Machine and method for assembling a stator provided with a casing and a plurality of wound teeth adhered inside

Abstract

The invention relates to a machine (14) for assembling a stator (2) provided with a casing (4) and a plurality of wound teeth (6) adhered inside the casing (4), which comprises: - a device for radially clamping the teeth (6) comprising a plurality of tooth supports (16) distributed annularly and a radial compression mechanism (18) configured to exert a radial stress on the tooth supports (16); - a lower plate (28) removably attached to the radial clamping device; - a device for axially clamping the teeth (6) comprising an upper plate (44) and a mechanism (46) for axially compressing the teeth (6) between the upper plate and the lower plate (28); and - a member for removably attaching the lower plate (28) to the casing (4).

Description

Description Title of the invention: Machine and method for assembling a stator provided with a casing and a plurality of wound teeth glued inside. Technical field

[0001] The technical field of the present invention is electric motors, in particular axial flux motors.

[0002] In particular, the present invention relates to a machine for assembling a stator, a method for assembling a stator, as well as a stator assembled by such a machine or such a method. Previous techniques

[0003] An axial flux electric motor comprises, for example, two stators and a rotor arranged axially between the two stators.

[0004] The rotor comprises a plurality of permanent magnets distributed in an annular manner. Each stator comprises a housing and a plurality of wound trapezoidal teeth distributed in an annular manner in the housing and screwed to the housing.

[0005] The wound teeth may be axially misaligned and / or distributed irregularly along the circumferential direction of the motor and / or loosely clamped along the circumferential direction. Statement of the invention

[0006] The present invention therefore aims to overcome all or part of the aforementioned drawbacks, to provide a stator provided with a casing and a plurality of wound teeth fixed inside the casing, to control the axial and radial positioning of the stator teeth.

[0007] The present invention relates to a machine for assembling a stator provided with a casing and a plurality of wound teeth glued inside the casing, this machine comprising:

[0008] - a radial tooth clamping device comprising a plurality of annularly distributed tooth supports and a radial compression mechanism configured to exert radial stress on the tooth supports,

[0009] - a lower plate removably attached to the radial clamping device,

[0010] - an axial tooth clamping device comprising an upper plate and an axial tooth compression mechanism between the upper plate and the lower plate, and

[0011] - a removable fixing member for the lower plate to the casing.

[0012] The radial clamping device of the stator teeth allows to form a contact between the sides of the coiled teeth.

[0013] The axial tooth clamping device allows the wound teeth of the stator to be held axially when the radial clamping device is tightened, and ensures control of the axial position of the stator teeth.

[0014] The removable fixing member of the lower plate to the housing is configured to removably fix the lower plate to the stator housing. The removable fixing member fixes the lower plate to the housing when the wound teeth have been clamped radially by the radial clamping device and axially by the axial clamping device. Advantageously, the removable fixing member is configured to fix the lower plate to the housing such that the wound teeth are maintained in their clamped position radially and axially between the lower plate and the housing.

[0015] The lower plate removably attached to the radial clamping device is capable of separating from the radial clamping device when the lower plate is attached to the housing by the removable fixing member. Thus, the assembly comprising the lower plate, the removable fixing member, the wound teeth and the housing is made independent, in particular in order to allow time for an adhesive of the teeth to the housing to set to fix the teeth to the housing.

[0016] Advantageously, the fixing member and the lower plate are resistant to a baking temperature of an adhesive of the teeth to the housing. Thus, the independent assembly comprising the lower plate, the removable fixing member, the wound teeth and the housing is capable of being placed in the oven to accelerate the setting of the adhesive of the teeth to the housing.

[0017] Preferably, when the removable bottom plate to housing attachment member is removed, the teeth to housing adhesive, e.g., teeth to housing glue, is the sole means of bonding the teeth to the housing.

[0018] Advantageously, the tooth supports are radially movable.

[0019] In a particular embodiment, the stator is a stator of an axial flux electric motor.

[0020] The machine may include a plurality of carriages, each carriage configured to attach a tooth.

