MEASURING DEVICE FOR A STATOR OF AN ELECTRIC MOTOR WITH EPOXY-COATED HAIR PINS

Abstract

A measuring device for a stator, comprising a height gauge component having at least a base, legs, and a height gauge surface. The base is oriented in a first direction to define a ground plane configured to abut an end face of a stator lamination stack. The legs are spaced circumferentially about an axis and extend in the first direction from the base. The legs are configured to be received in holes defined by the stator lamination stack. The height gauge surface is parallel to the ground plane and spaced from it by a predetermined distance. The height gauge surface is annular in shape and arranged around the axis.

Description

FIELD OF TECHNOLOGY

[0001] The present disclosure relates to a stator gauge and, more particularly, to a stator gauge having epoxy coated electrical components. GENERAL STATE OF THE ART

[0002] The statements in this section merely provide background information concerning the present disclosure and may not constitute prior art.

[0003] Electric machines (e.g., electric motors and generators) may be used in a vehicle, such as an all-electric vehicle or a hybrid electric vehicle. The electric machine includes, among other things, a stator and a rotor. The rotor is supported for rotation within a bore of the stator and includes windings or permanent magnets that interact with windings of the stator to generate rotation of the rotor when the electric machine is energized. The rotor may be supported on a drive shaft configured to be coupled to a load, such as a powertrain of the vehicle.

[0004] Stators may undergo a manufacturing process in which a section of electrical components (i.e., an end section of the hairpin windings, a section of the terminals, and a section of the neutral connection) is coated with an epoxy material to create an electrically insulating layer. After the coating process is complete, dimensions of the epoxy-coated electrical components are measured to ensure that the epoxy-coated electrical components are within predetermined tolerance ranges. Gauges can be used to measure the dimensions of the epoxy-coated electrical components. SUMMARY

[0005] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

[0006] In one form, the present disclosure provides a gauge for a stator that includes a height gauge part having at least a base, legs, and a first height inspection surface. The base faces in a first direction to define a ground plane configured to abut an end surface of a stator core. The legs are spaced in a circumferential direction about an axis and extend in the first direction from the base. The legs are configured to be received in holes defined by the stator core. The first height inspection surface is parallel to the base plane and spaced therefrom by a predetermined distance. The first height inspection surface has an annular shape disposed about the axis.

[0007] In variations of the measuring device of the preceding paragraph, which can be implemented individually or in any combination: the height measuring device part includes at least one second height checking surface recessed in a second direction opposite to the first direction, the second height checking surface extending in a circumferential direction; the second height checking surface is parallel to the ground plane; the height measuring device part includes an inner flange extending around an inner periphery of the first height checking surface and extending from the inner periphery of the first height checking surface in the first direction; the height measuring device part includes an outer flange extending around an outer periphery of the first height checking surface and extending from the outer periphery of the first height checking surface in the first direction;the height gauge part includes an outer flange extending from an outer periphery of the first height inspection surface in the first direction and extending in the circumferential direction, the outer flange including a first end and a second end spaced from the first end to define an opening; a flap pivotally coupled to the height gauge part between an open position in which the second gauge part is away from the opening and a closed position in which the second gauge part closes the opening; an inner diameter gauge part slidably engaged along an inner periphery of the first height inspection surface in a circular path;the inner diameter gauge part includes a first portion extending in the first direction of the height gauge part and a second portion extending from the first portion in a second direction of the height gauge part that is perpendicular to the first direction, the first portion extending beyond the first height test surface; a first diameter gauge part having an annular shape; the first diameter gauge part has a variable thickness; the first diameter gauge part includes a first end and a second end spaced from the first end to define an opening and a second diameter gauge part disposed within the opening and slidably engaging the stator core, the second diameter gauge part being movable in the circumferential direction within the opening;

[0008] In another form, the present disclosure provides a gauge for a stator that includes a first diameter gauge part having at least an annular base, legs, and first and second diameter inspection surfaces. The annular base faces in a first direction and is configured to abut an end surface of a stator core. The legs are spaced in a circumferential direction about an axis and extend in the first direction from the base. The legs are configured to be received in holes defined by the stator core. The first diameter inspection surface extends in the circumferential direction. The second diameter inspection surface extends in the circumferential direction and is recessed in a second direction relative to the first diameter inspection surface. The second direction is perpendicular to the first direction.

[0009] In variations of the gauge of the preceding paragraph, which may be implemented individually or in any combination: the first diameter gauge part has a variable thickness; the first diameter gauge part includes a first end and a second end spaced from the first end to define an opening; a second diameter gauge part is disposed within the opening and slidably engages the stator core, the second diameter gauge part being movable within the opening in the circumferential direction; and the first diameter gauge part includes a third diameter inspection surface extending in the circumferential direction and recessed in the second direction by a further distance than the second inner circumferential surface.

