Method of manufacturing conductor segments of AC generator

Details Method of manufacturing conductor segments of AC generator Method of manufacturing conductor segments of AC generator

2000-07-28

2001-11-13

Larson, Lowell A. (Department: 3725)

Metal deforming

By use of roller or roller-like tool-element

With work-forcer offset from, and relatively movable...

C072S383000

Reexamination Certificate

active

06314780

ABSTRACT:

CROSS REFERENCE TO RELATED APPLICATION
The present application is based on and claims priority from Japanese Patent Application Hei 11-220769, filed Aug. 4, 1999, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ac generator having a plurality of U-shaped conductor segments that are connected to form a stator winding.
2. Description of the Related Art
A rotary electric machine having an armature winding which is comprised of a plurality of U-shaped conductor segments. Each conductor segment has a U-shaped head and a pair of legs and is coated with an insulation layer.
U.S. Pat. Nos. 5,211,670 and 5,266,858 disclose a method of manufacturing such an armature winding. Each leg is inserted into one of a plurality of slots from one end of an armature core. Thereafter, leg ends of the conductor segments are connected to one another at the other end of the armature core to form the stator winding.
In manufacturing the conductor segments, a rotating disk having a bend core and a pin is provided. The bend core is formed at the center of a rotating disk to be fitted to the inner periphery of the U-shaped head of the conductor segment. A straight conductor wire is put between the outer periphery of the bend core and the pin, and, then, the disk is rotated in a certain angle to bend the wire along the outer periphery of the bend core.
However, the above manufacturing method causes the U-shaped head to incline to one of the legs, and the head has to be reshaped in order to form a coil end of the armature winding. This is an obstacle to productivity of the armature winding, and the reshaping of the conductor segments may cause insulation failure.
SUMMARY OF THE INVENTION
A main object of the invention is to provide an improved method of manufacturing reliable U-shaped conductor segments at a high productivity.
According to a feature of the invention, a method of manufacturing a U-shaped conductor segment includes a step of setting a straight conductor wire of a prescribed length on the outer peripheries of a pair of parallelly disposed rollers, and a step of pushing a bender against one side of the conductor wire opposite the rollers between the rollers so that the conductor wire can be bent to allow the bender to pass through between the pair of rollers.
The method may further comprise a step of reducing a gap between the pair of rollers when or after the step of pushing a bender. The step of reducing a gap may include a step of forming a gap between legs to be narrower than the gap of the head. In the step of pushing a bender may further include a step of holding the other side of the wire by a stopper while the bender passes through between the pair of rollers. In the step of pushing a bender may further include a step of inserting a spacer between the legs.


REFERENCES:
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patent: 5211670 (1993-05-01), Ohmi et al.
patent: 5237847 (1993-08-01), Owens
patent: 5266858 (1993-11-01), Ohmi et al.
patent: 5461897 (1995-10-01), Gray et al.
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patent: 55036082 (1980-03-01), None
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