[0021] The bottom plate may include a plurality of radial grooves, each tooth support extending axially through a radial groove.

[0022] Preferably, each tooth support is configured to drive a carriage in radial translation.

[0023] Advantageously, the radial compression mechanism of the radial clamping apparatus comprises a flywheel connected to the tooth supports and configured to transform a rotational force applied to the flywheel into a translational force applied radially to the tooth supports.

[0024] Advantageously, the lower plate comprises a central orifice, the member of fastener comprising a first compression piece inserted into the orifice and a second compression piece capable of cooperating with the first compression piece to compress the teeth between the lower plate and the casing.

[0025] Optionally, the lower plate comprises a plurality of spring plungers capable of cooperating with the removable fixing member of the lower plate to the housing to maintain the wound teeth in their radially and axially clamped position between the lower plate and the housing.

[0026] Advantageously, the machine comprises a member for temporarily holding a portion of the tooth supports in a clamped tooth position. The temporary holding member makes it possible in particular to manually position a portion of the tooth supports in their clamped tooth position before using the axial and radial clamping devices.

[0027] The present invention also relates to a method of assembling a stator provided with a casing and a plurality of wound teeth glued inside the casing, characterized in that it comprises the following steps:

[0028] - fixing teeth to tooth supports;

[0029] - axial tightening of the teeth;

[0030] - radial clamping of the teeth; and

[0031] - bonding of the teeth to the casing.

[0032] This method is, for example, implemented by the machine for the assembly of a stator provided with a casing and a plurality of wound teeth glued inside the casing as defined previously.

[0033] Advantageously, bonding the teeth to the housing includes applying an adhesive to the teeth and / or housing, as well as curing the adhesive.

[0034] Optionally, the method comprises, before the axial and radial clamping steps, a step of positioning a portion of the tooth supports in a clamped tooth position and temporarily fixing said portion of the supports.

[0035] The present invention also relates to a stator provided with a casing and a plurality of wound teeth glued inside the casing produced by the use of a machine as defined previously and / or by the implementation of a method as defined previously.

[0036] The present invention further relates to an electric motor comprising a rotor and at least one stator provided with a casing and a plurality of wound teeth glued inside the casing, the stator being produced by the use of a machine as defined previously and / or by the implementation of a method as defined previously.

[0037] In a particular embodiment, the electric motor comprises a rotor and two stators each comprising a casing and a plurality of wound teeth bonded to inside said casing, each stator being produced by the use of a machine as defined previously and / or by the implementation of a method as defined previously. Brief description of the drawings

[0038] Other aims, characteristics and advantages of the invention will appear on reading the following description, given solely by way of non-limiting example and made with reference to the appended drawings in which:

[0039] [Fig.l] schematically illustrates a stator provided with a casing and a plurality of wound teeth glued inside the casing according to the invention;

[0040] [Fig.2] schematically illustrates an electric motor according to the invention;

[0041] [Fig.3] schematically illustrates a machine for assembling a stator according to the invention;

[0042] [Fig.4] schematically illustrates the steps of a method of assembling a stator according to the invention;

[0043] [Fig.5] schematically illustrates a step of fixing the teeth to tooth supports according to the invention;

[0044] [Fig.6] schematically illustrates a step of axial and radial tightening of the teeth according to the invention;

[0045] [Fig.7] schematically illustrates a step of bonding the teeth to the casing according to the invention; and

[0046] [Fig.8] schematically illustrates a step of cooking the glue according to the invention. Detailed description

[0047] [Fig.l] schematically represents a stator 2 provided with a casing 4 and a plurality of teeth 6 glued inside the casing 4, the stator 2 here comprising fifteen teeth 6 glued inside the casing 4.

[0048] The teeth 6 here are trapezoidal section teeth, stacked and wound.

[0049] The teeth 6 are fixed to the casing 4 only by an adhesive, for example a one-component or two-component epoxy adhesive.