[0010] In yet another form, the present disclosure provides a gauge for a stator that includes a first gauge part and a second gauge part. The first gauge part includes at least a base, legs, and first and second height inspection surfaces. The base faces in a first direction to define a ground plane configured to abut an end surface of a lamination stack of the stator. The legs are spaced in a circumferential direction about an axis and extend in the first direction from the base. The legs are configured to be received in holes defined by the lamination stack of the stator. The first height inspection surface is parallel to the base plane and spaced therefrom by a first predetermined distance. The first height inspection surface has an annular shape disposed about the axis.The second height check surface is parallel to the ground plane and spaced therefrom by a second predetermined distance that is greater than the first predetermined distance. The second measuring device part is slidably engaged along a circumference of the first measuring device part in a circumferential direction.

[0011] In variations of the gauge of the preceding paragraph, which may be implemented individually or in any combination: the second gauge part extends in the first direction beyond the first height check surface, and the first gauge part includes supports extending radially outwardly from an outer peripheral surface of the first gauge part, and wherein the legs extend in the first direction from respective supports.

[0012] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. DRAWINGS

[0013] In order that the disclosure may be fully understood, various forms thereof will now be described by way of example with reference to the accompanying drawings, in which: Fig. 1 is a schematic view of an electric machine including a stator and a rotor according to the principles of the present disclosure; Fig. 2 is a perspective view of the stator of Fig. 1; Fig. 3 is a perspective view of a measuring device including a height measuring part and a diameter measuring part, according to the principles of the present disclosure; Fig. 4 is a perspective view of the height gauge part of the measuring device of Fig. 3; Fig. 5 is a perspective view of the measuring device of Fig. 3, which is attached to the stator Fig. 1, with a portion of the stator removed for clarity, in accordance with the principles of the present disclosure; Fig. 6A is a side view of the meter from Fig. 3, which is attached to the stator Fig. 1, with a portion of the stator removed for clarity; Fig. Figure 6B is an enlarged side view of area 6B shown in Fig. 6A is shown; Fig. Fig. 7 is a perspective view of yet another measuring device including the first and second measuring device parts mounted on the stator of Fig. 1, with a portion of the stator removed for clarity, in accordance with the principles of the present disclosure; Fig. 8 is a perspective view of the measuring device of Fig. 7 with the first measuring part in the open position; Fig. 9 is another perspective view of the measuring device from Fig. 7 with the first measuring part in the closed position; Fig. 10 is a cross-sectional view of the measuring device of Fig. 7, which is attached to the stator Fig. 1, with a portion of the stator removed for clarity, in accordance with the principles of the present disclosure; Fig. 11 is a perspective view of another measuring device including the first and second diameter measuring parts mounted on the stator of Fig. 1, with a portion of the stator removed for clarity, in accordance with the principles of the present disclosure; Fig. 12 is a plan view of the first diameter measuring device of Fig. 11; Fig. 13 is a cross-sectional view of yet another measuring device according to the principles of the present disclosure; Fig. 14 is a perspective view of another measuring device according to the principles of the present disclosure.

[0014] The drawings described in this document are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0015] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that corresponding reference characters indicate like or corresponding parts and features throughout the drawings.

[0016] With reference to Fig. 1, an electric machine 10 may be used in a vehicle (not shown), such as an all-electric vehicle or a hybrid electric vehicle. The electric machine 10 may be referred to as an electric motor, traction motor, generator, or the like. The electric machine 10 may be a permanent magnet machine, an induction machine, or the like. In the illustrated example, the electric machine 10 is a three-phase alternating current (AC) machine, although other types may be used, such as direct current (DC) machines or single-phase AC machines. In the example provided, the electric machine 10 is a traction motor capable of functioning both as a motor to propel the vehicle and as a generator, such as during regenerative braking, although the electric machine 10 may also be used for purposes other than a motor and / or generator.

[0017] The electric machine 10 may be powered by a traction battery (not shown) in the vehicle. The traction battery may provide a high-voltage direct current (HV DC) output from one or more battery cell arrays, sometimes referred to as battery cell stacks, within the traction battery. The battery cell arrays may include one or more battery cells that convert stored chemical energy into electrical energy. The cells may include a casing, a positive electrode (cathode), and a negative electrode (anode). An electrolyte allows ions to move between the anode and cathode during discharge and then move back during charging. Terminals allow current to flow from the cells for use by the vehicle.

