Patent ID: 6687974
Filing Date: 2004-02-10
Classification: H02K,Y10T

Abstract:
A method for manufacturing an alternator comprising:a rotor for forming north-seeking (N) and south-seeking (S) poles alternately about a rotational circumference; and a stator comprising: a stator core surrounding said rotor; and a polyphase stator winding installed in said stator core, said stator core being formed with a number of slots extending axially at a predetermined pitch in a circumferential direction, and said polyphase stator winding comprising a number of winding portions in which long strands of wire are wound such that each of the pair intercrosses each other to alternately occupy an inner layer and an outer layer in a slot depth direction within said slots at intervals of a predetermined number of slots, said strands of wire folding back outside said slots at axial end surfaces of said stator core, said number of winding portions being constructed with at least one wire-strand group formed by simultaneously bending and folding a plurality of said strands of wire, said wire-strand group being constructed by arranging at one slot pitch offset the same number of wire-strand pairs as said predetermined number of slots, each of said wire-strand pairs being constructed by arranging two strands of wire so that straight portions alternately overlap at a predetermined pitch, each of said strands of wire being formed into a pattern in which said straight portions are connected by turn portions so as to be arranged at a pitch of said predetermined number of slots and adjacent straight portions are offset so as to alternately occupy said inner layer and said outer layer in said slot depth direction, end portions of each of strands of wire respectively extending outwards at both sides of both ends of said wire-strand group, wherein said polyphase stator winding is constructed by connecting said end portions of said strands of wire which construct said wire-strand group installed in said stator core, said end portions extending outwards from said slot in both axial directions of said stator core, said method for manufacturing an alternator comprising: preparing a wire-strand group formed by bending said strands of wire so as to have straight portions which fit into said slots; forming a base core by laminating plate-shaped magnetic members formed with said slots; stacking said wire-strand group on said base core and pressing said wire-strand group such that said straight portions enter said slots; and forming said stator core by bending said base core into a cylindrical shape and abutting end surfaces of said base core.