APPARATUS AND METHOD FOR MANUFACTURING A STATOR

Abstract

A method and an apparatus are provided for manufacturing a stator with a plurality of hairpin conductors. For inserting the hairpin conductors (15, 15) into the slots (11) of a stator core (12) a stator core template (22) is provided. Hairpin conductors (15) are axially inserted into slots (21) of the stator core template (22) such that the hairpin conductor (15) is arranged at a first position (P1) within said slot (21). The hairpin conductor (15) is then moved within said slot (21) to a different position (P2). A complete nest (20) of hairpin conductors (15) formed within the stator core template (22) is then transferred to the stator core (12).

Claims

1. A method for manufacturing a stator with a plurality of hairpin conductors arranged in slots of a stator core, comprising the steps of: a. providing a stator core template having a number of radially and axially extending slots corresponding to the number of slots of the stator core, said slots of the stator core template having at least one of a circumferential width larger than the circumferential width of the slots of the stator core and a radial length larger than the radial length of the slots of the stator core b. inserting at least one hairpin conductor into at least one of said slots of the stator core template such that said hairpin conductor is arranged at a first position within said slot, wherein in said first position the hairpin conductor is arranged differently than in the intended position in the stator core c. moving said hairpin conductor within said slot of said a stator core template from said first position to a second position d. Repeating step a.) and step b.) for at least one additional hairpin conductor such as to form a first layer of a partial nest or a nest of hairpin conductors e. removing the partial nest or the nest of hairpin conductors from the stator core template f. inserting the nest or the partial nest into the slots of the stator core.

2. A method according to claim 1, wherein in step c.) the hair pin conductor is radially moved within said slot of said stator core template such that it is arranged at a second position radially different.

3.-21. (canceled)

22. A method according to claim 2, wherein the second position is inwardly from the first position.

23. A method according to claim 1, wherein steps b. to d. are repeated in order to form at least one further layer of a partial nest or a nest of hairpin conductors.

24. A method according to claim 23, wherein the first layer and the further layer(s) are axially removed jointly from the stator core template and axially inserted jointly into the stator core.

25. A method according to claim 1, wherein at least some hairpin conductors are preformed and comprise a pair of leg portions joined together by a bridge portion and wherein a first leg portion is arranged in the stator core template in a first slot at a first radial distance and a second leg portion is arranged in the stator core template in a second slot at a second radial distance larger than the first radial distance.

26. A method according to claim 25, wherein the second leg portion of at least some hairpin conductors is arranged in a slot of said stator core template such as to be adjacent a first leg portion of a hairpin conductor previously inserted into said slot.

27. A method according to claim 25, further comprising: arranging the second leg portion of an initial group of hairpin conductors in a slot of the stator core template neighboring a spacer element; by means of said spacer element, keeping the second leg portion at or moving the second leg portion to a predefined radial distance equal to or larger than the second radial distance, thereby maintaining or creating a radial gap within the respective slot of the stator core template; and inserting a first leg portion of a further hairpin conductor into the gap within the respective slot adjacent to said second leg portion.

28. A method according to claim 27, comprising the step of removing the spacer element.

29. A method according to claim 27, wherein the hairpin conductors of a subsequent group are inserted into slots of the stator core template and arranged with their second leg adjacent a first leg of another hairpin conductor of the initial group or of the subsequent group, and wherein the hairpin conductors of a final group are inserted into slots of the stator core template with first legs inserted into the gap maintained or created by said spacer.

30. A method according to claim 29, wherein the hairpin conductors of the initial, subsequent and final group are inserted in a continuous circumferential sequence.

31. A method according to claim 27, wherein a leg of at least one hairpin conductor of a different type is inserted.

32. A method according to claim 1, wherein each hairpin conductor is at least one of axially inserted by means of a manipulator and is moved by means of a pusher.