[0018] With reference to Fig. 1 and Fig. 2, the electric machine 10 includes, among other things, a stator 12 and a rotor 14 ( Fig. 1). The stator 12 includes a cylindrical laminated core 16 having an inner diameter 18 defining a bore 20 and an outer diameter 22. The laminated core 16 may be formed from a plurality of stacked laminations 24 ( Fig. 2). The rotor is supported for rotation within the bore 20 and includes windings or permanent magnets (not shown) that interact with windings of the stator 12 to generate rotation of the rotor 14 when the electric machine 10 is energized. The rotor 14 may be supported on a drive shaft 28 configured to be coupled to a load, such as a vehicle powertrain.

[0019] The stator lamination stack 16 defines stator slots 34 arranged circumferentially around and formed in the inner diameter 18. The slots 34 may be evenly spaced around the circumference and extend axially from a first end 36 of the lamination stack 16 to a second end 38 of the lamination stack 16. The electric machine 10 includes windings 40 placed in the slots 34 of the lamination stack 16. In the examples provided, the windings 40 are hairpin windings, which increase efficiency by providing a larger amount of stator conductors to reduce the resistance of the windings 40 without invading the space reserved for the electrical lamination and the magnetic flux path. Therefore, the windings 40 are also referred to herein as the hairpin windings 40. The hairpin windings 40 may be corrugated windings in which the windings 40 are woven in a wave-like pattern from pole to pole.The electric machine 10 may be a three-phase AC machine in which the hairpin windings 40 are arranged in a U-phase, a V-phase, and a W-phase. Each phase includes associated conductors (also known as needle, hairpin, or busbar connectors) arranged, in the illustrated form, in two parallel winding paths. Each phase (i.e., U-phase, V-phase, and W-phase) includes respective paths that begin at a respective terminal 50, 64, 78 and end at a neutral connection 52. The neutral connection 52 may be a single neutral connection, e.g., a single metal strip used to connect all six paths, or multiple neutral connections may be used.Terminals 50, 64, and 78 may be connected to an inverter and receive voltage from the inverter, thereby generating torque-producing current in the winding paths, causing rotor 14 to rotate within stator 12. An example of such a three-phase electric machine including terminals 50, 64, 78 and neutral connection 52 is described in U.S. Patent Application No. 17 / 358,489, entitled "HAIRPIN WINDING ELECTRIC MACHINE WITH MULTI-CONDUCTOR HAIRPIN ASSEMBLIES," which is commonly owned with the present application and is incorporated herein by reference in its entirety.

[0020] The stator 12 undergoes a manufacturing process in which a portion of electrical components (i.e., an end portion of the hairpin windings 40, a portion of the terminals 50, 64, 78, and a portion of the neutral connection 52) is coated with an epoxy material to create an electrically insulating layer. In one example, the manufacturing process involves immersing the portion of electrical components in an epoxy powder while it is hot. The latent heat in the stator 12 causes the epoxy powder to change from solid to liquid form, adhering to the portion of electrical components and beginning to solidify at the portion of electrical components. The stator 12, including the partially epoxy-coated electrical components, is then positioned in one or more ovens where the epoxy cures and fully solidifies onto the portion of electrical components.After the coating process is complete, the dimensions of the epoxy-coated electrical components are measured to ensure that the epoxy-coated electrical components remain within predetermined tolerance ranges. Measuring instruments can be used to measure the dimensions of the epoxy-coated electrical components.

[0021] With reference to Fig. 3-5, 6A and 6B, a measuring device 100 is provided that includes a height measuring device part 102 and a diameter measuring device part 104. The height measuring device part 102 is configured to be attached to the stator 12 and is configured to measure a height of epoxy-coated electrical components 80 ( Fig. 6A and Fig. 6B). In the illustrated example, the height gauge part 102 is attached to an outer sheet 24a of the stacked sheets 24 of the stator 12 and includes a body 106, supports 108, and a plurality of legs 110. When the height gauge part 102 is attached to the stator 12, the body 106 and supports 108 are substantially above the epoxy-coated electrical components 80 ( Fig. 6A and Fig. 6B).

[0022] The body 106 is arranged around a central axis 112 and has a ring shape. The body 106 includes an inner side 114 ( Fig. 4 and Fig. 6A) facing in a first direction +X towards the epoxy-coated electrical components 80, and an outer side 116 ( Fig. 3, Fig. 5 and Fig. 6A) facing in a second direction -X away from the epoxy-coated electrical components 80. The inner side 114 includes a height test surface 118 ( Fig. 4 and Fig. 6A) and a depressed region 120 ( Fig. 4). The recessed region 120 spans an angle β of less than or equal to 122 degrees along a circumference of the inner side 114 about the central axis 112. It is understood that the recessed region 120 may span a different angle based on the size of the stator 12. The recessed region 120 also includes a plurality of height check surfaces 122 that are recessed in the second direction -X relative to the height check surface 118. The outer side 116 includes an outer surface 124 that extends substantially around an entire circumference of the body 106 (i.e., extends 360 degrees around the body 106). The height check surfaces 122 are located between the outer surface 124 and the height check surface 118.

