Method for producing a stator

Abstract

Described is a method for producing a stator, in particular for electric motors. In a first step, a plurality of flexible electrical conductors are combined to form a conductor bundle. In a second step, two end regions of the conductor bundle are pressed in such a way that a central region of the conductor bundle formed between the two end regions remains flexible. Also described is a corresponding stator.

Claims

1. A method for producing a stator for electric motors, the stator having at least one stator coil that is round using hairpin technology, and a winding head of the stator coil that is constructed from hairpin conductors in a U-shape manner, said method comprising the steps of: combining a plurality of flexible electrical conductors to form a conductor bundle; bending the plurality of flexible electrical conductors to form a curved central region and two end regions extending from opposite ends of the curved central region; and pressing the two end regions of the conductor bundle to form two pressed end regions in such a way that the curved central region of the conductor bundle formed between the two pressed end regions is not pressed and has a greater flexibility than the pressed end regions such that a pressed litz-wire hairpin having a flexible head is formed, wherein each pressed end region has a greater length than the central region, and wherein each pressed end region intersects the curved central region.

2. The method as claimed in claim 1, wherein the end regions of the conductor bundle are pressed with a supply of heat.

3. The method as claimed in claim 1, further comprising fitting at least one winding head of the stator with the pressed conductor bundles.

4. The method as claimed in claim 3, further comprising embossing the winding head against a laminated core of the stator using a winding head embossing apparatus.

5. The method as claimed in claim 4, further comprising permanently mechanically fixing the winding head during the winding head embossing step.

6. The method as claimed in claim 5, wherein the step of permanently mechanically fixing comprises cementing.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) Further details, features and advantages of the invention emerge from the drawings and from the following description of preferred embodiments with reference to the drawings.

(2) Here, the drawings illustrate merely exemplary embodiments of the invention, which do not restrict the concept of the invention.

(3) The sole FIGURE schematically illustrates a pressed litz-wire hairpin having a flexible head in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(4) The sole FIGURE schematically shows a pressed litz-wire hairpin 1 having a flexible head 4 in accordance with the present invention. The litz-wire hairpin is a conductor consisting of a composite assembly of a plurality of litz wires. The individual litz wires 2 are insulated from one another. The litz-wire hairpin 1 is designed in a U-shaped manner, that is to say the litz-wire hairpin 1 has two end regions 3a and 3b and a central subregion, the so-called head 4 of the litz-wire hairpin 1. In one preferred embodiment of the present invention, the two end regions 3a and 3b of the litz-wire hairpin 1 are pressed. The head 4 of the litz-wire hairpin is not pressed and remains flexible. Thus, the head 4 is more flexible than the end regions 3a and 3b of the litz-wire hairpin 1.