33. A method according to claim 1, wherein for axially removing and for axially inserting the partial nest or the nest, a head portion of the partial nest or the nest is grasped with a gripper.

34. A method according to claim 33, wherein, prior to axially inserting the partial nest or the nest, a guide is inserted between the legs of circumferentially neighboring hairpin conductors at a site axially distant from the head portion.

35. A method according to claim 34, wherein the partial nest or the nest is only partially inserted by means of said gripper to an intermediate axial position and wherein the nest or the partial nest is inserted into a final axial position in the stator core by means of a separate presser.

36. An apparatus for manufacturing a stator with a plurality of hairpin conductors arranged in slots of a stator core, comprising: a stator core template with a number of radially and axially extending slots corresponding to the number of slots of the stator core, said slots of the stator core template having at least one of a circumferential width larger than the circumferential width of the slots of the stator core and/or a radial length larger than the radial length of the slots of the stator core; an insertion station for inserting at least one hairpin conductor into at least one of said slots of the stator core template such that said hairpin conductor is arranged at a first position within said slot, wherein in said first position the hairpin conductor is arranged differently than in the intended position in the stator core; a moving station for moving said hairpin conductor within said slot of said stator core template from said first position to a second position.

37. An apparatus according to claim 36, comprising a moving station for moving said hairpin conductor such that it is arranged at a second position radially inside from the first position.

38. An apparatus according to claim 36, wherein the slots in the stator core template are spirally formed seen in a plane perpendicular to the axis of the stator core template.

39. An apparatus according to claim 36, wherein the stator core template is provided with insertion deflectors at an upper axial end between neighboring slots.

40. An apparatus according to claim 36, wherein the apparatus is provided with a radial spacer for at least one of keeping and moving second legs of hairpin conductors at or to a predetermined radial distance.

41. An apparatus according to claim 36, wherein the apparatus is provided with a gripper for gripping a head portion of a nest or partial nest formed in said stator core template and for axially removing said nest or partial nest from the stator core template and for at least partially inserting said nest or partial nest into said stator core.

42. An apparatus according to claim 36, wherein the apparatus is provided with a presser for axially inserting said nest or partial nest from an intermediate position to a final position into said stator core.

43. An apparatus according to claims 36, wherein the apparatus is provided with a guiding element for insertion between the legs of circumferentially neighboring hairpin conductors at a site axially distant from the head portion.

Description

[0062] FIG. 1 shows a perspective view of a stator 10. The stator 10 comprises a stator core 12 which is provided with a plurality of axial slots 11 in a manner known to the skilled person. A number of hairpins 15 are inserted into the slots 11. Bridge portions 19 extend out of the slots 11 at the upper axial side whereas end portions 24 extend out of the slots at an axial lower end of the stator core 11.

[0063] A typical standard hairpin 15 is shown in FIGS. 2a and 2b. The hairpin 15 comprises two legs 18a , 18b which are connected to each other via a bridge portion 19. The legs 18a , 18b run substantially parallel. The bridge portion 19 is bent at an intermediate part. The hairpins 15 have a non-planar shape (see FIG. 8). The hairpins 15 are preformed to their final shape as shown in FIGS. 2a, 2b and 8 by a separate preforming arrangement outside of the stator core template. Such arrangement is known to the skilled person and is not explained in detail.

[0064] FIG. 2b shows a first and a second hairpin 15, 15′. On the right hand side of FIG. 2b, the bridge 19 of the hairpin 15 is arranged axially above the bridge 19′ of the hairpin 15′. On the left hand side of FIG. 2b, the bridge 19 is arranged axially below the bridge 19′ of the hairpin 15′. Due to this over1apping, it is not possible to simply axially insert the two hairpins 15, 15′ in a sequence directly into their final position within the stator core 11.