[0023] The supports 108 are spaced apart around the body 106 and extend radially outward from an outer peripheral surface 126 of the body 106. The supports 108 include openings that are vertically aligned with respective eyelet holes 128 ( Fig. 2) of the stator lamination stack 16. Each support 108 has a surface 130 that is coplanar with the surface 124 of the body 106. The plurality of legs 110 are attached to respective supports 108 and are configured to be received in eyelet holes 128 of the stator lamination stack 16. In this manner, the height gauge part 102 is attached to the stator 12. In the illustrated example, the legs 110 are removably attached to the respective support 108. In another form, the legs 110 are fixed to the respective supports 108. The legs 110 extend in the first direction +X from the respective supports 108 and are spaced apart from each other in a circumferential direction about the axis 112.

[0024] In the illustrated example, each leg 110 is configured to be attached to the body 106 of the height gauge part 102 on the stator 12 and includes a body portion 110a and an end portion 110b. The body portion 110a has a generally cylindrical shape and includes a first axial end surface 132 ( Fig. 6A) facing in the first direction +X, and a second axial end surface 134 ( Fig. 6A) facing in the second direction -X. The first axial end surfaces 132 of the legs 110 define a base plane Z ( Fig. 6A) and are configured to abut an end surface 136 of an outermost lamination 24a of the stator core 16. The ground plane Z is parallel to the height check surface 118. In the example shown in Fig. 3-5, 6A and 6B, the height check surfaces 122 are also planar and parallel to the ground plane Z. In other configurations, such as Fig. 14, one or more of the height verification surfaces 122a of the gauge 100a may, for example, be non-planar or non-parallel to the ground plane Z. The second axial end surface 134 of each leg 110 is adjacent to a respective support 108. The end portion 110b of each leg 110 extends in the first direction +X from the first axial end surface 132 and is configured to be received in a respective eyelet hole 128. A fastener 110c, such as a bolt or screw, may extend at least partially through a respective support 108 and at least partially through a respective leg 110, thereby securing the respective leg 110 to the body 106. In some forms, each leg 110 may include another end portion (not shown) extending in the second direction -X from the second axial end surface 134 and into a respective support 108.When the height measuring device part 102 is attached to the stator 12 as described above, the height inspection surfaces 118, 122 are spaced by predetermined distances from the ground plane Z. In the illustrated example, the distance between the ground plane Z and any one of the height inspection surfaces 122 is greater than the distance between the ground plane Z and the height inspection surface 118. In the illustrated example, the distance between the ground plane Z and the height inspection surface 118 is determined by a length of the body portion 110a.

[0025] With reference to Fig. 3 and Fig. 5, the diameter measuring part 104 is slidably engaged along an inner circumferential surface 140 of the height measuring part 102 in a circular path and is configured to measure an inner diameter of the epoxy-coated electrical components 80. The diameter measuring part 104 includes a first body portion 104a extending in an axial direction of the height measuring part 102 and a second body portion 104b extending perpendicularly from the first body portion 104a in a radial direction of the height measuring part 102. The first body portion 104a has a shape corresponding to the shape of the inner circumferential surface 140 of the height measuring part 102 and is slidably engaged with the inner circumferential surface 140 of the height measuring part 102.The second body portion 104b slidably engages the outer surface 124 of the body 106 as the diameter gauge part 104 moves on the circular path around the height gauge part 102. The height of the first body portion 104a is such that when the second body portion 104b slidably engages the outer surface 124 of the body 106, the first body portion 104a extends axially (in the X+ direction) beyond the height check surface 114. In the example provided, the height of the first body portion 104a is such that when the second body portion 104b slidably engages the outer surface 124 of the body 106, the first body portion 104a extends axially to a location axially between the height check surface 114 and the first axial end surface 132.

[0026] With continued reference to Fig. 3-5, 6A, and 6B, the operation of the measuring device 100 is described in detail. First, the height gauge part 102 is attached to the stator 12, as described above. Once the height gauge part 102 is attached to the stator 12, the height gauge part 102 is visually inspected to determine whether or not the epoxy coating is within a predetermined height tolerance range. That is, if the first axial end surface 132 of each leg 110 engages the outermost lamination 24a of the stator 12, then the epoxy-coated electrical components 80 are within a predetermined height tolerance range. If the first axial end surface 132 of each leg 110 does not engage the outermost lamination 24a of the stator 12, then the epoxy-coated electrical components 80 extend in the second direction -X beyond the predetermined height tolerance range.The predetermined height tolerance range can be between 33 millimeters (mm) and 48 millimeters (mm).

