Process for the manufacture of the stator of an electrical machi

Details Process for the manufacture of the stator of an electrical machi Process for the manufacture of the stator of an electrical machi

1992-08-27

1994-05-24

Hall, Carl E.

Metal working

Method of mechanical manufacture

Electrical device making

2642722, 310 43, 310 71, H02K 1514

Patent

active

053136985

DESCRIPTION:

BRIEF SUMMARY
BACKGROUND OF THE INVENTION

The present invention relates to a process for manufacture of a stator of an electrical machine, preferably a three-phase alternator for vehicles.
It is already known from the Japanese Utility Model Publication 57-65570 to provide the stator housing of an electric motor with cooling ribs for guiding off heat. These cooling ribs, together with the annular spaces at the winding ends of the stator winding, are filled with a heat conducting mold resin after the stator plate stack has already been inserted into the housing with the stator winding. In so doing, the winding ends are completely embedded in the mold resin so that the heat losses generated in them can be guided out. A disadvantage of an electrical machine produced in this way consists in that the entire prefabricated stator, including its housing, must be inserted in a compression or injection mold for embedding the winding ends in heat conducting plastic, which requires special steps for sealing the injection or compression mold. Such a solution becomes even more costly when the electrical machine has two stator plate stacks with stator windings located one after the other in the axial direction, and when these systems are inserted into a pot-shaped stator housing in addition.
Such a three-phase alternator for motor vehicles having a double-generator system in a closed, water-cooled housing is known from DE-OS 31 28 081 (FIG. 5). The winding ends of the two systems are exposed. Consequently, due to the relatively poor heat conduction at the winding ends, the output of such an electrical machine is limited and its outer diameter is relatively large. Moreover, the two stator plate stacks are inserted into the cylindrical stator housing from both sides, which is not possible with a pot-shaped construction of the housing.


SUMMARY OF THE INVENTION

Accordingly it is an object of the present invention to provide the most inexpensive possible production and assembly of the stator in surface-cooled electrical machines having two stator systems located one after the other in the axial direction with good heat conduction and in a compact construction.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a process for the manufacture of an electrical machine, preferably a three-phase alternator for vehicles, which is characterized in that the two stator plate stacks carrying the stator windings are first positioned relative to one another by spacing means for insertion into a compression mold, and the connection conductions of the rear stator winding are guided through slots of the front stator plate stack; in that connection parts for the stator windings are fastened at a base part of the compression mold so as to be detachable and the connection parts make contact with connection conductors of the stator windings; in that the two stator plate stacks are inserted into an outer annular wall of the compression mold at their outer diameter with the spacing means, and the stator plate stacks are received at their inner diameter by an inner annular wall of the compression mold with an axially guided male die, and in that a heat conducting plastic in the hot state is injected between the inner and outer annular wall so that the stator plate stacks, the spacing means, the windings end and the connection parts are embedded and/or anchored in the heat conducting plastic to form a structional unit.
When the process for the manufacture is performed in accordance with the present invention, it has the advantage that the two stator systems are manufactured beforehand so as to form a constructional unit in a compression mold by means of the heat conducting plastic in which the winding ends of the stator windings are embedded. A cylindrical or pot-shaped housing which is likewise manufactured beforehand can then be shrunk on to this constructional unit so that costly compression molds or assembly arrangements can be dispensed with. Since the plas

REFERENCES:
patent: 1584502 (1926-11-01), Apple
patent: 3758799 (1973-11-01), Dochterman
Patent Abstracts of Japan vol. 10, No. 27 (E-378) (2084) Japan GM/OS 57-65570/82.

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