CN118202560A

CN118202560A - Method of manufacturing a stator for a rotating electrical machine with asymmetric windings

Info

Publication number: CN118202560A
Application number: CN202280068978.4A
Authority: CN
Inventors: C·莫亚; N·朗格拉尔; S·德叙尔蒙
Original assignee: Blue Sky Co; Nedco Logo Citroen Electric Motor Co ltd
Current assignee: Blue Sky Co; Nedco Logo Citroen Electric Motor Co ltd
Priority date: 2021-10-12
Filing date: 2022-10-11
Publication date: 2024-06-14
Also published as: WO2023062313A1

Abstract

The invention relates to a method for manufacturing a stator (2) of a rotating electrical machine (1), comprising the steps of: (a) -providing a stator mass (25), the stator mass (25) comprising slots (21) arranged between teeth (23), electrical conductors (22) being accommodated in the slots (21), at least a portion of the electrical conductors being in the form of U-pins or I-pins, and wherein each comprises an inner leg (22 e) and an outer leg (22 f), at least one of the inner leg (22 e) and the outer leg (22 f) of the electrical conductor (22) being elongated outside the slots by a welded section; (b) -circumferentially offsetting the outer leg (22 f) of the electrical conductor by half a pitch relative to the inner leg (22 e); and (c) radially offsetting the outer legs (22 f) of some of the electrical conductors, in particular the outer legs of the phase input electrical conductors and/or the phase output electrical conductors, towards the outside.

Description

Method of manufacturing a stator for a rotating electrical machine with asymmetric windings

Technical Field

The present invention claims priority from french application 2110758 filed on 10/12 of 2021, the contents of which (text, figures and claims) are incorporated herein by reference.

The present invention relates to rotating electrical machines and more particularly to stators of such machines. The invention relates in particular to a manufacturing method for manufacturing the stator by means of a corresponding tool combination.

The invention relates more particularly to synchronous or asynchronous machines of the ac type. The invention relates in particular to traction or propulsion machines for electric motor vehicles (Battery electric vehicles (Battery ELECTRIC VEHICLE)) and/or Hybrid motor vehicles (Battery electric vehicles-Plug-in Hybrid electric vehicles (Hybrid ELECTRIC VEHICLE-Plug-in Hybrid ELECTRIC VEHICLE)), such as personal cars, minitrucks, vans or buses. The invention also applies to rotating electrical machines for industrial and/or energy-producing applications, in particular marine, aeronautical or wind applications.

Background

It is known to use, in order to obtain a deformation of an electrical conductor, a tool comprising teeth able to house the free end of said electrical conductor to be deformed.

A tool in the form of an arcuate sector is known in particular from application US 2014/023781. The deformation of the electrical conductor is performed on four concentric planes, each of the four concentric planes having the same number of conductors.

A tool comprising four concentric rings is also known from international application WO 2021/023623.

In applications JP2013/172575 and JP2020/110025 the tool comprises vertical fingers of different lengths.

Applications US2018/0212496 and US2018/0212499 relate to tools comprising two rings that are non-overlapping (imbriqu es). In US2018/0212499 the teeth of the ring have different widths.

There is a need to enjoy an easy-to-assemble rotating electric machine stator that allows for efficient filling of the slots while ensuring satisfactory electromagnetic performance.

There is also a need to reduce the manufacturing costs of the motor, in particular by simplifying the windings of the stator (for example by minimizing the number of parts to be used).

There is also a need to further improve the stator of the electric machine and in particular to reduce torque ripple and joule loss AC caused by induced currents, vibrations and electromagnetic noise.

Disclosure of Invention

Method of manufacture

The present invention aims to meet all or part of these needs, and according to one aspect of the present invention, the needs are achieved by a manufacturing method for manufacturing a stator of a rotating electrical machine, the manufacturing method comprising the steps of:

(a) Providing a stator mass comprising in particular a stack of magnetic metal sheets (paquet), the stator mass comprising slots arranged between the teeth, in which slots an electrical conductor is accommodated, at least a part of the electrical conductor, and even a majority of the electrical conductor, being in the form of a U-shaped pin (e pingle) or an I-shaped pin, and wherein each comprises an inner leg and an outer leg, which inner leg and outer leg extend in particular axially in a first slot a and a second slot R, respectively, at least one of the inner leg and outer leg of the electrical conductor being extended outside the slots by a welded section,

(B) Circumferentially offsetting the outer leg of the electrical conductor by half a pitch (PAS DENTAIRE) relative to the inner leg, and

(C) The inner legs or outer legs of some electrical conductors, in particular the legs of the phase input electrical conductors and/or the phase output electrical conductors, in particular the six legs, are respectively radially offset towards the inside or towards the outside.

Independently or in combination with the above, the present invention relates in particular to a manufacturing method for manufacturing a stator of a rotating electrical machine, comprising the steps of:

(a) Providing a stator mass comprising in particular a stack of magnetic metal sheets, the stator mass comprising slots arranged between the teeth, in which slots an electrical conductor is accommodated, at least a part of the electrical conductor, and even a majority of the electrical conductor, being in the form of a U-shaped pin or an I-shaped pin, and wherein each comprises an inner leg and an outer leg, which inner leg and outer leg extend in particular axially in a first slot a and a second slot R, respectively, at least one of the inner leg and the outer leg of the electrical conductor being extended outside the slot by a welded section,

(B) Circumferentially offsetting the outer leg of the electrical conductor by half a pitch relative to the inner leg, an

(C) The outer legs, in particular the six outer legs, of some of the electrical conductors, in particular the phase input electrical conductor and/or the phase output electrical conductor, are radially offset towards the outside.

(B) Circumferentially offsetting the inner leg of the electrical conductor by half a pitch relative to the outer leg, an

(C) The inner legs of some of the electrical conductors, in particular the inner legs of the phase input electrical conductors and/or the phase output electrical conductors, in particular the six inner legs, are radially offset towards the inside.

The method according to the invention makes it possible to obtain a desired inclination of the electrical conductor on the side of the welding section thereof outside the stator mass, with different inclinations for the different electrical conductors. Furthermore, the method according to the invention enables some electrical conductors, in particular phase input electrical conductors and/or phase output electrical conductors, to be radially offset. This configuration can facilitate connection of the electrical conductors with the electrical connectors of the machine.

Advantageously, the method according to the invention enables these operations to be performed without changing neither the station for the stator nor the tool nor the orientation of the stator in the station. The manufacturing method is thereby facilitated and simplified.

The positioning of the electrical conductor along an axial plane is facilitated.

The angular position of each electrical conductor can be more easily controlled.

Moreover, the number of types of electrical conductors to be introduced into the stator mass can thereby be reduced, which can facilitate the storage of the electrical conductors before they are inserted into the stator mass.

The deformation of the electrical conductor in and out of the circumferential plane can be performed by the same tool at the same station. The volume of the station can thereby be reduced.

The method according to the invention may also be able to easily add insulation between the inner and outer legs of the electrical conductor, which may be useful especially during press fitting of the stator.

During the implementation of the method according to the invention, the inner form of the chignon (which is formed by the U-shaped end of the electrical conductor) can also be supported opposite the welding section of the electrical conductor.

In the circumferential offset step (b) for circumferentially offsetting the outer leg of the electrical conductor by half a pitch relative to the inner leg, the outer leg of the electrical conductor may be deformed by half a pitch relative to the inner leg, or in a variant the inner leg may be deformed relative to the outer leg. The circumferential offset step (b) for circumferentially offsetting the inner or outer leg of the electrical conductor, in particular the outer leg of the electrical conductor, by half a pitch may comprise a seating step (b 1) for seating the two positioning rings of the inner and outer positioning ring of the electrical conductor.

The inner and outer retaining rings may be placed in position towards the stator mass just above the stack of metal sheets of the stator mass.

As described further below, the inner and outer positioning rings may include radially extending movable fingers, each of which is movable along a radial axis of the stator. During the seating step (b 1) for seating the retaining ring, the movable finger may be in a stowed position stowed in the retaining ring.

In step (b 2), the movable fingers are caused to protrude, each of the movable fingers being disposed between two consecutive electrical conductors. The movable fingers of the outer positioning ring are disposed between the outer legs of the electrical conductors and the movable fingers of the inner positioning ring are disposed between the inner electrical conductors.

The movable finger may or may not enter into contact with the electrical conductor, depending in particular on the winding. In any case, the aim is to avoid that the electrical conductor can slide between the inner and outer movable fingers.

The movable finger slides like a piston.

In step (b 3), the positioning ring is moved in translation along the longitudinal axis of the stator, in particular in translation upwards, in particular away from the stator mass. Thereby, the positioning ring is moved towards the end of the welding section. In this translational movement, the movable fingers act as a comb that enables good alignment of the electrical conductors.

In step (b 4), the outer retaining ring is rotated a given angle about the longitudinal axis of the stator. The angle may be equal to half the pitch. In this rotational movement, the movable finger is able to twist the outer leg by half a pitch relative to the inner leg.

In the radial offset step (c), phase movable fingers may be caused to protrude from the inner positioning ring, the phase movable fingers being particularly configured to have a longer radial travel than other movable fingers of the inner positioning ring.

The radial offset preferably occurs away from the longitudinal axis of the stator.

The longer radial travel of the phase moveable fingers allows the outer legs of some electrical conductors, particularly the outer legs of the phase input and/or phase output electrical conductors, to be offset radially outwardly relative to the other outer legs which remain circumferentially aligned.

These phase-movable fingers are able to offset some of the so-called phase input electrical conductors and/or phase output electrical conductors towards the outside and to place said phase input electrical conductors and/or said phase output electrical conductors on a third, in particular outermost, layer.

The radial offset towards the outside may be more or less exacerbated. The inclination of the outer leg may comprise a curved portion having a large radius of curvature or less, which results in the curved portion thereby being located closer to the stack of metal sheets.

In an embodiment, in the method according to the invention, before the phase input electrical conductor and/or the phase output electrical conductor is deformed, the length of the welded section of the outer leg of the phase input electrical conductor and/or the phase output electrical conductor may be different, in particular larger, than the length of the welded section of the outer leg of the other electrical conductor. In a variant, the lengths may be equal.