[0027] When the first axial end surface 132 of each leg 110 engages the outermost lamination 24a of the stator 12, the inner diameter of the epoxy-coated electrical components 80 is checked to determine whether or not the epoxy coating is within a predetermined inner diameter tolerance range. That is, the diameter measuring part 104 moves along the inner circumferential surface 140 as described above. If the diameter measuring part 104 moves along the inner circumferential surface 140 without being obstructed by the epoxy-coated electrical components 80, then the epoxy-coated electrical components 80 are within a predetermined inner diameter tolerance range.If the diameter measuring device part 104 is obstructed by the epoxy-coated electrical components 80, then the epoxy-coated electrical components 80 may not be within the predetermined inner diameter tolerance range (i.e., the epoxy-coated electrical components 80 may extend radially inward toward the axis 112 beyond the predetermined inner diameter tolerance range).

[0028] With reference to Fig. 7-10, another gauge 200 is provided. The structure and function of the gauge 200 may be similar or identical to those of the gauge 100 described above, except for any exceptions listed below. The gauge 200 includes a first gauge part 202 and a second gauge part or flap 204. The first gauge part 202 is configured to be attached to the stator 12 and is configured to measure a height and an inner and outer diameter of the epoxy-coated electrical components 80. In the illustrated example, the first gauge part 202 is configured to be attached to the outer lamination 24a of the stacked laminations 24 of the stator 12 and includes a body 206, an inner flange 208 ( Fig. 9 and Fig. 10), an outer flange 210, supports 212 and a plurality of legs 214 ( Fig. 9). When the gauge 200 is attached to the stator 12, the body 206 is located over the epoxy-coated electrical components 80.

[0029] The body 206 is arranged around a central axis 213 and has a ring shape. The body 206 includes an inner side 215 facing in a first direction +X toward the epoxy-coated electrical components 80, and an outer side 216 facing in a second direction -X away from the epoxy-coated electrical components 80. The inner side 215 includes a height inspection surface 218 and a recessed region 220. As shown in Fig. 9, the recessed region 220 spans an angle β of less than or equal to 122 degrees along a circumference of the inner side 215 about the central axis 213. The recessed region 220 also includes a plurality of height check surfaces 222 that are recessed in the second direction -X relative to the height check surface 218.

[0030] With reference to Fig. 9 and Fig. 10, the inner flange 208 extends around an inner periphery of the body 206 and extends from the inner periphery of the body 206 in the first direction +X. The outer flange 210 extends around an outer periphery of the body 206 and extends from the outer periphery of the body 206 in the first direction +X. The outer flange 210 includes a first end 210a and a second end 210b that are spaced apart from each other, forming an opening 211. The outer flange 210 is configured to abut the outer lamination 24a of the stacked laminations 24 of the stator 12 when the gauge 200 is attached to the stator 12. In some forms, the inner flange 208 may contact the outer lamination 24a of the stator 12 when the gauge 200 is attached to the stator 12. In other forms, the inner flange 208 may not contact (be spaced from) the outer sheet 24a of the stator 12 when the gauge 200 is attached to the stator 12.The body 206 and the inner and outer flanges 208, 210 cooperate to form an annular compartment 230 (. Fig. 9 and Fig. 10) configured to receive the epoxy-coated electrical components 80 when the gauge 200 is attached to the stator 12. In this manner, the inner flange 208 is located radially inward relative to the epoxy-coated electrical components 80 and can measure whether or not the epoxy-coated electrical components 80 are within an inner diameter tolerance range. Likewise, the outer flange 210 is located radially outward relative to the epoxy-coated electrical components 80 and can measure whether or not the epoxy-coated electrical components 80 that the outer flange 210 surrounds are within an outer diameter tolerance range.When the end surfaces 232 of the supports 212 engage the outermost sheet 24a of the stator 12, a portion of the epoxy coated electrical components 80 surrounded by the first gauge part 202 lies within a predetermined height tolerance range, outer diameter tolerance range, and inner diameter tolerance range.

[0031] The supports 212 are spaced apart from each other around the outer flange 210 and extend radially outward from the outer flange 210. The supports 212 are vertically aligned (and concentric) with respective eyelet holes 128 of the stator core 16. The plurality of legs 214 are attached to respective supports 212 and are configured to be received in eyelet holes 128 of the stator core 16. In this way, the first gauge part 202 is attached to the stator 12. The legs 214 extend in the first direction +X from the respective supports 212 and are spaced in a circumferential direction about the axis 213.

