for producing
coils of a stator of an electrical machine, the coil having several
windings, each winding being formed by connecting arms of
conducting pins inserted into slots of a magnetic circuit of the
stator, the equipment comprising: a shaper axisymmetric about an
axis, the shaper being designed to be placed inside free ends of
the arms and in contact with the magnetic circuit, a first series
of guide-pins equal in number to the slots and designed so that
each penetrates into a hole of the shaper, each hole being drilled
along an axis, the axes of the holes meeting at first point on an
axis of revolution of the shaper, each guide-pin being designed to
separate two arms of pins inserted into two adjacent slots to guide
the arms in a fixed direction, distinct from the direction of the
arms in their slots, wherein the equipment comprises a second
series of guide-pins equal in number to the slots and designed so
that each penetrates into a hole of the shaper, each hole being
drilled along an axis, the axes of the holes meeting at a second
point on the axis of revolution of the shaper, the second point
being at a distance from the first point, each guide-pin of the
second series being designed to guide the arms in a direction
parallel to the direction of the arms in their slot, wherein, after
having folded each of the arms by pressing it onto a guide-pin of
the first series, in successively carrying out the following
operations: putting the second series of guide-pins into place;
folding the arms by pressing onto a guide-pin of the second series
so as to guide them in a direction parallel to the direction of the
arms in their slots; and connect the arms in accordance with a
wiring scheme for the coil.
8. The method as claimed in claim 6, using a second shaper
axisymmetric about an axis, the second shaper being designed to be
placed inside the bends in the pins and in contact with the
magnetic circuit, a third series of guide-pins equal in number to
the slots and designed so that each penetrates into a hole of the
second shapers each hole being drilled along an axis, the axes of
the holes meeting at a point on the axis of revolution of the
second shaper, each guide-pin of the third series being designed to
separate two arms of pins threaded into two adjacent slots so as to
position the bends in the pin at a fixed distance from the magnetic
circuit, wherein, before inserting the pins into the slots, the
second shaper is put in place pressing against the magnetic circuit
and the third series of guide-pins is placed in the holes.
9. The method as claimed in claim 7, using a second shaper
axisymmetric about an axis, the second shaper being designed to be
placed inside the bends in the pins and in contact with the
magnetic circuit, a third series of guide-pins equal in number to
the slots and designed so that each penetrates into a hole of the
second shaper, each hole being drilled along an axis, the axes of
the holes meeting at a point on the axis of revolution of the
second shaper, each guide-pin of the third series being designed to
separate two arms of pins threaded into two adjacent slots so as to
position the bends in the pin at a fixed distance from the magnetic
circuit wherein, before inserting the pins into the slots, the
second shaper is put in place pressing against the magnetic circuit
and the third series of guide-pins is placed in the holes.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present Application is based on International
Application No. PCT/EP2006/066939, filed on Sep. 29, 2006, which in
turn corresponds to French Application No. 05 10019 filed on Sep.
30, 2005, and priority is hereby claimed under 35 USC .sctn.119
based on these applications. Each of these applications are hereby
incorporated by reference in their entirety into the present
application.
FIELD OF THE INVENTION
[0002] The invention relates to equipment for producing coils of a
stator of an electrical machine and to a method for producing
coils. The invention is of particular use in producing coils for
high-power electrical machines.
BACKGROUND OF THE INVENTION
[0003] The coils consist of several windings. Each winding is
formed by connecting conducting pins threaded into the slots of a
magnetic circuit of the stator. The pins are produced from
conductor bars, most often of rectangular section and made of a
copper alloy. The bars are folded to form U-shaped pins.
Consequently each branch of the U will be called an "arm", and the
central part of the U connecting the two arms will be called a
"bend". The free ends of the arms, that is the ends of the arms
opposite the bend, are connected to each other according to a
wiring scheme for the coil to form the windings. These connections
form a lead-out wire to which the power supply leads for the
windings are also connected. Each arm in the lead-out wire is
folded so as to bring it closer to another arm to which it must be
connected.