In an embodiment, the phase moveable finger is configured for pushing the phase input electrical conductor and/or the phase output electrical conductor towards the outside.

In a variant, the phase moveable finger may be configured to pull the phase input electrical conductor and/or the phase output electrical conductor towards the outside. To this end, the phase-movable fingers may include a clamp or other grasping tool. This embodiment variant can be implemented in particular by a phase input electrical conductor and/or a phase output electrical conductor which extends longitudinally beyond the other electrical conductor and is longer than the other electrical conductor.

In a further variant, in the radial offset step (c), the phase-movable fingers may be made to protrude from the outer positioning ring, the phase-movable fingers being in particular configured to have a longer radial travel than the other movable fingers of the outer positioning ring.

In this case, the radial offset occurs close to the longitudinal axis of the stator.

The longer radial travel of the phase moveable fingers allows the inner legs of some electrical conductors, particularly the inner legs of the phase input and/or phase output electrical conductors, to be offset radially inwardly relative to the other inner legs which remain circumferentially aligned.

These phase-movable fingers are able to offset some of the so-called phase input electrical conductors and/or phase output electrical conductors towards the inside and to place them on a third, in particular the innermost layer.

The radial offset towards the inside may be more or less exacerbated. The inclination of the inner leg may comprise a curved portion having a large radius of curvature or less, which results in the curved portion thereby being located closer to the stack of metal sheets.

In an embodiment, the length of the welded section of the inner leg of the phase input electrical conductor and/or the phase output electrical conductor may be different, in particular larger, than the length of the welded section of the inner leg of the other electrical conductor before the phase input electrical conductor and/or the phase output electrical conductor is deformed in the method of the invention. In a variant, the lengths may be equal.

In an embodiment, the phase moveable finger is configured for pushing the phase input electrical conductor and/or the phase output electrical conductor towards the inside.

The method may comprise the following additional step (d):

(d) The welded sections of the electrical conductor are deformed circumferentially with at least two different pitches, in particular three different pitches.

In an embodiment, the welded section of the inner leg of the electrical conductor may be deformed at a first step distance P1. At least a portion of the welded section of the outer leg of the electrical conductor may be deformed at a second step distance P2. All welded sections of the outer leg of the electrical conductor that are radially offset in step (c) may be deformed. Other welded sections of the outer leg of the electrical conductor may be deformed at a third step distance P3.

The third pitch P3 may be smaller than the first pitch P1 and the second pitch P2.

In the method according to the invention, the circumferential deformation step (d) may comprise a seating step (d 1) for seating a third deformation ring, which may be machined with tooth slots and may comprise as many slots as the stator slots. The third deformation ring can in particular deform the welded section of the inner leg of the electrical conductor at a first step distance P1.

In an embodiment, the third deformed ring includes 63 slots for a stator including 63 slots and 6 poles. The third deformation ring is capable of deforming 63 welded sections of the inner leg of the electrical conductor at a first step distance P1.

The circumferential deformation step (d) may comprise a seating step (d 2) for seating a first deformation ring, which may comprise at least one window for receiving a tab of a second deformation ring.

The first deforming ring may be machined with tooth slots and may include a number of slots equal to the number of slots of the stator from which the number of slots of the second deforming ring may be derived, as described below.

The first deformation ring can in particular deform at least a part of the welding sections of the outer leg of the electrical conductor and all the welding sections of the outer leg of the electrical conductor that are radially offset in step (c) by a second step distance P2.

In an embodiment, the first deformed ring includes 42 slots for a stator including 63 slots and 6 poles. The first deformation ring is capable of deforming 42 welded sections of the outer leg of the electrical conductor at a second step distance P2.

The first deformation ring may further comprise grooves, in particular (in the case of six welding sections radially offset in step (c)) six grooves, which also enable deformation of all welding sections of the outer leg of the electrical conductor radially offset in step (c).

The position of the slots may depend on the winding scheme of the stator.

Next, the circumferential deforming step (d) may include a seating step (d 3) for seating a second deforming ring in place.

The second deformable ring may be configured for overlapping in the first deformable ring, while being particularly configured for moving, particularly rotational, in the first deformable ring.

The second deformation ring may in particular comprise tabs, each of which is received in a window of the first deformation ring, in particular there being four windows and four tabs.

The tab is movable in the window when the second deformable ring is rotationally moved in the first deformable ring.

The second deformation ring can in particular deform further welded sections of the outer leg of the electrical conductor at a third step distance P3.

The tabs may be machined with splines.

In an embodiment, for a stator comprising 63 slots and 6 poles, the second deformed ring comprises 15 slots, said 15 slots being distributed over 4 tabs. The second deformation ring is capable of deforming the other welded sections of the outer leg of the electrical conductor at a third step distance P3.

Thereby, due to the configuration of the deformation ring, a smaller inclination angle for these electrical conductors is obtained, whereby in the manufactured stator the electrical conductors have a shorter step.

The circumferential deformation step (d) may comprise a repositioning step (d 4) for repositioning the inner and outer positioning rings towards the stator mass, in particular by a helical movement of the outer positioning ring.

The outer positioning ring may be lowered helically in order to follow the inclination of some so-called phase input and/or phase output electrical conductors arranged on the third layer, in particular the outermost layer.

The inner positioning ring may descend parallel to a longitudinal axis of the stator.

During this repositioning movement, the movable fingers of the inner and outer positioning rings may be in a stowed position.

The movable fingers may be seated in a dominant position that dominates the electrical conductor when the inner and outer locating rings are repositioned in place.

This movement enables to obtain protection of the insulator at the outlet of the tank during the next step. Thereby, maintenance of the insulation at the outlet of the groove, which is used for maintaining the groove in the circumferential deformation step (d), is improved.

The circumferential deforming step (d) may include a simultaneous rotating step (d 5) for simultaneously rotating at least two of the first, second and third deforming rings with at least two asynchronous distances.

In particular, the second deformable ring is rotatable relative to the first deformable ring.

Thereby, all welded sections of the stator are deformed simultaneously, each of the welded sections having an appropriate step pitch.

The first deformable ring and the second deformable ring may rotate in a first direction but not at the same pitch, while the third deformable ring may rotate in a second direction opposite the first direction.

After being set in rotation, the welding sections of the phase input electrical conductor and/or the phase output electrical conductor are radially aligned with the welding sections of the other electrical conductors.

In an additional step (e), the deformed ring may be removed, and then the inner and outer locating rings are also removed.

The outer positioning ring may advantageously comprise grooves, in particular six grooves, for receiving some of the phase input electrical conductors and/or phase output electrical conductors, which can avoid that the retracting movement of the outer positioning ring is prevented by the phase input electrical conductors and/or the phase output electrical conductors.

In an embodiment variant, the rotation of the first, second and third deformable rings takes place simultaneously for these three deformable rings.

In a variant, the rotation of the three deformation rings may not be performed simultaneously. The rotation may occur continuously.

In an embodiment variant, the setting of the first deformation ring in rotation can take place before the setting of the other deformation rings in rotation. The imparting of rotation may or may not occur prior to the radial offset of step (c). Thus, in an embodiment, the radial offset step (c) may occur before the circumferential offset step (b).

In an implementation variant, the positioning ring may not be configured to allow circumferential offset. The radial offset may be performed by means of a claw (griffes) as described below.

In the examples described above, the phase input electrical conductor and/or the phase output electrical conductor is pushed towards the outside. In a variant, the phase input electrical conductor and/or the phase output electrical conductor may be pulled towards the outside (e.g. by means of a clamp or other gripping tool, such as a separate jaw). The jaws may be configured to allow outward deformation of the welding segments. This embodiment variant can be implemented in particular by a phase input electrical conductor and/or a phase output electrical conductor which extends longitudinally beyond the other electrical conductor and is longer than the other electrical conductor.

In a further variant, the phase input electrical conductor and/or the phase output electrical conductor may be pushed towards the inside. In this case, the inner legs of the electrical conductors are offset circumferentially by half a tooth distance relative to the outer legs, and then the inner legs of some electrical conductors, in particular the inner legs of the phase input electrical conductors and/or the phase output electrical conductors, in particular the six inner legs, are offset radially towards the inside.

Such a configuration may generally be able to improve accessibility of the tool set. Moreover, this configuration may be able to avoid the use of an inner ring with movable fingers, since the accessibility from the outside is complete. Finally, this configuration can achieve more excellent compactness and thus can reduce the raw materials required for the connector when it is desired to position the connector on a large diameter stator.

At least one electrical conductor, and even a majority of the electrical conductors, introduced into the slot take the form of a U-shaped pin. The electrical conductor may be formed into a pin prior to introduction into the slot. All electrical conductors in the form of U-pins may be shaped simultaneously or consecutively and then introduced into the stator mass simultaneously or consecutively.

The shaping may comprise a first assembly step for assembling strands of the same electrical conductor.

The same electrical conductor in the form of a U can be arranged in two different slots of the stator mass of the stator, which are not connected. In case the electrical conductor takes the form of a U, it can be welded with two other electrical conductors on the same side of the machine.

Combination of two or more kinds of materials

The invention also relates to a tool combination, in particular for producing a stator of a rotating electrical machine, for carrying out the method described above.

Independently or in combination with the above, the invention also relates to a tool combination, in particular for manufacturing a stator of a rotating electrical machine, in particular for carrying out the method as described above, and comprising: a plurality of deformation rings, in particular three deformation rings, a second deformation ring of the plurality of deformation rings being configured for overlapping in a first deformation ring, while in particular being configured for movement, in particular rotational movement, in the first deformation ring.

The first deformable ring may include at least one window for receiving a tab of the second deformable ring. The first deformable ring may in particular comprise four windows. The second deformation ring may in particular comprise four tabs.

The one or more windows of the first deformable ring may have a longer circumferential extension than the one or more tabs of the second deformable ring, which may allow the second deformable ring to move, in particular rotationally move, in the first deformable ring.

The plurality of deformed rings may include a third deformed ring, which may include regular notches, all regularly distributed over the circumference of the third deformed ring.