[0032] The end surfaces 232 of the supports 212 define a ground plane Z and are configured to abut the end surface 136 of the outermost lamination 24a of the stator lamination stack 16. The ground plane Z is parallel to the height check surface 218. In the example provided, the height check surfaces 222 are also planar and parallel to the ground plane Z, although other configurations may be used, such as one or more of the height check surfaces 222 being non-planar or non-parallel to the ground plane Z. When the first gauge part 202 is attached to the stator 12 as described above, the height check surfaces 218, 222 are spaced from the ground plane Z by predetermined distances. In the illustrated example, the distance between the ground plane Z and any one of the height check surfaces 222 is greater than the distance between the ground plane Z and the height check surface 218.

[0033] The flap 204 is pivotable on a support 212 between an open position ( Fig. 8), in which the flap 204 is removed from the opening 211 of the first measuring part 202, and a closed position ( Fig. 7, Fig. 9 and Fig. 10), in which the flap 204 closes the opening 211 of the first gauge part 202, forming a continuous, closed profile of the outer flange 210. When the flap 204 closes to form a continuous, closed profile of the outer flange 210 when the first gauge part 202 is attached to the stator 12, the epoxy-coated electrical components 80 surrounding the flap 204 are within the outer diameter tolerance range.

[0034] The flap 204 includes a mounting portion 204a and a flange portion 204b. The mounting portion 204a may be arcuate and is pivotally attached to the support 212. The mounting portion 204a may have a thickness greater than a thickness of the flange portion 204b. The flange portion 204b is arcuate and extends from the mounting portion 204a. When the flap 204 is in the closed position, a first end 234a of the flange portion 204b is adjacent to or contiguous with the end 210a of the outer flange 210, and a second end 234b of the flange portion 204b is adjacent to or contiguous with the end 210b of the outer flange 210, thereby forming the continuous closed profile of the outer flange 210.

[0035] With reference to Fig. 11 and Fig. 12, another gauge 300 is provided. The structure and function of the gauge 300 may be similar or identical to those of the gauges 100, 200 described above, except for any exceptions listed below. The gauge 300 includes a first gauge part 302 and a second gauge part 304. The first gauge part 302 is configured to be attached to the stator 12 and is configured to measure an outer diameter of the epoxy-coated electrical components 80. In the illustrated example, the first gauge part 302 is configured to be attached to the outer lamination 24a of the stacked laminations 24 of the stator 12 and includes an annular body 306, supports 312, and a plurality of legs 314 ( Fig. 11). When the gauge 300 is attached to the stator 12, the gauge 300 is located radially outward relative to the epoxy-coated electrical components 80.

[0036] The body 306 includes an intermediate portion 306a and end portions 306b, 306c. The intermediate portion 306a is disposed between the end portions 306b, 306c and includes an inner peripheral surface 320. The end portion 306b includes one or more inner peripheral surfaces 322 that are recessed radially outward relative to the inner peripheral surface 320. As shown in Fig. 12, each inner peripheral surface 322 of the end portion 306b is recessed radially outwardly by a different distance from the inner peripheral surface 320 of the intermediate portion 306a. The end portion 306c includes one or more inner peripheral surfaces 324 that are recessed radially outwardly relative to the inner peripheral surface 320. Each inner peripheral surface 324 of the end portion 306c may be recessed radially outwardly by a different distance from the inner peripheral surface 320 of the intermediate portion 306a. In this way, the end portions 306b, 306c have a thickness that differs from the thickness of the body 306, thereby providing the first gauge part 302 having a variable thickness. The end portion 306b has an end surface 328 spaced from an end surface 330 of the end portion 306c, forming an opening 332 therebetween.When the first gauge part 302 is attached to the stator 12, a lower surface 315 of the body 306 abuts the outermost sheet 24a of the stator 12.

[0037] The supports 312 are spaced apart from each other around the body 306 (i.e., around the intermediate portion 306a and / or the end portions 306b, 306c) and extend radially outward from the body 306. The supports 312 are vertically aligned (and concentric) with respective eyelet holes 128 of the stator core 16. The plurality of legs 314 are attached to respective supports 312 and are configured to be received in eyelet holes 128 of the stator core 16. In this manner, the first gauge part 302 is attached to the stator 12. The legs 314 extend in an axial direction +X from the respective supports 312 and are spaced apart in a circumferential direction about an axis 313.