[0004] The operation of the electrical machine causes the stator to
heat up due essentially to the flow of currents through the
windings. An effective means of cooling the stator is to circulate
a coolant therein, such as oil for example, that is circulated in
the channels of the stator in immediate proximity of the pins. The
lead-out wire hampers the circulation of the oil, principally due
to the folds in the arms. In fact it is easy to fold the free ends
of the arms immediately at the exit of the slots that they occupy.
To provide a passage for oil between the arms in immediate
proximity of the magnetic circuit, it is necessary in folding the
arms to leave a part of the arm extended in continuation of the
slot that it occupies before proceeding to the folding. This
operation is particularly awkward to carry out manually, due
notably to the elasticity of the material used to produce the
pins.
SUMMARY OF THE INVENTION
[0005] The invention aims to overcome this problem by proposing
equipment that simplifies the operation of folding the arms of the
pins. This equipment guarantees a reproducible distance between the
magnetic circuit and the folding of each arm. In a more general
fashion, equipment conforming to the invention improves the
reproducibility of the form of the lead-out wire and all the
connections of the stator to be improved.
[0006] To this end, the subject of the invention is equipment for
producing coils of a stator of an electrical machine, the coil
comprising several windings, each winding being formed by
connecting arms of conducting pins inserted into the slots of a
magnetic circuit of the stator, characterized in that it comprises
a shaper axisymmetric about an axis, the shaper being designed to
be placed inside the free ends of the arms and in contact with the
magnetic circuit, a first series of guide-pins equal in number to
the slots and designed so that each penetrates into a hole of the
shaper, each hole being drilled along an axis, the axes of the
holes meeting at a first point on the axis of revolution of the
shaper, each guide-pin being designed to separate two arms of pins
inserted into two adjacent slots to guide the arms in a fixed
direction, distinct from the direction of the arms in their
slot.
[0007] The subject of the invention is also a method for producing
coils of a stator of an electrical machine, the coil comprising
several windings, each winding being formed by connecting arms of
conducting pins threaded into the slots of a magnetic circuit of
the stator, the method using the equipment of the invention,
characterized in that it consists in successively carrying out the
following operations: [0008] inserting the pins into the slots
according to a wiring scheme for the coil; [0009] putting the first
shaper into place along the axis of revolution of the magnetic
circuit on the free side of the arms in contact with the magnetic
circuit; [0010] putting the first series of guide-pins into place;
and [0011] folding each of the arms by pressing it onto a
guide-pin.
[0012] Still other objects and advantages of the present invention
will become readily apparent to those skilled in the art from the
following detailed description, wherein the preferred embodiments
of the invention are shown and described, simply by way of
illustration of the best mode contemplated of carrying out the
invention. As will be realized, the invention is capable of other
and different embodiments, and its several details are capable of
modifications in various obvious aspects, all without departing
from the invention. Accordingly, the drawings and description
thereof are to be regarded as illustrative in nature, and not as
restrictive.
BRIEF DESCRIPTION OF THE DRAWING
[0013] The present invention is illustrated by way of example, and
not by limitation, in the figures of the accompanying drawings,
wherein elements having the same reference numeral designations
represent like elements throughout and wherein:
[0014] FIG. 1 shows equipment according to the invention set up for
wiring a stator;
[0015] FIG. 2 shows a pin outside of its slot; and
[0016] FIG. 3 shows a partial section of two adjacent slots in a
plane perpendicular to the axis of the stator.
[0017] For the sake of clarity the same elements have the same
references in the different figures.