The deformation ring takes a circular form. The deformation ring is not in particular manufactured in a separate industry.

The deformed ring may be manufactured, for example, by machining or by molding, but also by additive manufacturing, known as 3D printing.

Each of the deformation rings may include a longitudinal slot for receiving a welding section of the electrical conductor.

Each welding section of the electrical conductor may be received in a notch of one of the deformation rings. Each slot may receive a single welded section of the electrical conductor.

One or more tabs of the second deformable ring may be machined with a spline.

The different deformation rings may be concentric about the longitudinal axis of the stator. In embodiments, each deformation ring may include a different number of notches.

For example, the deformation ring, in particular the third deformation ring, may comprise as many notches as slots of the stator.

For example, the deformation ring, in particular the second deformation ring, may comprise a number of slots smaller than the number of slots of the stator, for example equal to 15.

For example, the deformation ring, in particular the first deformation ring, may comprise a number of slots equal to the number of slots of the stator, from which the number of slots of the second deformation ring is derived.

All slots of the first deformable ring may have the same circumferential width and/or the same height and/or the same radial depth along the longitudinal axis of the stator.

All slots of the second deformable ring may have the same circumferential width and/or the same height and/or the same radial depth along the longitudinal axis of the stator.

All slots of the third deformable ring may have the same circumferential width and/or the same height and/or the same radial depth along the longitudinal axis of the stator.

The combination may include at least one outer locating ring of the electrical conductor, the outer locating ring including a plurality of movable fingers.

The movable fingers extend radially, each of the movable fingers being movable along a radial axis of the stator.

The outer retaining ring may include as many movable fingers as teeth of the stator.

The movable finger may take on a conical form, in particular with a chamfered end and/or a radial end.

The movable finger is movable between a stowed position and a dominant position that dominates the electrical conductor. The movable finger is slidable like a piston in the outer positioning ring.

In the stowed position, the movable fingers do not interfere with movement of the outer retaining ring relative to the stator. In particular, the outer positioning ring is translationally movable along the longitudinal axis of the stator.

In the dominant position, each of the movable fingers is inserted between two consecutive electrical conductors. The movable fingers may be capable of facilitating alignment of the electrical conductors, particularly during translational movement of the outer locating ring along the longitudinal axis of the stator. Moreover, the movable finger may allow torsional deformation of the electrical conductor, especially over a circumferential distance of half a tooth pitch.

In an embodiment, all the movable fingers of the outer positioning ring may be identical to each other.

The outer retaining ring may comprise slots, in particular six slots, for receiving some of the phase input electrical conductors and/or phase output electrical conductors.

These slots may allow the phase input electrical conductor and/or the phase output electrical conductor to be disposed on a third layer, in particular the outermost layer.

In an embodiment, the outer locating ring comprises six slots, each of which may receive a phase input electrical conductor and/or a phase output electrical conductor.

Each of some or all of the movable fingers of the outer locating ring may include a shoulder that may be capable of wedging the electrical conductor.

In particular, the movable finger present at the above-mentioned slot position may comprise such a shoulder.

The shoulder may allow for maintenance of the electrical conductor and maintenance of an insulator of the electrical conductor.

The shoulder may be capable of facilitating maintenance of an optional insulator disposed on the electrical conductor and allowing protection of the insulator.

The combination may include at least one inner positioning ring of the electrical conductor, the inner positioning ring including a plurality of movable fingers.

The inner positioning ring may include as many movable fingers as teeth of the stator.

The movable finger may be cylindrical (especially with a chamfered end and/or a radial end).

The movable finger is movable between a stowed position and a dominant position that dominates the electrical conductor. The movable finger is slidable like a piston in the inner positioning ring.

In the stowed position, the movable fingers do not interfere with movement of the inner positioning ring relative to the stator. In particular, the positioning ring is translationally movable along the longitudinal axis of the stator.

In the dominant position, each of the movable fingers is inserted between two consecutive electrical conductors. The movable fingers may be capable of facilitating alignment of the electrical conductors, particularly during translational movement of the positioning ring along the longitudinal axis of the stator. Moreover, the movable finger may allow torsional deformation of the electrical conductor, especially over a circumferential distance of half a tooth pitch.

The inner ring may have the form of a disc.

The movable fingers of the inner positioning ring may comprise phase movable fingers, in particular four or six phase movable fingers, which are configured to have a longer radial travel than the other movable fingers.

These phase-movable fingers are able to offset some of the so-called phase input electrical conductors and/or phase output electrical conductors towards the outside or towards the inside and to place said phase input electrical conductors and/or said phase output electrical conductors on a third layer, in particular the outermost layer.

Thus, the positioning ring may comprise movable fingers with two possible radial strokes, a shorter radial stroke for most of the movable fingers and a longer radial stroke for some of the movable fingers, in particular six of the movable fingers.

The combination may be configured such that the outer locating ring and the inner locating ring are movable relative to the stator from top to bottom and bottom to top along a longitudinal axis of the stator.

Moreover, the combination may be configured such that the outer positioning ring and the inner positioning ring are rotationally movable relative to each other. In particular, one of the two rings may be rotationally movable relative to the other and relative to the stator, while the other ring may remain stationary relative to the stator. In an embodiment, the outer positioning ring is configured for rotational movement relative to the inner positioning ring and relative to the stator, while the inner positioning ring may remain stationary relative to the stator.

The tool assembly includes a simple form of ring configured to have simple kinematics.

In an implementation variant, the combination may not be equipped with an inner positioning ring. The combination may include only the outer retaining ring.

Stator

The invention also relates to a stator of a rotating electrical machine obtained by implementing the method as described above.

Independently or in combination with the above, the invention also relates to a stator of a rotating electrical machine, the stator comprising a stator mass comprising slots arranged between teeth, in which slots an electrical conductor is accommodated, at least a part of the electrical conductor, and even a majority of the electrical conductor, being in the form of a U-shaped pin or an I-shaped pin, and wherein each comprises an inner leg and an outer leg, which extend axially in a first slot A and a second slot R, respectively, at least one of the inner leg and the outer leg of the electrical conductor extending outside the slot by a welding section, which is inclined with respect to a plane perpendicular to the longitudinal axis of the stator, to be cantilevered circumferentially above the stator mass at the location of a slot or tooth, which slot or tooth is separated from the first slot A or the second slot R by a number of N1 and/or N2 of teeth, respectively,

At least a portion, and even a majority, of the electrical conductors each have a weld section that is innermost with respect to the longitudinal axis of the stator, more preferably all of the electrical conductors each have a weld section that is innermost with respect to the longitudinal axis of the stator,

At least a portion, and even a majority, of the electrical conductors each have an outermost weld section with respect to the longitudinal axis of the stator, more preferably all of the electrical conductors each have an outermost weld section with respect to the longitudinal axis of the stator,

The innermost or outermost weld segment is inclined at the same inclination with respect to a plane perpendicular to the longitudinal axis of the stator,

The other of the outermost or innermost weld segments of the electrical conductor is inclined at least two or even three or four different inclinations with respect to a plane perpendicular to the longitudinal axis of the stator,

At least one welding section of the phase input electrical conductor and/or the phase output electrical conductor is radially aligned with a welding section of the other electrical conductor.

Independently or in combination with the above, the invention also relates to a stator of a rotating electrical machine, in particular obtained by implementing a method as described above, comprising a stator mass comprising slots arranged between teeth, in which slots an electrical conductor is accommodated, at least part of the electrical conductor, and even most of the electrical conductor, being in the form of a U-shaped pin or an I-shaped pin, and wherein each comprises an inner leg and an outer leg, in particular extending axially in a first slot A and a second slot R, respectively, at least one of the inner leg and the outer leg of the electrical conductor being elongated outside the slot by a welding section, the welding section being inclined with respect to a plane perpendicular to the longitudinal axis of the stator so as to be circumferentially cantilevered over the stator mass at a slot or tooth position, which slot or tooth is separated from the first slot A or the second slot R by a number of N1 and/or N2 teeth, respectively,

The innermost weld segment is inclined at the same inclination with respect to a plane perpendicular to the longitudinal axis of the stator,

The outermost welded section of the electrical conductor is inclined at least two, even three or four different inclinations with respect to a plane perpendicular to the longitudinal axis of the stator.

Each welding section of the phase input electrical conductor may be radially aligned with a welding section of another electrical conductor.

In particular, the welding section of the phase input electrical conductor may not be offset by half a tooth with respect to the welding sections of the other electrical conductors.

The welding sections of the electrical conductors may be arranged in a plurality of layers, in particular three layers, with respect to the longitudinal axis of the stator, at least two layers comprising a different number of electrical conductor welding sections.

The electrical conductor welding sections of the different layers are concentric about the longitudinal axis of the stator.

In embodiments, each layer may include a different number of electrical conductor welding segments.

For example, the layers, in particular the innermost layer, may comprise as many welded sections as slots of the stator.

For example, the layers, in particular the outermost layer, may comprise a number of welded sections equal to twice the number of phases of the windings of the stator.

For example, a layer, particularly an intermediate layer disposed between the innermost layer and the outermost layer, may include a number of welded sections equal to a number of slots of the stator from which twice a number of phases of a winding of the stator is derived (e.g., six in the case where the winding is three-phase).

Thereby, the welding sections of the electrical conductors are well aligned with each other, which may facilitate welding of the electrical conductors and may simplify manufacturing of the stator.

The number of layers may be different from 4, for example.

The numbers N1 and N2 may be equal or different.

The first and second grooves a, R are separated by a number Nd of teeth.

The number of teeth Nd is preferably the same for all electrical conductors of the stator in the form of U-pins. It can also be said that in the present invention the number of steps Nd of the electrical conductor is the same for all electrical conductors of the stator in the form of U-pins. Thereby facilitating the manufacture of the U-shaped pin and simplifying the positioning step for positioning the U-shaped pin in the stator mass, in particular the insertion of the U-shaped pin.