[0050] The teeth 6 are arranged in an annular manner, each tooth 6 being in contact with two other teeth 6.

[0051] [Fig.2] schematically represents an axial flux electric motor 8 comprising a rotor 10 and two stators 2 arranged axially on either side of the rotor 10.

[0052] Each casing 4 of stator 2 comprises a central hole 12 for the passage of a transmission shaft.

[0053] [Fig. 3] schematically represents a machine 14 for assembling a stator 2 provided with a casing 4 and a plurality of wound teeth 6 glued inside of the crankcase 4.

[0054] The machine 14 comprises a radial tooth clamping device 6 comprising a plurality of tooth supports 16 distributed in an annular manner.

[0055] The radial clamping device comprises a radial compression mechanism 18 comprising a flywheel provided with a flange 20 of circular section and levers 22 extending radially from the flange 20 in order to facilitate the application of a rotational force on the flywheel.

[0056] The flange 20 comprises a plurality of recesses 24 each extending along a sector limited in the circumferential direction and each having a curvature greater than the flange 20. Each recess 24 extends between a first end and a second end, the distance between the first end of the recess 24 and the circular periphery of the flange 20 being less than the distance between the second end of the recess 24 and the circular periphery of the flange 20.

[0057] The radial compression mechanism 18 comprises a plurality of rods 26 provided with a first end movable in a recess 24 of the flange 20 and a second end mechanically connected to a tooth support 16.

[0058] The machine 14 includes a bottom plate 28 including a plurality of radial grooves 30 and a central hole. The bottom plate 28 is removably attached to the radial clamping device.

[0059] The lower plate 28 comprises a plurality of spring pushers 32 each arranged circumferentially between two successive radial grooves 30 of the lower plate 28 and capable of exerting an axial force.

[0060] Each tooth support 16 of the radial clamping device extends axially through a radial groove 30 of the lower plate 28.

[0061] Thus, when the flywheel is rotated, the rods 26 of the radial compression mechanism 18 constrained in the recesses 24 of the flange 20 exert a radial force on the tooth supports 16 so as to radially move the tooth supports 16 in the radial grooves 30 of the lower plate 28.

[0062] The machine 14 also comprises a removable fixing member for the lower plate 28 to the casing 4 comprising a first compression piece 34 inserted into the central orifice of the lower plate 28.

[0063] Advantageously, the first compression part 34 is integral with the lower plate 28.

[0064] The machine 14 is capable of implementing a method of assembling a stator 2 provided with a casing 4 and a plurality of wound teeth 6 glued inside the casing 4, the method being represented schematically in [Fig.4],

[0065] We begin with a step 36 of fixing the teeth 6 to the tooth supports 16 shown schematically in [Fig.5].

[0066] The machine 14 comprises a plurality of carriages 38 for attaching the teeth 6. Each tooth 6 comprises, for example, a groove (not shown), each carriage 38 comprising a complementary attachment to the groove of the tooth 6 so that the complementary attachment of the carriage 38 is able to clamp in the groove of the tooth 6.

[0067] When the tooth holders 16 are disposed in the radial grooves 30 of the bottom plate 28 such that the tooth holders 16 abut against the distal ends of the radial grooves 30, the carriages 38 attached to the teeth 6 are fixed to the tooth holders 16. The distal end of the radial grooves 30 is the end closest to the periphery of the bottom plate 28.

[0068] The teeth 6 are thus arranged on the lower plate 28 so that the air gap of the stator 2, intended to be located on the side of the rotor 10, corresponds to the side of the lower plate 28 relative to the teeth 6.

[0069] Steps 40, 42 of axial and radial tightening of the teeth 6 are then carried out, shown schematically in [Fig.6].

[0070] For this, the machine 14 also comprises an axial clamping device for the teeth 6 comprising an upper plate 44 and an axial compression mechanism 46 for the teeth 6 between the upper plate 44 and the lower plate 28.

