Manufacturing process and stator of a rotating electrical machine with asymmetrical winding

Abstract

Method for manufacturing and stator of a rotating electrical machine with asymmetrical winding. Method for manufacturing a stator (2) of a rotating electrical machine (1), comprising the following steps: (a) providing a stator mass (25), the stator mass (25) having slots (21) formed between teeth (23), electrical conductors (22) being housed in the slots (21), at least a portion of the electrical conductors being U- or I-shaped, each having inner (22e) and outer (22f) legs, at least one of the inner (22e) and outer (22f) legs of the electrical conductors (22) extending out of the slots by a weld portion, (b) circumferentially offset the outer legs (22f) of the electrical conductors by half a tooth pitch relative to the inner legs (22e), and (c) radially offset outward the outer legs (22f) of certain electrical conductors,in particular the outer legs of the phase input and / or output electrical conductors. Figure for the abbreviation: Fig. 1,

Description

Title of the invention: Manufacturing method and stator of a rotating electrical machine with asymmetric winding

[0001] The present invention relates to rotating electrical machines and more particularly to the stators of such machines. It relates in particular to a method of manufacturing the stator, with a corresponding set of tools. Technical field

[0002] The invention relates more particularly to synchronous or asynchronous alternating current machines. It relates in particular to traction or propulsion machines for electric (Battery Electric Vehicle) and / or hybrid (Hybrid Electric Vehicle - Plug-in Hybrid Electric Vehicle) motor vehicles, such as individual cars, vans, trucks or buses. The invention also applies to rotating electrical machines for industrial and / or energy production applications, in particular naval, aeronautical or wind power. Prior art

[0003] It is known to use, in order to obtain a deformation of electrical conductors, tools comprising teeth making it possible to accommodate the free ends of the electrical conductors to be deformed.

[0004] Tools in the form of arcuate sectors are known in particular from application US 2014 / 0237811. The deformation of the electrical conductors is carried out on four concentric planes, each with an identical number of conductors.

[0005] International application WO 2021 / 023523 also discloses tools comprising four concentric rings.

[0006] In applications JP 2013 / 172575 and JP 2020 / 110025, the tools comprise vertical fingers of different lengths.

[0007] Applications US 2018 / 0212496 and US 2018 / 0212499 relate to tools comprising two non-nested crowns. In US 2018 / 0212499, the teeth of the crowns have different widths.

[0008] There is a need to benefit from a rotating electrical machine stator that is easy to assemble and allows efficient filling of the slots, while ensuring satisfactory electromagnetic performance.

[0009] There is still a need to reduce the manufacturing cost of electrical machines, in particular by simplifying the manufacturing of the stator winding, for example by minimizing the number of parts to be used.

[0010] There is also a need to further improve the stators of electrical machines and in particular to reduce torque ripples and AC Joule losses by induced currents, vibrations and electromagnetic noise. Statement of the invention Manufacturing process

[0011] The invention aims to meet all or part of these needs and achieves this, according to one of its aspects, by means of a method for manufacturing a stator of a rotating electrical machine, comprising the following steps: (a) providing a stator mass, in particular comprising a pack of magnetic laminations, the stator mass comprising notches formed between teeth, electrical conductors being housed in the notches, at least a portion of the electrical conductors, or even a majority of the electrical conductors, being in the shape of a U-shaped or I-shaped pin, each comprising inner and outer legs, which extend in particular axially respectively in first A and second R notches, at least one of the inner and outer legs of the electrical conductors extending outside the notches by a welding portion, (b) circumferentially offsetting the outer legs of the electrical conductors by one-half tooth pitch relative to the inner legs, and (c) radially shifting inwards or outwards respectively the inner legs or the outer legs of certain electrical conductors, in particular the outer legs of certain electrical conductors, in particular the legs of the phase input and / or output electrical conductors, in particular six legs.

[0012] The invention relates in particular to, independently or in combination with the above, a method of manufacturing a stator of a rotating electrical machine, comprising the following steps: (a) providing a stator mass, in particular comprising a pack of magnetic laminations, the stator mass comprising notches formed between teeth, electrical conductors being housed in the notches, at least a portion of the electrical conductors, or even a majority of the electrical conductors, being in the shape of a U-shaped or I-shaped pin, each comprising inner and outer legs, which extend in particular axially respectively in first A and second R notches, at least one of the inner and outer legs of the electrical conductors extending outside the notches by a welding portion, (b) circumferentially offsetting the outer legs of the electrical conductors by one-half tooth pitch relative to the inner legs, and (c) radially offsetting outwardly the outer legs of certain electrical conductors, in particular the outer legs of the phase input and / or output electrical conductors, in particular six outer legs.

[0013] The invention relates in particular to, independently or in combination with the above, a method of manufacturing a stator of a rotating electrical machine, comprising the following steps: (a) providing a stator mass, in particular comprising a pack of magnetic laminations, the stator mass comprising notches formed between teeth, electrical conductors being housed in the notches, at least a portion of the electrical conductors, or even a majority of the electrical conductors, being in the shape of a U-shaped or I-shaped pin, each comprising inner and outer legs, which extend in particular axially respectively in first A and second R notches, at least one of the inner and outer legs of the electrical conductors extending outside the notches by a welding portion, (b) circumferentially offsetting the inner legs of the electrical conductors by one-half tooth pitch relative to the outer legs, and (c) radially inwardly offsetting the inner legs of certain electrical conductors, in particular the inner legs of the phase input and / or output electrical conductors, in particular six inner legs.