In view of the constant spacing between the legs of all electrical conductors, the present invention enables to reduce the height of the chignons on the side opposite to the weld, which is advantageous in minimizing the volume of the machine and the amount of material (in particular copper) required for the electrical conductors. Hereby, a more optimal compactness of the stator (including when the stator is assembled) and thus of the machine produced (which may be especially shorter) is obtained. The shaft of the rotor may be shorter and the housing may be shorter, the integration of the machine in its environment of use may be facilitated. Finally, the total mass of the machine may be minimized.

On the other hand, the spacing between each of the chignons is more regular, which may enable to minimize the risk of contact with each other and thus to eliminate the covering step for covering the chignons by an insulator.

In addition, the present invention can reduce the number of pin-shaped pieces to be used in the same stator. Thereby, the manufacturing of the stator can be accelerated by fewer manufacturing steps. This simplifies the manufacture, the space required and the tools to be used.

Finally, the invention makes it possible to free up the space on both sides of the pin at the outlet of the slot, which makes it possible to locate in this space, in particular on the side of the stator where the yoke is located, the connection to the other connection or to the inverter. In embodiments, the space between the pins at the outlet of the slot may be constant or substantially constant. This may facilitate the implementation of the welding on the one hand and the cooling of the electrical conductor on the other hand.

In the present invention, N1 may vary from Nd/2-0.5 to Nd teeth, and N2 may vary from 0 to Nd/2+1.5 teeth.

In an embodiment, N1 is equal to Nd or nd+1, and N2 is equal to 0 or 1.

In another embodiment, N1 and N2 are equal or nearly equal. Each of N1 and N2 may be equal to one of Nd/2 or Nd/2+0.5 or Nd/2-0.5 or Nd/2+/-1 or Nd/2+1.5.

Hereinafter, the outer and inner legs of the electrical conductor may be denoted as the terms "first and second leg".

In an embodiment, the welded section of the second leg of the electrical conductor is aligned with the second leg. In this case, N2 is zero.

In other cases where N2 is non-zero, each of the first and second legs of the electrical conductor may be elongated outside the slot by a weld section that is inclined relative to a plane perpendicular to the longitudinal axis of the stator to overhang the stator mass circumferentially at a slot or tooth position, the slot being separated from the first or second slot a or R by a number N1 and N2 of teeth, respectively, the numbers N1 and N2 may be equal or different.

The compactness of the stator can be further improved when N1 and N2 are equal or almost equal.

The two welded sections of each of the first and second legs of the electrical conductor may be oriented away from each other, which may be especially the case when the winding is a wave winding. In a variant, the electrical conductors may be oriented in the same direction, which may be especially the case when the windings are series windings.

According to a further aspect thereof, the invention also relates to a stator of a rotating electrical machine, comprising a stator mass comprising slots in which electrical conductors are accommodated, at least a part of the electrical conductors, and even a majority of the electrical conductors, being in the form of U-pins, and wherein each comprises a first leg and a second leg extending axially in a first slot a and a second slot R, respectively, the first slot a and the second slot R being separated by a number Np of slots. The number of slots Np is the same for all electrical conductors of the stator in the form of U-pins.

It can also be said that in the present invention the number Np of steps of the electrical conductor is the same for all electrical conductors of the stator in the form of U-pins. Thereby facilitating the manufacture of the U-shaped pin and simplifying the positioning step for positioning the U-shaped pin in the stator mass, in particular the insertion of the U-shaped pin.

At least one of the first and second legs of the electrical conductor may be elongated outside the slot by a welding section that is inclined with respect to a plane perpendicular to the longitudinal axis of the stator to overhang the stator mass circumferentially at the slot location, the slot being separated from the first slot a or the second slot R by a number N1 and/or N2 of teeth, respectively. The numbers N1 and N2 may be equal or different.

In an embodiment, N1 may vary from Np/2-0.5 to Np slots, and N2 may vary from 0 to Np/2+0.5 slots. In an embodiment, N1 is equal to Np and N2 is equal to 0. In another embodiment, N1 and N2 are equal and equal to Np/2 or Np/2+0.5 or Np/2-0.5.

In other cases where N2 is non-zero, each of the first and second legs of the electrical conductor may be elongated outside the slot by a weld section that is inclined relative to a plane perpendicular to the longitudinal axis of the stator to overhang the stator mass circumferentially at the slot location, the slot being separated from the first or second slot a or R by a number N1 and N2 of teeth, respectively, the numbers N1 and N2 may be equal or different.

Pin leg

At least a portion, and even a majority, of the electrical conductors each have a weld section that is innermost relative to the longitudinal axis of the stator, more preferably all of the electrical conductors each have a weld section that is innermost relative to the longitudinal axis of the stator.

At least a portion, and even a majority, of the electrical conductors each have an outermost weld section relative to the longitudinal axis of the stator, more preferably all of the electrical conductors each have an outermost weld section relative to the longitudinal axis of the stator.

The inner section is arranged closer to the rotor than the outer section.

In the present invention, the innermost weld zone is inclined at the same inclination with respect to a plane perpendicular to the longitudinal axis of the stator. These innermost weld segments all extend parallel to each other.

As regards the outermost welding sections, it is not necessary that all of them are inclined at the same inclination with respect to a plane perpendicular to the longitudinal axis of the stator. The outermost weld section may be inclined at least two, and even three or four, different inclinations relative to a plane perpendicular to the longitudinal axis of the stator.

In an embodiment, the outermost welding section of the electrical conductor is inclined with respect to a plane perpendicular to the longitudinal axis of the stator with at least two, even three or four different inclinations.

The first leg may be disposed closer to the rotor than the second leg. May be referred to as an inner leg. The second leg may be disposed closer to a yoke of the stator than the first leg. May be referred to as the outer leg.

In a variation, the first leg may be disposed closer to a yoke of the stator than the second leg, and the second leg may be disposed closer to the rotor than the first leg.

At least a portion of the electrical conductors may have a second leg that is elongated out of the slot by a welding section that extends along the same radial plane as, or even is aligned with, the second leg. When only the first leg of the electrical conductor has an inclined welding section, the manufacture of the stator is thereby facilitated, since the tilting operation of the pin can be simplified and accelerated. In this configuration, only one of the legs of the electrical conductor is inclined so as to make it possible to limit thereby the deformations and stresses on the electrical conductor. In particular, the risk of electrical contact between the phases of the windings of the stator can thereby be reduced.

In an embodiment, only the first leg of the electrical conductor has an inclined welding section. The welded section of the second leg may be aligned with the second leg while extending in an extension of the second leg and forming a straight line with the second leg. When only a first leg of the electrical conductor has an inclined welding section, the first leg may be arranged closer to the rotor than the second leg. In a variation, the first inclined leg may be disposed closer to a yoke of the stator than the second leg.

At least a portion of the electrical conductors may have a second leg that is elongated outside the slot by a welding section that forms a kink (d crochement) with respect to the slot while extending along the same radial plane as the second leg. Kinking of the electrical conductor may be able to reach the metallic elements of the phase connector. The metallic element may be arranged radially outwardly with respect to the electrical conductor to which it is connected.

At least a portion of the electrical conductors may have a second leg that is elongated out of the slot by a circumferentially extending weld section.

At least a portion of the electrical conductors may have a second leg that is elongated out of the groove by a welding section that extends out of the circumferential surface. These welded sections outside the circumferential surface may be able to reach a phase connector which may be arranged around the welded sections, rather than above, compared to the longitudinal axis of the stator.

The stator may include two electrical conductors per slot.

The electrical conductor may form a distributed winding. The windings may be wave windings or series windings. The electrical conductor may form a fractional slot winding. The windings may be full-step. In an embodiment, the winding may have a shortened step size.

Multiphase winding

The electrical conductors housed in the slots may form a multiphase winding having at least a first phase a, the input electrical conductor a of which is located in a first slot (slot number 1), and a second phase b, one or more electrical conductors of which are located in a second slot (slot number 2), which immediately follows the first slot when moving circumferentially around the axis of rotation of the machine in the direction of passage of the current around the axis of rotation of the machine.

In this case, the input electrical conductor of the first phase is located in the first slot and just before the second slot (for receiving the electrical conductor or conductors of the second phase) when moving circumferentially around the rotational axis of the machine in the direction of passage of the current around the rotational axis of the machine.

Whereby the input electrical conductor of the first phase is located in a position opposite to the usual position, i.e. in which a first slot (for receiving the input electrical conductor of the first phase) is followed by a second slot (for receiving one or more electrical conductors of the same first phase) when moving circumferentially around the rotational axis of the machine in the direction of passage of the current flow around the rotational axis of the machine.

The input slot of the first phase is followed by a slot (for receiving an electrical conductor of a second phase different from the first phase).

Thereby, the number of slots between the in-phase input and output electrical conductors is reduced. The first input slot of a phase may be close to the third output slot having the same phase. In other words, the number of slots (of the first input slot for separating the phase and the third output slot for the same phase) may be smaller. Thus, the implementation of the invention enables to reduce the pitch of the electrical conductors (for connecting the different winding tracks advancing in the same direction around the rotation axis of the machine) and the average length of each phase measured circumferentially around the rotation axis of the machine (due to the better overlap of the sub-members of the electrical conductors constituting the winding). Shortening the average length of the phases can improve the linear resistance and thermal properties and can reduce the required copper mass.

A bun head with a lower height on the side opposite the weld can also be obtained for the electrical conductor. The amount of copper required for the manufacture of the conductor is thus reduced, which is economically advantageous. Furthermore, the insertion of the electrical conductor in the slot may be facilitated.

In addition, the output electrical conductor of the first phase may be located in a first slot, and the one or more electrical conductors of the second phase are located in a second slot immediately following the first slot when moving circumferentially around the axis of rotation of the machine in the direction of passage of the current around the axis of rotation of the machine.

The output electrical conductor of the first phase is located in a first slot immediately before a second slot (for receiving one or more electrical conductors of the second phase) when moving circumferentially around the axis of rotation of the machine in a direction of passage of the current around the axis of rotation of the machine.

Whereby the output electrical conductor of the first phase is located in a position opposite to the usual position, i.e. in which the first slot (for receiving the output electrical conductor of the first phase) is followed by the second slot (for receiving the electrical conductor or conductors of the same first phase) when moving circumferentially around the rotational axis of the machine in the direction of passage of the current flow around the rotational axis of the machine.