DETAILED DESCRIPTION OF THE DRAWING
[0018] FIG. 1 shows the stator 1 of an electrical machine. The
stator 1 comprises a magnetic circuit 2 and a coil consisting of
several windings. The magnetic circuit 2 is formed by a stack of
laminations in which slots 3 are produced to receive the pins 4
which form the conducting elements of the coil. The magnetic
circuit rotates about an axis 5. The laminations are planar and
their plane is perpendicular to the axis 5, each winding being
formed by connecting arms 6 of pins inserted into the slots 3. So
as not to overload the figure, only some of the pins 4 are shown. A
pin 4 is formed of two arms 6 linked by a bend 7. In FIG. 2 a pin 4
has been shown before being mounted in a slot 3. In general the
slots 3 are filled by several bundles of pins 4. An example of how
the slots 3 are filled is provided in FIG. 3. In FIGS. 1 and 3 two
bundles have been shown. The various bundles can be separated by
electrical insulators 8 and/or channels allowing a coolant, such as
oil for example, serving to cool the stator in operation, to
circulate. Electrical insulation 9 can surround all the elements,
arms 6 and insulation 8, being located in a slot 3.
[0019] According to the invention, equipment for producing coils of
the stator 1 comprise an axisymmetric shaper 10. The shaper is
located inside the free ends 11 of arms 6 and in contact with the
magnetic circuit 2. The axis of revolution of the shaper is
coincident with the axis 5 of the magnetic circuit 2 and
consequently has the same reference. The equipment furthermore
comprises a first series of guide-pins 12 equal in number to the
slots 3 and designed so that each penetrates into a hole 13 of the
shaper 10. So as not to overload the figure, only one guide-pin 12
is shown. Each hole 13 is drilled along an axis, the axes of the
holes 13 meeting at a first point 14 on the axis of revolution 5 of
the shaper 10. Each guide-pin 12 is designed to separate two arms 6
threaded into two adjacent slots 3 to guide the arms 6 in a fixed
direction, distinct from the direction of the arms 6 in their slot
3. In other words, once the guide-pins 12 are put into their
respective hole 13, it is possible to fold the arm 6, which come to
press against a guide-pin 12, to guide it in a direction different
from that of the slot 3 it occupies. The shaper 10 is supported on
the magnetic circuit 2, for example, by means of a shoulder 15 of
the shaper 10 which comes to bear on an end lamination 16 of the
magnetic circuit 2. The shaper 10 is, in addition, centered with
respect to the magnetic circuit 2 by means of a cylindrical part 17
of the shaper 10 set into a bore 18 of the magnetic circuit 2. The
bore 18 is, for example, used to put in place a rotor of the
electrical machine, the rotor not being shown in FIG. 1.
[0020] Advantageously, the first point 14 is situated at a fixed,
nonzero distance from the shoulder 15. This allows the arms 6 to be
folded only from a certain distance from the end lamination 16 and
therefore guarantees a reproducible distance between the magnetic
circuit 2 and the folding of each arm 6. Maintaining the alignment
of the arms 6 in their respective slots 3 allows the coolant to
circulate better in the vicinity of the magnetic circuit 2, and
more precisely along the end lamination 16.
[0021] The equipment also comprises two rings 20 and 21 constructed
by means of bolts 22 and supporting the lamina of the magnetic
circuit 2 during production of the coil.
[0022] Advantageously, the equipment comprises a second series of
guide-pins 25, equal in number to the slots 3 and designed so that
each penetrates into a hole 26 of the shaper 10. Each hole 26 is
drilled along an axis. The axes of the holes 26 meet at a second
point 27 on the axis of revolution 5 of the shaper 10. The point 27
is at a distance from the point 14. Each guide-pin 25 is designed
to guide the arms 6 in a direction parallel to the direction of the
arms 6 in their slot 3. As with the guide-pins 12, once the
guide-pins 25 are put into their respective hole, it is possible to
fold the arm 6, which ends up pressing against a guide-pin 25, in
order to guide it in a direction parallel to that of the slot 3 it
occupies.
[0023] Advantageously, the shaper 10 comprises a conical part 30
designed to move the arms 6 away from the axis 5 of the magnetic
circuit 2. The conical part 30 comes into contact with the arms 6
when the shaper 10 is in contact with the magnetic circuit 2. The
arms 6 thus follow the form of the conical part to move away from
the axis 5. This provides the internal form of the lead-out
wire.
