Method of manufacturing stator coil for electric rotating machine

摘要

A method of manufacturing a stator coil includes the steps of: (1) forming substantially planar electric wires each including in-slot portions to be received in slots of a stator core and turn portions to be located outside of the slots to connect the in-slot portions; (2) rolling each of the planar electric wires into a spiral shape by plastically deforming the turn portions; and (3) assembling the rolled electric wires through relative axial movements therebetween, each of the relative axial movements being made by axially moving first and second components relative to each other with both the first and second components radially elastically deformed and with each of the first and second components circumferentially positioned by at least one positioning member, each of the first and second components being one of the rolled electric wires or an electric wire sub-assembly comprised of a plurality of the rolled electric wires.

主权项

1. A method of manufacturing a stator coil for an electric rotating machine, the electric rotating machine including a hollow cylindrical stator core having a plurality of slots that are formed in a radially inner surface of the stator core and spaced in a circumferential direction of the stator core, the method comprising the sequential steps of:
forming a plurality of substantially planar electric wires, each of the planar electric wires including a plurality of in-slot portions to be received in corresponding ones of the slots of the stator core and a plurality of turn portions to be located outside of the slots of the stator core to respectively connect adjacent pairs of the in-slot portions; rolling each of the planar electric wires by a predetermined number of turns into a spiral shape by plastically deforming each of the turn portions of the electric wire into an arc shape; and assembling the rolled electric wires through relative axial movements therebeween to form a hollow cylindrical electric wire assembly that makes up the stator coil, each of the relative axial movements being made by axially moving first and second components relative to each other with both the first and second components radially elastically deformed and with each of the first and second components circumferentially positioned by at least one positioning member, each of the first and second components being made up of either one of the rolled electric wires or an electric wire sub-assembly that is comprised of a plurality of the rolled electric wires, wherein the at least one positioning member comprises a plurality of positioning member that are configured to be radially advanced into and retreated out of the first and second components and located at the same circumferential position but different axial positions from each other, and during the relative axial movement, each of the first and second components is always in a state of being circumferentially positioned by at least one of the plurality of positioning member.