Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
2001-02-12
2004-05-25
Le, Dang (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S216006, C310S203000, C310S195000, C310S179000, C310S049030
Reexamination Certificate
active
06741004
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dynamo-electric machines for apparatuses such as alternators driven by, for example, internal combustion engines. In particular, the present invention relates to an armature for an automotive alternator to be mounted on an automotive vehicle, such as an automobile or a truck.
The entire content of the basic Japanese Patent Application from which the priority under the Convention is claimed in this application is hereby incorporated by reference into this application.
2. Description of the Related Art
FIG. 27
is a perspective view of a stator for a known automotive alternator.
In
FIG. 27
, a known stator
1
includes a stator core
2
provided with a plurality of slots
2
a
extending in the axial direction and disposed alongside each other in the circumferential direction at a predetermined pitch, a stator winding
3
mounted on the stator core
2
, and substantially U-shaped insulators
4
disposed in the slots
2
a
for electrically insulating between the stator core
2
and the stator winding
3
. Thirty-six slots
2
a
are formed in the stator core
2
for receiving the stator winding
3
configured with a three-phase alternating winding.
With reference to
FIGS. 28
to
34
, a method for manufacturing the known stator
1
is described below.
A belt-shaped member having projections and recesses is made of a belt-like magnetic SPCC thin plate. A given number of the belt-shaped members are laminated and are welded to each other by a laser at the peripheries thereof, thereby forming a rectangular parallelepiped laminated-core
5
shown in FIG.
28
. Thirty-six slots
5
a
are formed at one face of the laminated core
5
.
A winding assembly
7
A is formed in a plane shape with one strand of wire
6
, made of a copper wire having a circular section and coated with an insulating film, wound in a predetermined number of waves at a three-slot pitch. The winding-starting end and the winding-finishing end of the strand of wire
6
forming the winding assembly
7
A serve as a lead wire
6
a
and a neutral-point lead wire
6
b
, respectively. Winding assemblies
7
B and
7
C are formed with other two strands of wire
6
, respectively, wound in the same manner.
In
FIG. 29
, a substantially U-shaped insulator
4
is inserted in each slot
5
a
of the laminated core
5
from the open side of the slot
5
a
, whereby the insulator
4
is received completely in the slot
5
a
. The three winding assemblies
7
A,
7
B, and
7
C overlap each other by being offset by a one-slot pitch from each other, as shown in FIG.
30
. In
FIG. 31
, the overlapping winding assemblies
7
A,
7
B, and
7
C are inserted in every third slots
5
a
, respectively, from the open sides of the slots
5
a
. As shown in
FIGS. 32 and 33
, the winding assemblies
7
A,
7
B, and
7
C are thus mounted on the laminated core
5
.
In
FIG. 34
, the laminated core
5
mounted with the winding assemblies
7
A,
7
B, and
7
C is rolled up and is formed in a cylinder by a forming device (not shown), and butt-welded by a laser at the longitudinal ends thereof, whereby the stator
1
shown in
FIG. 27
is obtained.
The neutral-point lead wires
6
b
of the strand of wires
6
forming the winding assemblies
7
A,
7
B, and
7
C are connected to each other, thereby forming a three-phase alternating winding constituting the stator winding
3
included in the known stator
1
. The winding assemblies
7
A,
7
B, and
7
C have a phase difference of 120 degrees from each other, which are windings for phase-a, phase-b, and phase-c, respectively, of the three-phase alternating winding. When the stator
1
is mounted in an automotive alternator, the lead wires
6
a
of the strands of wire
6
forming the winding assemblies
7
A,
7
B, and
7
C are connected to a rectifier.
In a method for manufacturing the known stator, the substantially U-shaped insulators
4
are inserted in the slots
5
a
of the rectangular parallelepiped laminated core
5
, then the winding assemblies
7
A,
7
B, and
7
C are inserted in the slots
5
a
from the open sides thereof. Since the gap between the stator
1
and a rotor (not shown) of an automotive alternator is very small, even a small protrusion of the insulator
4
from the slot
5
a
may interfere with the rotator. Therefore, the insulators
4
are formed so as not to protrude from the slots in the radial directions.
Therefore, there is a problem that the mounting operation of the winding assemblies is not easy to perform because the ends of the insulators
4
are disposed substantially on the same level as that of the ends of teeth
5
b
, whereby the ends of the insulators
4
do not function as guides when the winding assemblies
7
A,
7
B, and
7
C are inserted in the slots
5
a.
Two sides of each U-shaped insulator
4
, opposing to each other, are formed in parallel to each other, and the open sides of the slots
5
a
are not closed when the winding assemblies
7
A,
7
B, and
7
C have been received in the slots
5
a
. Therefore, during the operation of rolling the laminated core
5
, the strand of wires
6
are likely to fall away from the slots
5
a
, whereby the operation cannot be performed efficiently.
The ends of the insulators
4
are drawn toward the bottoms of the slots
5
a
during the insertion of the winding assemblies
7
A,
7
B, and
7
C due to the friction between the winding assemblies
7
A,
7
B, and
7
C and the insulators
4
, whereby flanges
5
c
of the teeth
5
b
are exposed at ends thereof in the peripheral direction of the laminated core
5
. Therefore, there is a problem in that the strands of wire
6
of the winding assemblies
7
A,
7
B, and
7
C are scratched by the peripheral ends of the flanges
5
c
, thereby causing damages to the insulating films of the strand of wires
6
, whereby the insulation is deteriorated. Moreover, the insulators
4
between the inner walls of the slots
5
a
and the strands of wire
6
are removed from some portions in the slots
5
a
after inserting the winding assemblies
7
A,
7
B and
7
C in the core, whereby the insulation is deteriorated.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method for manufacturing an armature for a dynamo-electric machine and an armature manufactured by the method, in which a substantially U-shaped insulator having top sides thereof bent so as to be apart from each other is mounted in each slot in a manner such that the top sides of the insulator protrude from the slot, and a winding assembly is inserted in the slots from open sides thereof. The winding assembly can be easily inserted due to the top sides of the insulator serving as guides. Due to the top sides of the insulator, which are bent so as to be apart from each other, strands of wire forming the winding assembly inserted in the slots are prevented from falling away from the slots by the top sides deformed so as to enclose an opening of each slot, and the insulator is prevented from being removed the top edges thereof toward the bottom of the slot, thereby improving the insulation.
To these ends, according to an aspect of the present invention, a method is provided for manufacturing an armature for a dynamo-electric machine, the armature comprising an armature core provided with a plurality of slots extending in an axial direction and disposed alongside each other in a circumferential direction, an armature winding inserted in the slots so as to be mounted on the armature core, and an insulator mounted in each of the slots for insulating between the armature core and the armature winding. The method comprises the steps of forming a substantially U-shaped insulator having side portions connected with a bottom portion, the side portions being bent at a first bent part of each side portion so as to be apart from each other to form outwardly bent portions on the top sides of the side portions; forming a winding assembly composed of strands of wire formed in a predetermined wound state; mounting the insulator in each of
Oketani Naohiro
Oohashi Atsushi
Senoo Akira
Takizawa Takusi
Cuevas Pedro J.
Le Dang
Mitsubishi Denki & Kabushiki Kaisha
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