The output slot of the first phase may be followed by a slot (for receiving an electrical conductor of a second phase different from the first phase).

The phase inputs may be offset by an angle of, for example, 30 °, 60 °,90 °, or 120 °.

The second slot may include one or more electrical conductors that are only in phase.

The first input slot of the first phase may include one or more electrical conductors of only the first phase.

In a variation, the first input slot of the first phase may include one or more electrical conductors of the first phase and one or more electrical conductors of the second phase. The one or more electrical conductors of the first phase may be arranged on the side of the yoke or in a variant on the side of the air gap. The one or more electrical conductors of the second phase may be arranged on the side of the air gap or in a variant on the side of the yoke. The phase input and the phase output can be arranged on the side of the yoke or in a variant on the side of the air gap.

At least one first electrical conductor received in the first slot may be electrically coupled with a second electrical conductor received in the second slot at an outlet of the slot.

All electrical conductors having free ends located at the same circumferential position around the axis of rotation of the machine can be electrically coupled together regardless of their radial position.

The stator may include a phase connector including a metal element connected to an electrical conductor of the stator. The metallic element may be arranged radially outward or inward with respect to the electrical conductor to which it is connected. The metal elements connected to the conductors of the windings of the stator may be maintained by an insulator support. In addition, the connector may have a connection tab for connection to a power bus. The machine may thereby be coupled with an inverter, which is electrically connected with the connection tab of the connector.

At least, and even a substantial portion of the electrical conductors may take the form of U-shaped pins or I-shaped pins. The pin may take the form of a U (U-pin in English) or straight while taking the form of an I (I-pin in English).

In an embodiment, all electrical conductors take the form of a U. In a variant, all electrical conductors take the form of an I-shape.

The electrical conductor, which is in the form of a pin and flat, enables an increase in the slot filling rate while making the machine more compact. Due to the higher filling rate, the heat exchange between the electrical conductor and the stator mass is improved, which enables to reduce the temperature of the electrical conductor inside the slot.

Moreover, the manufacture of the stator may be facilitated due to the electrical conductor in the form of a pin. Finally, the pin need not have an open slot, but may have a closed slot that is able to grip the pin and may therefore eliminate the stator shim insertion step.

The electrical conductor, and even a majority of the electrical conductor, extends axially in the slot. The electrical conductor may be introduced into the corresponding slot from one or both of the two axial ends of the machine.

An electrical conductor in the form of an I has two axial ends, each of which is disposed at one of the axial ends of the stator. The electrical conductor passes through a single slot and is weldable with two other electrical conductors at an axial end position of the stator and at each of the axial ends of the electrical conductor. The stator may for example comprise 6, 10, 12, 14, 18, 22 or 26 electrical conductors in the form of an I-shape, the other electrical conductors may all take the form of a U.

The stator may not be equipped with an electrical conductor in the form of an I-shape.

The electrical conductor in the form of a U has two axial ends, both of which are arranged at one of the axial ends of the stator. The two axial ends are defined by the two legs of the U. The electrical conductor passes in these two different slots and may be welded with two other electrical conductors at the same axial side position of the stator and at each of the axial ends of the electrical conductor. The bottom of the U (that is to say, the side of the U forming the winding, the chignon or the head) is arranged on the other axial side of the stator.

At least a portion of the electrical conductors, and even a majority of the electrical conductors, may take the form of U-pins.

Moreover, the volume of the electrical conductor at the head position of the winding is reduced. This facilitates the overlapping of the electrical conductors.

The windings may not be provided with U-pins of a width different from Np. In some embodiments of the prior art, there are at least three U-shaped pins having different widths. The width of the U-shaped pin is equal to the number of pitches +1. The width of the U-shaped pin is defined as the number of slots (for separating the first and second legs of the U-shaped pin), including two slots (for receiving the two legs of the U-shaped pin in question). The first leg and the second leg may be separated by a number of slots (e.g., 6, 7, 8, 9, or 10 or 11 slots) between 3 and 20, more preferably between 6 and 16.

Strand wire

In the present invention, each electrical conductor may comprise one or more strands (in english "wire" or "strand"). "strand" is understood to be the most basic unit for electrical conduction. The strands may have a circular cross-section (which may thus be referred to as "strands") or be flat. The flat strands may be shaped, for example, to form U-shaped pins or I-shaped pins. Each strand is covered with an insulating glaze.

Each slot may comprise a plurality of conductors and/or a plurality of strands, which fact enables to minimize losses (or AC joule losses) caused by the induced current, which evolve with the square of the supply frequency, which is particularly advantageous at high frequencies and when the operating speed is high. Heat transfer towards the cold source is also facilitated. Whereby a better efficiency can be obtained at high speed.

When the grooves are closed, a reduction in leakage flux observed from the conductor is obtained, which results in a reduction of losses in the strand caused by foucault currents.

In an embodiment, each electrical conductor may comprise a plurality of pins, each of which forms a strand, as mentioned above. All strands of the same electrical conductor may be electrically coupled to each other at the outlet of the slot. The strands electrically coupled to each other are arranged in a short-circuited state. The number of strands electrically coupled together may be greater than or equal to 2 (e.g., between 2 and 12), such as 3, 4, 6, or 8 strands.

Multiple strands may form the same electrical conductor. The same current in phase flows through all strands of the same electrical conductor. All strands of the same electrical conductor may be electrically coupled to each other, in particular at the outlet of the slot. All strands of the same electrical conductor may be electrically coupled to each other, in particular at the outlet of the groove and at each of the two axial ends of the electrical conductor. The strands may be electrically coupled in parallel.

All strands of all electrical conductors having free ends at the same circumferential position around the rotational axis of the machine can be electrically coupled to each other regardless of their radial position.

In an embodiment, each electrical conductor comprises only one strand. In another embodiment, each electrical conductor comprises three strands.

In case the groove comprises two electrical conductors, the groove may thus accommodate two strands (or in a variant, six strands), for example distributed between the two electrical conductors.

In a variant, the slot comprises four electrical conductors. Each electrical conductor may comprise two strands. The groove thereby accommodates eight strands, which are distributed between the four electrical conductors.

The strands may be positioned in the grooves such that a circumferential dimension of the strands about a rotational axis of the machine is greater than a radial dimension of the strands. This arrangement can reduce losses caused by foucault currents in the strands.

The strands may have a width of between 1mm and 5mm (e.g., about 2.5mm or 3 mm). The width of the strand is defined as the dimension of the strand in the circumferential direction around the axis of rotation of the machine.

The strands may have a height of between 1mm and 5mm (e.g., about 1.6mm or 1.8 mm). The height of the strands is defined as the thickness of the strands in the radial dimension.

The electrical conductor may be made of copper or aluminum.

Winding

The windings are made up of several (m) phases offset in space so that a rotating field is generated when the phases are supplied by a multiphase current system.

The electrical conductor may form a single winding (in particular with an integer step or a fractional step). By "single winding" is understood that the electrical conductors are electrically coupled together in the stator and that the connection between the phases is implemented in the stator (e.g. in a terminal box) rather than outside the stator.

The electrical conductor may form a distributed winding. The windings are not concentrated or wound on teeth.

The windings may be full-step. Each slot accommodates only electrical conductors of the same phase and/or the width of the electrical conductors is equal to the number of slots divided by the number of poles.

In a variant, the winding may have a shortened step. The slots may receive electrical conductors that are not in phase. In an embodiment, at least one slot accommodates an electrical conductor of the first phase and an electrical conductor of the second phase, and/or a majority of the electrical conductors have a width less than the number of slots divided by the number of poles.

In the present invention, the winding is an integer slot winding or a fractional slot winding. The windings may be integer slot windings with or without shortening of the step size or fractional slot windings in variations. In an embodiment, the electrical conductor forms a fractional-slot winding.

For fractional slot windings, the number of slots per pole per phase is fractional, that is, the ratio q defined by q=ne/(2 pm) is written in the form of an irreducible fraction z/n, z and n being two non-zero integers, n being different from 1, where Ne is the number of stator slots, m is the number of winding phases, and p is the number of stator pole pairs.

The number of stator slots may be between 18 and 96, more preferably between 30 and 84 (e.g., 18, 24, 27, 30, 36, 42, 45, 48, 54, 60, 63, 72, 78, 81, 92, 96, more preferably, 60 or 63). The number of poles of the stator may be between 2 and 24, even between 4 and 12 (e.g., 6 or 8).

The combination of stator slot number/stator pole number may be selected from the following list of combinations without limitation: 30/4, 42/4, 45/6, 48/8, 63/6, 60/8, 78/8, 84/8.

In an embodiment, the combination of the number of stator slots/the number of stator poles is 60/8. In this case, q=60/(2×4×3) =5/2 is obtained.

In an embodiment, the combination of the number of stator slots/number of stator pole pairs is 63/6. In this case, q=63/(2×3×3) =7/2 is obtained.

More broadly, for a three-phase winding, the combination between the number of stator slots Ne and the number of stator pole pairs p may be one of the combinations labeled in table 1.

[ Table 1]

In this case, the number of phases is three, but it does not depart from the scope of the invention when the number of phases is different, for example two (the machine thus comprises two-phase windings), or for example 5, 6, 7, 9, 11 or 13. The winding is a multi-phase winding.

The series arrangement of the electrical conductors may be implemented as a so-called wave winding or as a so-called series winding.

A "wave winding (bobinage ondul e)" is understood to be a winding in which the same-pole and same-phase electrical conductors are electrically coupled to one another in such a way that, for a winding track, the phase current always flows in only one direction in the electrical conductor which rotates about the axis of rotation of the machine. For a wound track, the same and in-phase electrical conductors do not overlap when viewed perpendicular to the axis of rotation of the machine.

By "series winding (bobinage en serie)" is understood a winding in which electrical conductors of the same polarity and phase are electrically coupled to each other such that the current of the phase circulates alternately in one direction and then in the other in the electrical conductors rotating about the axis of rotation of the machine. For a wound track, the same and in-phase electrical conductors overlap when viewed perpendicular to the axis of rotation of the machine.