[0065] FIG. 3 shows a perspective view of a stator core template 22 which is used to overcome this problem and in particular to preassemble a nest 20 (see FIG. 12) of hairpin conductors 15 outside of the stator core 12. The stator core template 22 comprises a body which is provided with axial slots 21. The axial slots 21 are evenly distributed along the circumference of the stator core template 22. The number of slots 21 of the stator core template 22 corresponds to the number of slots 11 in the stator core 12. Between neighbouring slots 21 of the stator core template 22 deflectors 23 are arranged at the axial upper end of the stator core template 22. The stator core template 22 can be made of any suitable materials such as metal, but also of suitable plastic material.

[0066] FIG. 4 shows an enlarged top view on a section of the stator core template 22. For the purpose of comparison, the shape of a slot 11 of the stator core 12 is over1aid to the drawing in figure 4. The slots 21 of the stator core template 22 have a crosssection which is larger than the cross-section of the slots 11. In particular, the circumferential width w and the radial length 1 of the slots 21 of the stator core template 22 are larger than the width w′ and the length 1′ of the slots 11 of the stator core 12. Because of the relatively large size of the slot 21 as compared to the size of the slot 11 in the stator core 12, the hairpin conductors 15 can be loosely arranged within the slots 21.

[0067] FIG. 5 shows end parts of three hairpin conductors 15 which are inserted into a slot 21 of the stator core template 22. The deflectors 23 are arranged between neighbouring slots 21. The deflectors 23 have a rounded upper edge which facilitates insertion of the ends of the legs 18b of the conductors 15. FIG. 5 schematically shows a plurality of neighbouring hairpin conductors 15 inserted in one slot 21 of the stator core template 22.

[0068] For forming a nest 20 (see also FIG. 12) individual hairpins 15, 15′ are inserted into the stator core template 22 in a sequence. FIG. 6 shows stator core template 22 with four previously inserted hairpin conductors 15 and the insertion of an additional hairpin conductor 15′. The hairpin conductor 15′ is held by a manipulator 30 which is also schematically shown. By means of the manipulator 30, the hairpin 15′ is axially inserted into the stator core template 22 with a first leg 18b being inserted in a first slot and a second leg 18a being inserted into a second slot 21 which is different from the first slot. The axial length A of stator core template 22 is substantially smaller than the axial length of the hair pin conductors, so that the lower ends of the legs of the hairpin conductors 15 substantially extend from the lower axial end of the stator core template 22 and therefore are relatively flexible.

[0069] When the hairpin conductor 15′ has been axially inserted by the manipulator 30, it is radially moved in a subsequent step by means of a pusher 40 (see FIG. 7). The pusher 40 moves the hairpin 15′ from an initial position P2 (see FIG. 8) to a final, radially inwardly arranged position P1. In the position P1 a second leg 18b of the hairpin conductor 15′ is adjacent to a first leg 18a of a previously inserted hairpin conductor 15 in the same slot.

[0070] This axial and radial placement of hairpin conductors is repeated until the desired arrangement of hairpins has been achieved. In this final arrangement, typically a part or all slots 21 of the stator core template 22 will have received a first and a second leg of two different hairpin conductors. In this way a first layer of hairpin conductors is formed. As can be seen in FIGS. 6 and 7 there is sufficient radial space in the slots of the stator core template allowing insertion of an additional layer of hairpin conductors in the same way as the first layer.

[0071] FIGS. 9a to 9d show the formation of one layer of hairpin conductors 15 of the same type which are homogenously arranged along the circumference of the stator core template. The hairpin conductors 15 are sequentially inserted into the slots 21 of a stator core template 22 in the manner as described hereinabove.

[0072] Contrary to the stator core template 22 shown in the previous figures, the slots 21 of the stator core template 22 are slightly spirally formed. This allows the radial outward and/or inward movement of the hairpin conductors 15 within the slots 21 of the stator core template 22 without the risk of jamming or deforming the hair pin conductors 15, in particular in case of a radial outward movement by means of a spacer 25 as will described herein below with reference to FIG. 9b.