[0038] The second gauge part 304 is configured to be received in the opening 332 between the end portions 306b, 306c and to slidably engage the outer lamination 24a of the stator 12. In this manner, the second gauge part 304 is configured to measure an outer diameter of a portion of the epoxy-coated electrical components 80. The second gauge part 304 includes a first body portion 304a and a second body portion 304b. When the second gauge part 304 is received in the opening 332, the second gauge part 304 is movable within the opening 332 in a circumferential direction. The first body portion 304a extends beyond the bottom surface 315 of the first gauge part 302 and is configured to slidably engage an outer circumferential surface 317 of the laminations 24.The second body portion 304b is configured to slidably engage the end surface 136 of the outermost sheet 24a and is movable in a circumferential direction. The second body portion 304b may abut the end portion 306b to prevent further movement in a first circumferential direction and may abut the end portion 306c to prevent further movement in a second circumferential direction opposite the first circumferential direction.

[0039] With continued reference to Fig. 11 and Fig. 12, the operation of the gauge 300 is described in detail. First, the first gauge part 302 is attached to the stator 12 as described above (i.e., the legs 314 are received in the eyelet holes 128 of the stator core 16). When the first gauge part 302 is attached to the stator 12 such that it is level with the stator 12, the epoxy-coated electrical components 80 surrounded by the first gauge part 302 are within a predetermined outer diameter tolerance range. If the first gauge part 302 cannot be attached to the stator 12 (i.e., the legs 314 are not received in the holes 128), the epoxy-coated electrical components 80 may extend radially outward beyond the predetermined outer diameter tolerance range.

[0040] When the first gauge part 302 is attached to the stator 12, the outer diameter of a portion of the epoxy-coated electrical components 80 not surrounded by the first gauge part 302 is measured to determine whether or not the epoxy coating is within the predetermined outer diameter tolerance range. That is, the second gauge part 304 moves circumferentially within the opening 332, as described above. If the second gauge part 304 moves along the opening 332 without being obstructed by the portion of the epoxy-coated electrical components 80, then the portion of the epoxy-coated electrical components 80 is within the predetermined outer diameter tolerance range.If the diameter gauge part 104 is obstructed by the epoxy-coated electrical components 80, then the epoxy-coated electrical components 80 may not be within the predetermined outside diameter tolerance range.

[0041] In some forms, such as Fig.13, a first gauge portion 402 is provided. The structure and function of the first gauge portion 402 may be similar or identical to the first gauge portion 302 described above, except for any exceptions listed below. The first gauge portion 402 includes a lip 404 extending radially inward from a top surface 405 of the body 406. The lip 404 may include a structure and function similar to the body 106 described above (i.e., the lip 404 may include a plurality of height measuring surfaces (not shown) recessed relative to the height measuring surface 418). In this manner, when the first gauge portion 402 is attached to the stator 12, the lip 404 extends over the epoxy-coated electrical components 80 and may measure the height of the epoxy-coated electrical components 80 as described above.

[0042] Unless expressly stated otherwise herein, all numerical values ​​indicating mechanical / thermal properties, composition percentages, dimensions and / or tolerances, or other characteristics are to be understood as modified by the word "about" or "approximately" when describing the scope of the present disclosure. This modification is desirable for various reasons, including industrial practice, material, manufacturing and assembly tolerances, and testability.

[0043] As used in this document, the phrase "at least one of A, B, and C" should be interpreted to mean a logical (A OR B OR C) using a non-exclusive logical OR, and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C."

[0044] In this application, the terms "controller" and / or "module" may refer to, be part of, or include: an application specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); processor circuitry (shared, dedicated, or group) that executes code; memory circuitry (shared, dedicated, or group) that stores code executed by the processor circuitry; other suitable hardware components (e.g.,An operational amplifier circuit integration circuit as part of the heat flow data module) that provides the described functionality; or a combination of some or all of the foregoing, such as in a system-on-chip.

[0045] The term "memory" is a subset of the term "computer-readable medium." As used herein, the term "computer-readable medium" does not include transitory electrical or electromagnetic signals propagating through a medium (such as a carrier wave); therefore, the term "computer-readable medium" can be considered tangible and non-transitory.Non-limiting examples of a non-transitory, tangible computer-readable medium include non-volatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only memory circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).

[0046] The devices and methods described in this application may be implemented in part or in whole by a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions embodied in computer programs. The functional blocks, flowchart components, and other elements described above serve as software specifications that can be translated into computer programs through the routine work of a skilled technician or programmer.

[0047] The description of the disclosure is merely exemplary in nature, and thus variations that do not depart from the essence of the disclosure are intended to be within the scope of the disclosure. Such variations should not be considered a departure from the spirit and scope of the disclosure.