The winding may comprise only one winding track or a plurality of winding tracks. The current in phase through the winding track flows in the "electrical conductor". By "winding track" is understood all the electrical conductors of the machine through which the same current in phase flows. These electrical conductors may be connected in series or parallel or both with each other. In the case where there is only one track, the electrical conductors are connected in series. In the case where there are a plurality of tracks, the electrical conductors of each track are connected in series, and the tracks are connected in parallel.

At least one first electrical conductor (which is received in a first slot) may be electrically coupled with a second electrical conductor (which is received in a second slot) at an outlet of the slot.

By "electrical connection" is understood any type of electrical connection, in particular by welding using different possible welding methods (in particular laser, induction, friction, ultrasound, vibration or soldering) or by mechanical clamping (in particular, for example, by embedding, screwing or riveting). The welding step may be carried out by means of a heat source, in particular a laser or an arc, for example an arc generated by means of a tungsten electrode. The welding method using the tungsten electrode may be TIG welding (english "Tungsten Inert Gas (tungsten inert gas)"). In this welding method, an arc is generated based on a tungsten electrode and plasma. The use of a heat source enables melting of the free ends of the strands to be performed without degrading assembly of the strands of one or more electrical conductors. The same weld may be performed using only one heat source. In a variation, the same weld may be performed using multiple heat sources.

The first and second electrical conductors may be electrically coupled at the outlet of the slots, that is, an electrical connection is formed on the electrical conductors at the axial ends of the stator mass just after the electrical conductors are disengaged from both slots. The electrical connection may be implemented in a plane perpendicular to the rotational axis of the machine. The plane of the electrical connection may be about 30mm to 70mm (more preferably about 40mm to 60 mm) away from the stator mass.

The electrical conductors may be distributed in the slots. "distributed" is to be understood as meaning that each of the outgoing electrical conductor and the return electrical conductor is accommodated in a different, non-consecutive slot. At least one of the electrical conductors may pass continuously through two slots that are not consecutive.

The electrical conductors may be arranged in rows in the slots. By "row" is understood that the electrical conductors are not arranged in a cluttered manner but rather in an orderly manner in the slots. The electrical conductors are stacked in the slots in a non-random manner, for example, in rows of electrical conductors aligned in a radial direction.

The electrical conductor may have a substantially rectangular cross-section, in particular with rounded edges. The circumferential dimension of the electrical conductor may substantially correspond to the width of the slot. Thus, the slot may comprise only one electrical conductor in its width. The width of the groove is measured along a circumferential dimension about the rotational axis of the machine.

The electrical conductors may be adjacent to each other by their broad sides (also referred to as flat sides).

Optimization of the stack may enable a greater number of electrical conductors to be arranged in the slots.

The stator may include a sensor (e.g., a thermocouple) for measuring the temperature of the electrical conductor. The sensor may be arranged in the groove or in a variant at the location of the weld.

At least one, and more preferably all, of the teeth may be generally trapezoidal in cross-section. At least one tooth, and more preferably all teeth, may have edges that diverge away from the axis of rotation of the machine.

The stator mass may be made of a stack of metal plates. The teeth are coupled to each other by a material bridge and on the opposite side by a yoke. The closed channel can be implemented entirely by cutting in the metal plate. Each metal plate in the stack of metal plates may be unitary.

Each metal plate is cut out of, for example, a magnetic steel sheet or a sheet containing magnetic steel (for example, steel having a thickness of 0.1mm to 1.5 mm). The metal plates may be covered with an electrically insulating varnish on opposite sides of the metal plates before they are assembled in the stack. Electrical insulation can also be obtained by heat treatment of the metal plate when required.

In a variant, the stator mass may be manufactured based on compacted or bonded magnetic powder.

Machine and rotor

The invention also relates to a rotating electrical machine (e.g. a synchronous engine or a synchronous generator) comprising a stator as defined above. The machine may be synchronous or asynchronous. The machine may be magneto-resistive. The machine may constitute a synchronous engine.

The maximum rotational speed of the machine may be relatively high, for example greater than 10000tr/min, more preferably greater than 12000tr/min (for example about 14000tr/min to 15000tr/min, even 20000tr/min or 25000 tr/min). The maximum rotational speed of the machine may be less than 100000tr/min, even less than 60000tr/min, more even less than 40000tr/min, more preferably less than 30000tr/min.

The rotating electrical machine may include a rotor. The rotor may be permanent magnet type with either surface magnets or embedded magnets. The rotor may be flux-centralized. The rotor may comprise one or more magnet layers arranged in an I-shape, a U-shape or a V-shape. In a variant, the rotor may involve a wound rotor or a squirrel cage rotor or a variable reluctance rotor.

The diameter of the rotor may be less than 400mm, more preferably less than 300mm, and more preferably greater than 50mm, more preferably greater than 70mm (e.g. between 100mm and 200 mm).

The rotor may comprise a rotor mass extending along the rotation axis and arranged around the shaft. The shaft may comprise a torque transmission member for driving the rotor mass in rotation.

The rotor may be cantilevered or non-cantilevered.

The machine may be inserted in the housing alone or in the gearbox housing. In this case, the machine is inserted in a housing which also houses the gearbox.

Drawings

The invention will be better understood from reading the following detailed description of non-limiting embodiments of the invention and from the accompanying drawings, in which:

fig. 1 is a schematic partial perspective view of a stator made in accordance with the present invention.

Fig. 1a is a schematic partial perspective view of the stator of fig. 1.

Fig. 2 illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 3 illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 4 illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 5 illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 6 illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 6a shows a manufacturing method for manufacturing the stator of fig. 1.

Fig. 6b illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 6c illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 7a illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 7b illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 7c illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 8 illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 8a is a perspective view of a deformed ring used in a manufacturing method for manufacturing the stator of fig. 1.

Fig. 9 illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 9a is a perspective view of a deformed ring used in a manufacturing method for manufacturing the stator of fig. 1.

Fig. 10 illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 10a is a perspective view of a deformed ring used in a manufacturing method for manufacturing the stator of fig. 1.

Fig. 11 illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 11a shows a manufacturing method for manufacturing the stator of fig. 1.

Fig. 11b illustrates a manufacturing method for manufacturing the stator of fig. 1.

Fig. 12a shows an embodiment variant of the method.

Fig. 12b shows this variant of the embodiment of the method.

Fig. 12c shows this variant of the implementation of the method.

Fig. 13 is a schematic partial perspective view of an implementation variant.

Detailed Description

Fig. 1 and 1a show a stator 2 of a rotating electrical machine 1, which also comprises a rotor (not shown). In the context of synchronous or asynchronous engines, the stator is capable of generating a rotating magnetic field for driving the rotor in rotation, and in the case of an alternator, the rotation of the rotor causes an electromotive force in the electrical conductors of the stator.

The examples shown below are illustrative and do not necessarily follow the dimensions associated with the individual constituent elements.

The stator 2 comprises electrical conductors 22 arranged in slots 21 provided between teeth 23 of a stator mass 25. The tank 21 is closed. The slots 21 are closed on the side of the air gap by material bridges 27, each of which couples two successive teeth of the stator mass 25 and on the opposite side by a yoke 29. The yoke and the teeth 23 are integrally formed. Most of the electrical conductors 22 take the form of pins (i.e., U-pins) and extend axially in the slots.

In the example described, all the electrical conductors 22 of the stator 2 are identical and all take the form of U-pins, and have the same pitch Np for all the electrical conductors of the stator in the form of U-pins. Each electrical conductor in the form of a U-shaped pin comprises a first leg 22e and a second leg 22f, which extend axially in a first slot a and a second slot R, respectively. The first and second grooves a, R are separated by a number Np of grooves and a number Nd of teeth. The number of slots Np is the same for all electrical conductors of the stator in the form of U-pins. In the example described, np takes the value 11. The number of teeth Nd is the same for all electrical conductors of the stator in the form of U-pins. In the example described, nd takes a value of 10.

The first leg 22e is inboard and the second leg 22f is outboard.

In the described example, a first electrical conductor (which is received in a first slot) is electrically coupled with a second electrical conductor (which is received in a second slot) at an outlet of the slots. The first slot and the second slot are non-contiguous. In the example shown, the first slot and the second slot are separated by 12 other slots and 11 teeth. In a variant, the first and second slots are separated by, for example, 3, 4, 5, 6, 7, 8, 9, 10, 11 or 13 other slots and 2,3, 4, 5, 6, 7, 8, 9, 10, 12 or 13 teeth.

The electrical conductors are distributed in the slots and form a distributed winding (in the example described as a fractional-slot winding). In this example, the number of slots is 63. The number of stator poles is 6. Thus, the combination of slot number/stator pole number was 63/6.

The electrical conductors form fractional-slot windings for which the ratio q defined by q=ne/(2 pm) is written in the form of an irreducible fraction z/n, z and n being two non-zero integers, n being different from 1, where Ne is the number of stator slots, m is the number of winding phases, and p is the number of stator pole pairs. Thus, for this machine with 63 slots and 6 poles, q=63/(3×6) =7/2 is obtained.

Electrical conductor 22 is made of copper or aluminum, or any other conductor material that is glazed or covered with any other suitable insulating covering.

The electrical conductors 22 are arranged in the slots 21 in rows along the rows of aligned electrical conductors.

The electrical conductor may have a generally rectangular cross-section, particularly with rounded corners. In the example, the electrical conductors are described as being radially stacked in only one row. The circumferential dimension of the electrical conductor substantially corresponds to the width of the slot. Whereby the slot comprises only one electrical conductor in its width. The slot may include a plurality of electrical conductors in its radial dimension. In the described example, the slot comprises two electrical conductors.

In addition, each of the electrical conductors in the form of pins has a first leg 22e and a second leg 22f, which are elongated outside the slot by a welded portion 22b, which is inclined with respect to a plane perpendicular to the longitudinal axis of the stator, so as to overhang the stator mass circumferentially at the slot position, which slot is separated from the first slot a or the second slot R by a number N1 and/or N2 of teeth, respectively.