[0071] For example, the upper plate 44 is positioned on the teeth 6 attached to the carriages 38 fixed to the tooth supports 16. Thus, the teeth 6 are axially clamped between the upper plate 44 and the lower plate 28, in particular by interposition of the carriages 38.

[0072] The upper plate 44 here comprises a central orifice, the first compression piece 34 comprising a pin passing through the central orifice of the lower plate 28 and provided with a shoulder. The pin is fitted into the central orifice of the upper plate 44, the upper plate 44 resting on the shoulder when the teeth 6 are axially tightened.

[0073] Advantageously, before performing the axial and radial clamping steps 40, 42, a step 48 is performed for positioning a portion of the tooth supports 16 in a clamped tooth position. For example, a portion of the tooth supports 16 is manually moved, for example three tooth supports 16 angularly offset by 120°, to place said tooth supports 16 in abutment against the proximal ends of the radial grooves 30. The proximal end of the radial grooves 30 is the end furthest from the periphery of the lower plate 28.

[0074] Then, the part of the tooth supports 16 is fixed in the clamped tooth position corresponding to the position occupied by the tooth 6 fixed to the tooth support 16 when the teeth 6 are clamped radially.

[0075] The machine 14 comprises a member 50 for temporarily holding a portion of the tooth supports 16 in the clamped tooth position.

[0076] The upper plate 44 comprises, for example, a plurality of threads, the temporary holding member 50 then comprising a plurality of screws inserted into the threads of the upper plate 44 to hold the tooth supports 16 and the teeth 6 in the clamped tooth position. Alternatively, the temporary holding member 50 may comprise shims cooperating with the radial grooves 30 to hold the tooth supports 16 in the clamped tooth position.

[0077] The step 40 of axially tightening the teeth 6 is then carried out. For example, the axial compression mechanism 46 is used to compress the teeth 6 between the upper plate 44 and the lower plate 28. The axial compression mechanism 46 comprises, for example, a press or screws from the upper plate 44 to the lower plate 28.

[0078] Thus, the axial clamping device of the teeth 6 makes it possible to axially hold the wound teeth 6 of the stator 2 to carry out the radial clamping of the teeth 6.

[0079] Advantageously, the upper plate 44 is fixed to the first compression part 34 of the removable fixing member when the teeth 6 are axially tightened. For example, the first compression part 34 of the removable fixing member comprises a thread for fixing the upper plate 44.

[0080] Step 42 of radially tightening the teeth 6 is then carried out. For example, the handwheel is turned to move the tooth supports 16 radially inwards so as to obtain contact between the flanks of the wound teeth 6.

[0081] Optionally, a template (not shown) is placed in the center of the plurality of teeth 6 in order to check that the teeth 6 are properly tightened radially.

[0082] When the teeth 6 are clamped axially and radially, the upper plate 44 is removed. For example, an ejector plate (not shown) is positioned on the upper plate 44, then an axial force is exerted on the ejector plate in the direction of the lower plate 28 to undo the attachment of the upper plate 44 to the first compression piece 34.

[0083] A step 52 of gluing the teeth 6 is then carried out, shown schematically in [Fig.7],

[0084] An adhesive is applied to the teeth 6 and / or to the inside of the casing 4, then the casing 4 is placed on the teeth 6 so that the teeth 6 are inside the casing 4.

[0085] Preferably, the first compression piece 34 makes it possible to center the casing 4 on the lower plate 28.

[0086] The spring pushers 32 then make it possible to keep the teeth 6 pressed against the casing 4.

[0087] Optionally, the surface of the teeth 6 and / or the inner surface of the housing 4 is prepared before applying the adhesive, for example by laser surface preparation.

[0088] In order to better distribute the adhesive, the casing 4 and the lower plate 28 are axially tightened in order to make the adhesive flow.

[0089] For this, the removable fixing member comprises a second compression part 54 capable of cooperating with the first compression part 34 to compress the teeth 6 between the lower plate 28 and the casing 4.

[0090] For example, the second compression part 54 comprises a plate capable of being screwed through the central orifice 12 of the casing 4 into the thread of the first compression part 34 of the removable fixing member to axially compress the teeth 6 between the lower plate 28 and the casing 4.