[0024] Advantageously, the equipment comprises a second shaper 35,
also axisymmetric. The second shaper 35 is designed to be placed
inside the bends 7 and in contact with the magnetic circuit 2. The
equipment also comprises a third series of guide-pins 36, equal in
number to the slots 3 and designed so that each penetrates into a
hole 37 of the second shaper 35. So as not to overload the figure,
only one guide-pin 36 is shown. Each hole 37 is drilled along an
axis, the axes of the holes 37 meeting at a point 38 on the axis of
revolution 5 of the second shaper 35. Each guide-pin 36 is designed
to separate two arms 6 threaded into two adjacent slots 3 so as to
position the bends 7 at a fixed distance from the magnetic circuit
2. As with the shaper 10, the shaper 35 allows the arms 6 to be
kept from being inserted totally into their respective slot and to
preserve a straight part of the arms 6 outside of the slots 3. This
allows the coolant to circulate better in the vicinity of the
magnetic circuit 2, and more precisely along the end lamination 39
opposite the end lamination 16. In fact the pins 4 are preformed
before being inserted in the slots 3. The longest part of the arms
6 is straight, a part designed to be inserted into the slots 3, and
close to the bend 7, the arms 6 comprising folds 40. The position
of the point 38 in relation to the end lamination 39 allows the
folds 40 to be pressed against the third series of guide-pins 36.
Using the guide-pins 36 makes it easier to produce the form of the
lead-out wire containing the bends 7.
[0025] A method for producing coils using equipment as previously
described consists in successively carrying out the following
operations: [0026] inserting the pins 4 into the slots 3 according
to a wiring scheme for the coil; [0027] putting the first shaper 10
into place along the axis of revolution 5 of the magnetic circuit 2
on the free side of the arms 6 in contact with the magnetic circuit
2; [0028] putting the first series of guide-pins 12 into place; and
[0029] folding each of the arms 6 by pressing it onto a guide-pin
12.
[0030] Before inserting the pins 4 into the slots 3, it is possible
to insert insulating sleeves into the slots 3, into which sleeves
the pins 4, where these are not insulated, are in turn
inserted.
[0031] When several levels of arms 6 are inserted into the slots 3,
as shown in FIG. 1, the various levels are generally folded with a
different orientation. For example, folding is started at the level
furthest from the axis 5 in a clockwise direction about the axis 5.
Folding continues at a level closer to the axis 5 in a
counterclockwise direction about the axis 5.
[0032] Advantageously, after having folded each of the arms 6 by
pressing it onto a guide-pin 12 of the first series, the method
consists in successively carrying out the following operations:
[0033] putting the second series of guide-pins 25 into place;
[0034] folding the arms 6 by pressing onto a guide-pin 25 of the
second series so as to guide the arms 6 in a direction parallel to
the direction of the arms 6 in their slots 3; and [0035] connecting
the arms 6 in accordance with a wiring scheme for the coil.
[0036] This latter connection operation is carried out, for
example, by means of rings inserted in two neighboring arms 6 at
the free end, beyond the guide-pins 25. These rings are then
brazed.
[0037] Advantageously, before the pins 4 have been inserted into
the slots 3, the second shaper 35 pressing against the magnetic
circuit 2 is put in place and the third series of guide-pins 36 is
placed in the holes 37. Thus the folds 40 press against the
guide-pins 36 to guarantee an identical distance between the bends
7 and the magnetic circuit 2. Supporting the folds 40 on the
guide-pins 36 also allows a certain length of the straight part of
the arms 4 to be kept out of the slots 3.
[0038] It will be readily seen by one of ordinary skill in the art
that the present invention fulfils all of the objects set forth
above. After reading the foregoing specification, one of ordinary
skill in the art will be able to affect various changes,
substitutions of equivalents and various aspects of the invention
as broadly disclosed herein. It is therefore intended that the
protection granted hereon be limited only by definition contained
in the appended claims and equivalents thereof.
* * * * *