In the example described with reference to fig. 1 and 1a, welded portion 22b of second outer leg 22f of electrical conductor 22 is aligned with the second leg. In this case, N2 is zero. The first inner leg 22e is disposed closer to the rotor than the second outer leg 22 f. The second outer leg 22f is arranged closer to the yoke of the stator than the first inner leg 22 e. Thus, in this example, N1 takes a value of 11.

For each electrical conductor, the innermost weld 22b relative to the longitudinal axis of the stator is arranged closer to the rotor, the weld being inclined at the same inclination relative to a plane perpendicular to the longitudinal axis of the stator as the other innermost welds.

For each electrical conductor, an outermost weld with respect to the longitudinal axis of the stator is disposed furthest from the rotor, the weld being inclined at a different inclination with respect to a plane perpendicular to the longitudinal axis of the stator than the other outermost welds. The outermost weld portions need not all be inclined at the same inclination relative to a plane perpendicular to the longitudinal axis of the stator. The outermost weld portions may be inclined at least two, and even three or four, different inclinations relative to a plane perpendicular to the longitudinal axis of the stator.

In addition, some electrical conductors have a second outer leg 22f that is elongated out of the slot by a weld 22b, the weld section kinking relative to the slot and extending along the same radial plane as the second leg. The welding section 22b is further radially distant from the axis of rotation of the machine. This kink of the electrical conductor can reach the metal elements of the connector of the machine. The electrical conductors may relate to phase input electrical conductors and/or phase output electrical conductors.

As can be seen well from fig. 1a, it is thereby obtained that at least one welded section of the phase input electrical conductor and/or the phase output electrical conductor is radially aligned with the welded sections of the other electrical conductors. Each welding section of the phase input electrical conductor is in particular radially aligned with a welding section of the other electrical conductor.

In addition, the welding sections of the electrical conductors are arranged in three layers relative to the longitudinal axis of the stator, each layer comprising a different number of electrical conductor welding sections. The electrical conductor welding sections of the different layers are concentric about the longitudinal axis of the stator.

In the example described, the innermost layer Int comprises as many welded sections as slots of the stator. The outermost layer Ext comprises welded sections (here, six for three-phase windings) equal in number to twice the number of phases of the windings of the stator. Finally, the intermediate layer Cen (disposed between the innermost layer and the outermost layer) comprises a number of welded sections equal to the number of slots of the stator from which twice the number of phases of the winding of the stator (here, six for three-phase windings) is derived.

Thereby, the welding sections 22b of the electrical conductors are well aligned with each other, which may facilitate welding of the electrical conductors 22 and may simplify manufacturing of the stator.

The method of manufacturing the stator will now be described in detail with reference to fig. 2 to 12 c.

In a first step (a) of the manufacturing method, as can be seen on fig. 2, a stator mass 25 is provided, said stator mass comprising a stack of magnetic metal sheets, the stator mass 25 comprising slots 21 arranged between teeth 23, the electrical conductors 22 being housed in the slots 21. All electrical conductors take the form of U-pins and each of them comprises an inner leg 22e and an outer leg 22f which extend axially in particular in the first and second grooves a and R, respectively. At least one of the inner leg 22e and the outer leg 22f of the electrical conductor 22 is elongated by a welded section outside the slot.

In a second step (b), the outer leg of the electrical conductor is circumferentially offset relative to the inner leg by half a pitch. The second step (b) may be broken down into a plurality of sub-steps (b 1) to (b 4).

The circumferential offset step (b) for circumferentially offsetting the outer leg of the electrical conductor by half a pitch includes a seating step (b 1) for seating the two positioning rings of the inner positioning ring 31 and the outer positioning ring 32 of the electrical conductor 22 in place. The two positioning rings, inner 31 and outer 32, are placed in position towards the stator mass 25 just above the stack of metal sheets of the stator mass, as can be seen on fig. 2. The inner ring 31 has the form of a disc.

As described further below, the inner and outer positioning rings 31 and 32 include radially extending movable fingers 33 and 34, respectively, each of which is movable along the radial axis of the stator. During the seating step (b 1) for seating the retaining ring in place, the movable finger is in a stowed position stowed in the retaining ring.

In step (b 2), movable fingers 33 and 34 are made to protrude, each of which is disposed between two consecutive electrical conductors 22 by sliding like a piston, as can be seen on fig. 3. The movable fingers 34 of the outer positioning ring 32 are disposed between the outer legs 22f of the electrical conductors, and the movable fingers 33 of the inner positioning ring 31 are disposed between the inner electrical conductors 22 e.

The outer retaining ring 32 includes as many movable fingers 34 as the teeth of the stator. The movable fingers may all be identical to each other.

The inner positioning ring 31 also comprises as many movable fingers 33 as the teeth of the stator. The movable fingers may all be identical to each other.

In the dominant position, each of all the movable fingers 33, 34 is inserted between two consecutive electrical conductors. The movable fingers are capable of facilitating alignment of the electrical conductors, particularly during translational movement of the positioning rings 31, 32 along the longitudinal axis of the stator, as described below.

In step (b 3), the positioning rings 31, 32 are moved in translation along the longitudinal axis of the stator (i.e. in translation upwards away from the stator mass 25 in fig. 4). Thereby, the positioning ring moves toward the end of the welding section 22 b. In this translational movement, the movable fingers 33, 34 act as combs enabling a good alignment of the electrical conductors.

In step (b 4), the outer retaining ring is rotated a given angle about the longitudinal axis of the stator, as shown on fig. 5. The angle here is equal to half the pitch. In this rotational movement, the movable finger is able to twist the outer leg 22f by half a pitch relative to the inner leg 22 e.

In particular, the outer positioning ring 32 moves rotationally relative to the inner positioning ring 31 and relative to the stator, while the inner positioning ring 31 remains fixed relative to the stator.

In step (c) shown in fig. 6, the six outer legs 22f of the phase input electrical conductor and/or the phase output electrical conductor are offset radially towards the outside and the phase input electrical conductor and/or the phase output electrical conductor are arranged on the third, outermost layer Ext.

For this purpose, the phase-movable fingers 35 are made to protrude from the inner positioning ring 31, said phase-movable fingers being configured to have a longer radial travel than the other movable fingers 33 of the inner positioning ring 31.

The movable fingers of the inner positioning ring 31 thus comprise phase movable fingers 35 (here six phase movable fingers 35) which are configured to have a longer radial travel than the other movable fingers 33. The inner positioning ring thus comprises movable fingers with two possible radial strokes, a shorter radial stroke for the majority 33 of the movable fingers and a longer radial stroke for some 35 of the movable fingers, in particular six of the movable fingers.

The longer radial travel of these phase moveable fingers allows the outer legs 22f of the phase input electrical conductor and/or the phase output electrical conductor to be offset radially outwardly away from the longitudinal axis of the stator relative to the other outer legs which remain circumferentially aligned.

Moreover, the outer positioning ring 32 comprises a slot 38 for receiving the phase input electrical conductor and/or the phase output electrical conductor. These slots 38 allow for placement of the phase input electrical conductors and/or the phase output electrical conductors on the outermost third layer Ext.

Each of some or all of the movable fingers of the outer locating ring may include a shoulder 36, as shown on fig. 6a, which may be capable of cushioning the electrical conductor. In particular, the movable finger present at the above-mentioned slot position may comprise such a shoulder.

The radial offset towards the outside may be more or less exacerbated. The inclination of the outer leg may comprise a curved portion with a large radius of curvature (as shown on fig. 6 b) or a curved portion with a smaller radius of curvature (as shown on fig. 6 c), which results in the welded section thereby being located closer to the stack of metal sheets.

In the method according to the invention, before the phase input electrical conductor and/or the phase output electrical conductor is deformed, the length of the welded section of the outer leg of the phase input electrical conductor and/or the phase output electrical conductor may be greater than the length of the welded section of the outer leg of the other electrical conductor, as shown in fig. 7a to 7 c.

The method next comprises the following additional step (d):

(d) The welded sections of the electrical conductor are deformed circumferentially with at least two different pitches, in particular three different pitches. This step (d) can be broken up into a plurality of sub-steps (d 1) to (d 5) and is carried out by means of three concentric deformation rings 41, 42, 43, of which a second deformation ring 42 is configured for overlapping in the first deformation ring 41 and for a rotational movement in said first deformation ring.

In step (d 1), the third deforming ring 43 is first put in place, as shown on fig. 8. The third deformation ring 43 deforms, in particular, the welded section of the inner leg of the electrical conductor at a first step distance P1.

The third deformation ring 43 takes the general form of a circle machined with tooth slots and in particular comprises as many slots as the slots of the stator for receiving the welded sections of the electrical conductor. The notches 49 are regular and all are regularly distributed over the circumference of the third deformable ring.

In the example described, for a stator comprising 63 slots and 6 poles, the third deformed ring comprises 63 slots 49, as can be seen on fig. 8 a. The third deformation ring is capable of deforming 63 welded sections of the inner leg of the electrical conductor at a first step distance P1.

In step (d 2), the first deforming ring 41 is put in place, as shown on fig. 9. The first deformation ring 41 deforms a part of the welded section of the outer leg 22f of the electrical conductor and all the welded sections of the outer leg of the electrical conductor that were radially offset in step (c) by a second step distance P2.

The first deforming ring 41 takes a generally circular form with tooth grooves machined therein, and includes the number of notches 49 equal to the number of slots of the stator, from which the number of notches of the second deforming ring 42 described below is derived.

In the example described, the first deformed ring comprises 42 slots 49 for a stator comprising 63 slots and 6 poles. The first deformation ring 41 is capable of deforming 42 welded sections of the outer leg of the electrical conductor at a second pitch P2.

The first deforming ring further comprises grooves 48 which are also capable of deforming all welding sections of the outer leg of the electrical conductor that are radially offset in step (c), in particular for six welding sections that are radially offset in step (c), there are six grooves 48.