[0048] According to the present invention, there is provided a gauge for a stator, comprising: a first diameter gauge part including: an annular base facing in a first direction and configured to abut an end face of a lamination stack of the stator; a plurality of legs spaced in a circumferential direction about an axis and extending in the first direction from the base, the legs configured to be received in holes defined by the lamination stack of the stator; a first diameter inspection surface extending in the circumferential direction; and a second diameter inspection surface extending in the circumferential direction and recessed in a second direction relative to the first diameter inspection surface, the second direction being perpendicular to the first direction.

[0049] According to one embodiment, the first diameter measuring device part has a variable thickness.

[0050] According to one embodiment, the first diameter measuring device part includes a first end and a second end spaced from the first end to define an opening.

[0051] According to one embodiment, the invention is further characterized by a second diameter measuring part arranged within the opening and slidably engaging the laminated core of the stator, wherein the second diameter measuring part is movable within the opening in the circumferential direction.

[0052] According to one embodiment, the first diameter measuring device part includes a third diameter inspection surface extending in the circumferential direction and recessed in the second direction by a further distance than the second diameter inspection surface.

[0053] According to the present invention, there is provided a gauge for a stator, comprising: a first gauge part including: at least one base surface facing in a first direction to define a ground plane configured to abut an end surface of a lamination stack of the stator; a plurality of legs spaced in a circumferential direction about an axis and extending in the first direction from the at least one base surface, the legs configured to be received in holes defined by the lamination stack of the stator; and a first height inspection surface parallel to the base plane and spaced therefrom by a first predetermined distance, the first height inspection surface having an annular shape arranged around the axis;at least one second height inspection surface parallel to the ground plane and spaced therefrom by a second predetermined distance greater than the first predetermined distance; and a second gauge member slidably engaged along a periphery of the first gauge member in a circumferential direction.

[0054] According to one embodiment, the second measuring device part extends in the first direction beyond the first height test surface.

[0055] According to one embodiment, the first measuring device part includes supports extending radially outward from an outer peripheral surface of the first measuring device part, and wherein the legs extend in the first direction from respective supports. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 17 / 358,489

[0019]

Claims

[1] Measuring device for a stator, the measuring device comprising: a height measuring device part, including: at least one base surface facing in a first direction to define a base plane configured to abut an end surface of a lamination stack of the stator; a plurality of legs spaced in a circumferential direction about an axis and extending in the first direction from the at least one base surface, the legs configured to be received in holes defined by the stator core; and a first height inspection surface parallel to the base plane and spaced therefrom by a predetermined distance, the first height inspection surface having an annular shape disposed about the axis. [2] The measuring device according to claim 1, wherein the height measuring device part includes at least one second height checking surface recessed in a second direction opposite to the first direction, the at least one second height checking surface extending in a circumferential direction. [3] Measuring device according to claim 2, wherein the at least one second height test surface is parallel to the ground plane. [4] Measuring device according to claim 2, wherein the at least one second height test surface is not parallel to the ground plane. [5] The measuring device according to claim 1, wherein the height measuring device part includes an inner flange extending around an inner periphery of the first height inspection surface and extending from the inner periphery of the first height inspection surface in the first direction. [6] The measuring device according to claim 5, wherein the height measuring device part includes an outer flange extending around an outer periphery of the first height inspection surface and extending from the outer periphery of the first height inspection surface in the first direction. [7] Measuring device according to claim 5, wherein: the height gauge part includes an outer flange extending from an outer periphery of the first height test surface in the first direction and extending in the circumferential direction, the outer flange including a first end and a second end spaced from the first end to define an opening; and a flap pivotally coupled to the height gauge portion between an open position in which the flap is away from the opening and a closed position in which the flap closes the opening. [8] The measuring device according to claim 1, further comprising an inner diameter measuring device part slidably engaged along an inner circumference of the first height inspection surface in a circular path. [9] The measuring device according to claim 8, wherein the inner diameter measuring part has a first portion extending in the first direction of the height measuring part and a second portion extending from the first portion in a second direction of the height measuring part that is perpendicular to the first direction, the first portion extending beyond the first height inspection surface. [10] The measuring device according to claim 1, further comprising a first diameter measuring device part having a ring shape. [11] A measuring device according to claim 10, wherein the first diameter measuring device part has a variable thickness. [12] Measuring device according to claim 10, wherein: the first diameter measuring part includes a first end and a second end spaced from the first end to define an opening; and a second diameter measuring part is arranged within the opening and slidably engages the laminated core of the stator, wherein the second diameter measuring part is movable within the opening in the circumferential direction. [13] The measuring device according to claim 1, wherein the height measuring device part includes an outer flange extending around an outer periphery of the first height inspection surface and extending from the outer periphery of the first height inspection surface in the first direction.

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