[0073] In this embodiment, insertion of the hairpin conductors 15 is started with a first group G1 of hairpin conductors 15. In the embodiment shown in FIGS. 9a to 9d, the hairpins have a pitch of 6, i.e. the legs of one hairpin are inserted into two separate slots which are separated from each other by five empty slots. The hairpin conductors are inserted into the slots 21 of the stator core template 22 with a first leg 18a at a first radius r1 and with a second leg 18b at a second, larger radius r2 (see also FIG. 10). A first conductor is inserted with its second leg 18b in slot 21′. During insertion of the conductors 15 of the initial group G1 there are no previously inserted hairpin conductors 15 present in the slots. Therefore, the position at radius r1 in those slots where the second legs 18b are inserted at radius r2 is not occupied and therefore the second legs 18b cannot abut against first legs 18a of the previously inserted hairpin conductors 15 in the same slot.

[0074] Once the hairpin conductors 15 of the initial group G1 have been brought to their final position by using the pusher 40 as described above, hairpin conductors 15 of a second group G2 are sequentially inserted. Their second legs 18b are arranged at the radius r2 in slots 21 where a first leg 18a of a previously arranged hairpin conductor 15 of group G1 or of group G2 is present. Insertion of hairpin conductors 15 of the second group G2 is sequentially repeated until a first leg 18a of a hairpin is placed into slot 21″ (see FIG. 9a).

[0075] The insertion of hairpin conductors is completed by the insertion of conductors of a final group G3. The first leg 18a of hairpin conductors 15 of the third group G3 has to be placed at a radius r1. This is, however, not easily possible due to the second leg 18b of the previously inserted hairpin conductor 15 of group G1 in slot 21′.

[0076] In order to allow insertion of the hairpin conductors of group G3, a spacer 25 is provided (see FIG. 9b). By means of the spacer 25, the hairpin conductors 15 of the first group G1 are moved radially outwardly (see FIG. 9c) such as to create a gap 26 radially inwardly of the second leg 18b of the hairpin conductors 15 of the first group G1. Once the hairpin conductors 15 of the first group G1 are in a radially outward position, the spacer 25 can be removed such as to clear the gap 26. It is now easily possible to insert the hairpin conductors of the third group G3 with their first leg 18a into the gap 26 in the slots 21 in the same manner as described hereinabove with reference to the FIGS. 6, 7 and 8. Once the conductors of the final group G3 have been inserted, the hairpin conductors of the first group G1 (which previously were moved radially outwardly by the spacer 25) can be brought back into their final position, e.g. by means of the radial pusher 40.

[0077] While in the embodiment shown in FIGS. 9a to 9d a movable spacer 15 for actively bringing the hairpins of the first group G1 radially outwardly has been shown, it is also conceivable to provide a static spacer which defines a radial abutment for the hairpin conductors of the first group G1, thereby directly creating a gap without the need of actively moving the hairpin conductors 15 of the first group g1 radially outwardly.

[0078] FIGS. 10 and 11 schematically show two types of a final nest of hairpin conductors.

[0079] FIG. 10 shows two layers 16, 17 of homogenously and continuously arranged hairpin conductors. In the embodiment shown in FIG. 10, the pitch is 1. Arrangements with larger pitches or arrangements with hairpin conductors having different pitches are also conceivable. The hairpin conductors are arranged in a first, radially inner layer 16 and a second, radially outer layer 17. The layers 16 and 17 together form a complete nest 20.

[0080] The top of FIG. 10 shows in more detail that, within a specific slot, a first leg 18a of the hairpin 15 is arranged at a first radial distance r1 whereas a second leg 18b of the same hairpin 15 is arranged at a radial distance r2 in a different slot. The second leg 18b ′ of a neighbouring hairpin conductor 15′ (shown on the left to the first conductor 15 in FIG. 10) is arranged neighbouring the first leg 18a of the first hairpin conductor 15 in the same slot.