[0091] Preferably, the spring pushers 32 are independent of each other to independently press the different teeth 6 onto the casing 4. Thus, the thickness of adhesive between the casing 4 and the teeth 6 is close from one tooth 6 to the next, the spring pushers 32 making it possible to compensate for any differences in height of the teeth 6.

[0092] Advantageously, a step 56 of cooking the adhesive is carried out in order to accelerate the setting of the adhesive.

[0093] The lower plate 28 is detached from the radial clamping device, thus making the assembly comprising the lower plate 28, the removable fixing member, the wound teeth 6 and the casing 4 independent, the carriages 38 then being removed.

[0094] Then the independent assembly is placed in an oven, the removable fixing member and the lower plate 28 being, preferably, resistant to a cooking temperature of the adhesive of the teeth 6 to the casing 4.

[0095] When the adhesive has set, the independent assembly is removed from the oven, then the lower plate 28 fixed by the removable fixing member of the lower plate 28 to the casing 4 is detached.

Claims

Claims

1. Machine (14) for assembling a stator (2) provided with a casing (4) and a plurality of wound teeth (6) glued inside the casing (4), characterized in that it comprises: - a radial tooth clamping device (6) comprising a plurality of annularly distributed tooth supports (16) and a radial compression mechanism (18) configured to exert a radial stress on the tooth supports (16), - a lower plate (28) removably attached to the radial clamping device, - an axial clamping device for the teeth (6) comprising an upper plate (44) and an axial compression mechanism (46) for the teeth (6) between the upper plate (44) and the lower plate (28), and - a removable fixing member for the lower plate (28) to the casing (4).

2. A machine (14) according to claim 1, wherein the fixing member and the lower plate (28) are resistant to a baking temperature of an adhesive of the teeth (6) to the housing (4).

3. Machine (14) according to one of claims 1 and 2, comprising a plurality of carriages (38), each carriage (38) being configured to attach a tooth, the lower plate (28) comprising a plurality of radial grooves (30), each tooth support (16) extending axially through a radial groove (30) and being configured to drive a carriage (38) in radial translation.

4. A machine (14) according to any one of claims 1 to 3, wherein the radial compression mechanism (18) of the radial clamping apparatus comprises a flywheel connected to the tooth supports (16) and configured to transform a rotational force applied to the flywheel into a translational force applied radially to the tooth supports (16).

5. Machine (14) according to any one of claims 1 to 4, in which the lower plate (28) comprises a central orifice, the fixing member comprising a first compression piece (34) inserted in the orifice and a second compression piece (54) adapted to cooperate with the first compression piece (34) to compress the teeth (6) between the lower plate (28) and the housing (4).

6. Machine (14) according to any one of claims 1 to 5, comprising a member (50) for temporarily holding a portion of the tooth supports (16) in a clamped tooth position.

7. Method for assembling a stator (2) provided with a casing (4) and a plurality of wound teeth (6) glued inside the casing (4), characterized in that it comprises the following steps: fixing (36) the teeth (6) to tooth supports (16); axial clamping (40) of the teeth (6); radial clamping (42) of the teeth (6); and gluing (52) the teeth (6) to the casing (4).

8. A method according to claim 6, wherein bonding the teeth (6) to the housing (4) comprises applying an adhesive to the teeth (6) and / or the housing (4), and curing (56) the adhesive.

9. Method according to one of claims 6 and 7 comprising, before the axial and radial clamping steps (40, 42), a step of positioning (48) a part of the tooth supports (16) in a clamped tooth position and temporarily fixing said part of the tooth supports (16).

10. Electric motor (8) comprising a rotor (10) and at least one stator (2) provided with a casing (4) and a plurality of wound teeth (6) glued inside the casing (4), the stator (2) being produced by the use of a machine (14) according to any one of claims 1 to 6 and / or by the implementation of a method according to any one of claims 7 to 9.

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