The first deformable ring further includes a window 45 for receiving a tab 46 of the second deformable ring 42. The windows 45 of the first deformable ring have a longer circumferential extension than the tabs 46 of the second deformable ring 42, which may allow the second deformable ring to move rotationally in the first deformable ring.

In step (d 3), the second deforming ring 42 is put in place, as shown on fig. 10. The second deformation ring 42 can in particular deform other welded sections of the outer leg of the electrical conductor at a third step distance P3.

The second deforming ring 42 is configured for overlapping in the first deforming ring 41 and configured for rotational movement therein.

The second deformation ring 42 takes the general form of a circle machined with a spline and in particular comprises tabs 46, each of which is received in a window 45 of the first deformation ring 41. The tab 46 is movable in the window 45 when the second deforming ring 42 is rotationally moved in the first deforming ring 41. The tabs 46 are splined and include notches 49.

In the example described, for a stator comprising 63 slots and 6 poles, the second deformed ring comprises 15 slots 49, said 15 slots being distributed over 4 tabs 46.

In step (d 4), the inner and outer retaining rings 31 and 32 are replaced towards the stator mass. The outer positioning ring 32 is helically lowered so as to follow the inclination of the phase input electrical conductor and/or the phase output electrical conductor disposed on the outermost third layer Ext. The inner retaining ring 31 descends parallel to the longitudinal axis of the stator. During this repositioning movement, the movable fingers of the inner and outer positioning rings are in a stowed position.

When the inner and outer locating rings are relocated into position, the movable fingers may be relocated into position in a dominant position that dominates the electrical conductor. This movement enables to obtain protection of the insulator at the outlet of the tank during the next step.

In step (d 5), the first, second and third deforming rings 41, 42, 43 are simultaneously driven to rotate at an asynchronous distance, as shown in fig. 11.

In particular, the second deformable ring is arranged to rotate relative to the first deformable ring. The starting positions of the first deformable ring and the second deformable ring are shown in fig. 11a, and the reaching positions of the first deformable ring and the second deformable ring are shown in fig. 11 b. The first deformable ring and the second deformable ring rotate in a first direction but not at the same pitch, while the third deformable ring is set in rotation in a second direction opposite to the first direction.

The welding section of the inner leg of the electrical conductor is deformed by a first step distance P1 by a rotational movement of the deformation ring. A part of the welded section of the outer leg of the electrical conductor is deformed at a second step distance P2. Deforming all welded sections of the outer leg of the electrical conductor that were radially offset in step (c) and other welded sections of the outer leg of the electrical conductor by a third step distance P3. The third pitch P3 is smaller than the first pitch P1 and the second pitch P2.

In an additional step (e), the deformed ring is removed, and then the inner and outer retaining rings are also removed.

In the example just described, the setting up of the first, second and third deformable rings is then simultaneous for these three deformable rings.

In the example just described, the phase input electrical conductor and/or the phase output electrical conductor is pushed towards the outside.

In a variant, as shown on fig. 12a to 12c, the phase input electrical conductor and/or the phase output electrical conductor may be pulled towards the outside. To this end, the tool assembly may include a clamp or other gripping tool (e.g., independent jaws 50). The jaws 50 may be configured to allow outward deformation of the welding segments. This embodiment variant can be implemented in particular by a phase input electrical conductor and/or a phase output electrical conductor which extends longitudinally beyond the other electrical conductor and is longer than the other electrical conductor.

In a further embodiment variant, the phase input electrical conductor and/or the phase output electrical conductor is pushed towards the inside. In this case, as shown on fig. 13, the inner legs 22e of the electrical conductors have been shifted circumferentially by half a pitch relative to the outer legs 22f, and then the six inner legs 22e of the phase input electrical conductors and/or the phase output electrical conductors have been shifted radially inward.

Claims

1. A manufacturing method for manufacturing a stator (2) of a rotating electrical machine (1), the manufacturing method comprising the steps of:

(a) -providing a stator mass (25), in particular comprising a stack of magnetic metal sheets, the stator mass (25) comprising a slot (21) arranged between teeth (23), an electrical conductor (22) being housed in the slot (21), at least a portion of the electrical conductor, and even a majority of the electrical conductor, being in the form of a U-shaped pin or an I-shaped pin, and wherein each comprises an inner leg (22 e) and an outer leg (22 f), in particular extending axially in a first slot (a) and a second slot (R), respectively, at least one of the inner leg (22 e) and the outer leg (22 f) of the electrical conductor (22) being elongated outside the slot by a welding section,

(B) Circumferentially offsetting the outer leg (22 f) of the electrical conductor by half a pitch relative to the inner leg (22 e), and

(C) The inner legs (22 e) or the outer legs (22 f) of some of the electrical conductors, in particular the legs of the phase input electrical conductors and/or the phase output electrical conductors, in particular the six legs, are respectively radially offset towards the inside or towards the outside,

A circumferential offset step (b) for circumferentially offsetting the inner leg (22 e) or the outer leg (22 f) of the electrical conductor by half a pitch comprises a positioning step (b 1) for positioning two positioning rings, a positioning ring (31) and an outer positioning ring (32), of the electrical conductor in place,

Wherein in the radially displacing step (c), phase movable fingers (35) are caused to protrude from the inner positioning ring.

2. Manufacturing method according to claim 1, the circumferential offset step (b) for circumferentially offsetting the outer leg (22 f) of the electrical conductor by half a pitch comprising a seating step (b 1) for seating two positioning rings of the inner positioning ring (31) and the outer positioning ring (32) of the electrical conductor in place.

3. The manufacturing method according to claim 2, wherein in the radial offset step (c), the phase movable fingers (35) of the inner positioning ring are configured to have a longer radial stroke than the other movable fingers (33) of the inner positioning ring (31).

4. The manufacturing method according to claim 2, wherein in the radial offset step (c) the phase movable fingers (35) are caused to protrude from the outer positioning ring, the phase movable fingers being in particular configured to have a longer radial travel than the other movable fingers (33) of the outer positioning ring (32).

5. The manufacturing method according to any one of the preceding claims, comprising the following additional step (d):

(d) The welded sections of the electrical conductor (22) are deformed circumferentially with at least two different pitches, in particular three different pitches.

6. The manufacturing method according to claim 5, the circumferential deformation step (d) comprising a seating step (d 2) for seating a first deformation ring (41), which can comprise at least one window (45) for receiving a tab (46) of a second deformation ring (42).

7. A manufacturing method for manufacturing a stator (2) of a rotating electrical machine (1), the manufacturing method comprising the steps of:

(D) The welded sections of the electrical conductor (22) are deformed circumferentially with at least two different pitches, in particular three different pitches,

The circumferential deformation step (d) comprises a seating step (d 2) for seating a first deformation ring (41) which can comprise at least one window (45) for receiving a tab (46) of a second deformation ring (42).

8. The manufacturing method according to either one of the two preceding claims, the second deformation ring (42) being configured for overlapping in the first deformation ring (41), in particular for moving, in particular rotating, in the first deformation ring.

9. Manufacturing method according to any one of the four preceding claims, the circumferential deformation step (d) comprising a repositioning step (d 4) for repositioning the inner and outer positioning rings (31, 32) towards the stator mass, in particular by a helical movement of the outer positioning ring (32).

10. The manufacturing method according to claim 9, the circumferential deforming step (d) comprising a simultaneous rotating step (d 5) for simultaneously rotating at least two of the first, second and third deforming rings (41, 42, 43) with at least two unsynchronized distances.

11. Tool combination, in particular for carrying out a manufacturing method according to any one of the preceding claims, comprising a plurality of deformation rings (41, 42, 43), in particular three deformation rings, a second deformation ring (42) of the plurality being configured for overlapping in a first deformation ring (41), in particular for moving, in particular rotating, in the first deformation ring,

The tool assembly comprises at least one inner positioning ring (31) of the electrical conductors, the inner positioning ring comprising a plurality of movable fingers (33).

12. Tool combination according to claim 11, each of the deformation rings (41, 42, 43) comprising a longitudinal slot (49) for receiving a welding section of the electrical conductor (22).

13. Tool combination according to either of the two preceding claims, comprising at least one outer positioning ring (32) of the electrical conductor, the outer positioning ring (32) comprising a plurality of movable fingers (34).

14. Tool combination according to claim 13, the outer positioning ring (32) comprising slots (38), in particular four or six slots (38), for receiving some phase input electrical conductors and/or phase output electrical conductors.

15. Tool combination according to any one of the four preceding claims, the movable fingers of the inner positioning ring comprising phase movable fingers (35), in particular six phase movable fingers, configured to have a longer radial travel than the other movable fingers (33).

16. A stator (2) of a rotating electrical machine (1), the stator comprising a stator mass (25) comprising slots (21) arranged between teeth (23), electrical conductors (22) being accommodated in the slots (21), at least a portion of the electrical conductors, and even a majority of the electrical conductors, taking the form of U-shaped pins or I-shaped pins, and wherein each comprises an inner leg (22 e) and an outer leg (22 f) extending axially in a first slot (a) and a second slot (R), respectively, at least one of the inner leg (22 e) and the outer leg (22 f) of the electrical conductor (22) being elongated outside the slots by a welding section, the welding section being inclined with respect to a plane perpendicular to the longitudinal axis of the stator, so as to be circumferentially cantilevered over the stator mass at a slot or tooth position, the slots or the teeth being separated from the first slot (a) or the second slot (R) by a number N1 and/or N2 of teeth, respectively,

The innermost welding section (22 b) or the outermost welding section (22 b) is inclined at the same inclination with respect to a plane perpendicular to the longitudinal axis of the stator,

The other of the outermost or innermost welding sections (22 b) of the electrical conductor (22) is inclined with at least two, even three or four different inclinations with respect to a plane perpendicular to the longitudinal axis of the stator,

At least one welded section of the phase input electrical conductor and/or the phase output electrical conductor (22) is radially aligned with a welded section of the other electrical conductor.

17. Stator according to claim 16, the welded sections (22 b) of the electrical conductors being arranged in a plurality of layers (Int, ext, cen), in particular three layers, with respect to the longitudinal axis of the stator, at least two layers comprising a different number of welded sections of electrical conductors.