[0081] FIG. 11 shows an alternative embodiment. Similar to the embodiment in FIG. 10, hairpins of the same type are homogenously arranged over a sector S1 of about 300°. In the remaining sector S2 some hairpin conductors are of different types. Typically, jumpers 70 are used to connect the first layer 16 with the second layer 17. Furthermore, i-pin conductors 71 may be arranged in order to create connection points. Because of the use of different type of hairpin conductors used in FIG. 11, depending on the insertion sequence it may not be necessary to use a spacer 25 similar to the one shown with reference to FIGS. 9a to 9d. I-pin connectors 71 and/or jumpers 70 may be previously inserted and provide abutments to subsequently inserted hairpin conductors.

[0082] FIG. 12 shows a perspective view of completed nest 20. The nest 20 is still partly contained in the stator core template 22, but has been lifted up axially by using a pusher (not shown) from below. The nest 20 is built by three layers of hairpin conductors, i.e. is similar to the embodiments of FIG. 10 or 11 with one additional layer (not shown in FIG. 10 or 11).

[0083] A gripper unit 50 which is circumferentially oriented with respect to the slots 21 of the stator core template 22 is then lowered down towards the nest 20. The complete nest 20 is grasped at an upper end portion 14 by means of the gripper unit 50 (see in more detail FIGS. 15, 16 and 17) and axially removed from the stator core template 22. It is then transferred to and axially inserted into stator core 12 (see FIG. 13).

[0084] In FIG. 13, the nest 20 is shown in an intermediate position I. In a subsequent step (see FIG. 14) the nest 20 is moved from the intermediate position I to a final position F by means of an axial presser 60. The axial presser 60 is designed in a manner known to the skilled person and typically is driven by an electric motor or pneumatically or hydraulically actuated and controlled by an appropriate control.

[0085] An upper part of the gripper unit 50 is schematically shown in FIG. 15. The upper part of the gripper unit 50 comprises a radially internal abutment member 52 and pivotable clamps 51. The head portion 14 of the nest 20 is gripped between a radially inner surface of the clamps 51 and a radially outer surface of abutment members 52. The abutment members 52 are provided with slots 53 providing flexibility and an adequate clamping force.

[0086] For gripping the nest 20, the gripper 50 is axially moved onto the head portion 14 of the partly lifted nest 20 in the stator core template 22 (see FIG. 12) with the clamps 51 in an open position allowing to receive the head portion 14. By pivoting the clamps 51, the head portion 14 is grasped. The nest 20 can be axially removed from the stator core template 22 by lifting the gripper 50. Lifting motion and actuating of the clamps is made in a manner known to the skilled person, typically by an electric motor or pneumatically or hydraulically actuated and controlled by an appropriate control.

[0087] In a lower part the gripper unit 50 is provided with a guiding element 55. The guiding element 55 is applied to the lower end of the hairpin conductors 15 of the nest 20 at a site 56 which is axially spaced from the head portion 14 (see FIG. 16). The guiding element 55 comprises a support 54 with an opening 61 in which a plurality of radially moveable tongues 59 are arranged. The tongues 59 are movable radially between an insertion position (radially outward, not shown) and a guiding position (radially inward, as shown in FIGS. 16 and 17). When the gripper unit 50 is lowered onto the nest 20 as described above, the tongues 59 are in their radial outward position, allowing the legs of the hairpin conductors to be received within the opening 61 of the support 54. The tongues 59 are then moved radially inwardly so as to become arranged with their tips between neighbouring legs of hairpin conductors. The tongues 59 comprise radial abutment surfaces 57 and circumferential abutment surfaces 58 for guiding the lower ends of the hairpin conductors 15 to a suitable circumferential and radial position allowing insertion into the stator core 12. Once the tongues 59 are radially moved and placed between neighbouring legs, the clamps are actuated as described above and the nest 20 is removed from the stator core template 22.