[0014] The method according to the invention makes it possible to obtain the desired inclination of the electrical conductors outside the stator mass, on the side of the welding portions thereof, with different inclinations for different electrical conductors. Furthermore, the method according to the invention makes it possible to radially offset certain electrical conductors, in particular those of phase input and / or output. Such a configuration makes it easier to connect them to an electrical connector of the machine.

[0015] The method according to the invention advantageously makes it possible to carry out these operations without changing the workstation for the stator, nor changing the tooling, nor changing the orientation of the stator in the workstation. The manufacturing process is thus made easier and simpler.

[0016] The positioning of electrical conductors in an axial plane is facilitated.

[0017] The angular position of each electrical conductor can be more easily controlled.

[0018] Furthermore, the number of types of electrical conductors to be introduced into the stator mass can be reduced, which can facilitate the storage of the electrical conductors before their insertion into the stator mass.

[0019] The deformation of electrical conductors in the circumferential plane and outside the circumferential plane can be carried out at the same workstation, with the same tools. The size of the workstation can be reduced.

[0020] The method according to the invention can also make it possible to easily add an insulator between the inner and outer legs of the electrical conductors, which can be particularly useful when increasing stator voltage.

[0021] During the implementation of the method according to the invention, the internal shape of the buns formed by the U-shaped ends of the electrical conductors, opposite the welding portions thereof, can also be well supported.

[0022] In step (b) of circumferentially offsetting the outer legs of the electrical conductors by half a tooth pitch relative to the inner legs, the outer legs of the electrical conductors may be deformed by half a tooth pitch relative to the inner legs, or alternatively the inner legs may be deformed relative to the outer legs. Step (b) of circumferentially offsetting the inner legs or the outer legs of the electrical conductors, in particular the outer legs of the electrical conductors, by half a tooth pitch may comprise a step (bl) of positioning two inner and outer crowns for positioning the electrical conductors.

[0023] The two inner and outer positioning rings can be placed against the stator mass, just above the latter's sheet metal pack.

[0024] The two inner and outer positioning rings may comprise, as described below, movable fingers extending radially, which are each movable along a radial axis of the stator. During the step (bl) of positioning the positioning rings, the movable fingers may be in the retracted position in the positioning rings.

[0025] In a step (b2), the movable fingers are removed, each of which can be placed between two consecutive electrical conductors. The movable fingers of the outer positioning ring are placed between the outer legs of the electrical conductors and the movable fingers of the inner positioning ring are placed between the inner electrical conductors.

[0026] The movable fingers may or may not come into contact with the electrical conductors, in particular depending on the winding. In any case, the aim is to prevent an electrical conductor from being able to slide between two inner and outer movable fingers.

[0027] The movable fingers slide like pistons.

[0028] In a step (b3), the positioning rings are moved in translation along the longitudinal axis of the stator, in particular away from the stator mass, in particular upwards. Thus, the positioning rings can be moved towards the ends of the welding portions. In this translational movement, the movable fingers act as combs which allow the electrical conductors to be properly aligned.

[0029] In a step (b4), the outer positioning ring is rotated by a given angle around the longitudinal axis of the stator. The angle may be equal to half a step dental. In this rotational movement, the movable fingers allow the outer legs to be twisted by half a dental step relative to the inner legs.

[0030] In step (c) of radial shifting, it is possible to move phase moving fingers out of the inner positioning ring, which are in particular configured to have a longer radial stroke than other moving fingers of the inner positioning ring.

[0031] The radial offset preferably takes place away from the longitudinal axis of the stator.

[0032] The longer radial travel of these movable phase fingers allows the radial outward shifting of the outer legs of certain electrical conductors, in particular the outer legs of the phase input and / or output electrical conductors, relative to the other outer legs which remain circumferentially aligned.

[0033] These movable phase fingers make it possible to shift certain electrical conductors called phase input and / or output conductors outwards and place them on a third layer, in particular an outermost layer.

[0034] The radial offset outwards may be more or less accentuated. The inclination of the outer legs may comprise a curved portion having a large radius of curvature or a smaller radius of curvature, which means that the curved portion is then located closer to the sheet metal pack.

[0035] In one embodiment, before their deformation in the method of the invention, the length of the welding portions of the outer legs of the phase input and / or output electrical conductors may be different, in particular greater, than the length of the welding portions of the outer legs of the other electrical conductors. Alternatively, the lengths may be equal.

[0036] In one embodiment, the phase movable fingers are configured to push outwardly the phase input and / or output electrical conductors.

[0037] Alternatively, they may be configured to pull them outwards. For this purpose, they may comprise a clamp or other gripping tool. This embodiment variant may in particular be implemented with phase input and / or output electrical conductors extending longitudinally beyond the other electrical conductors, being longer than the latter.

[0038] As a further variant, in step (c) of radial shifting, it is possible to move phase moving fingers out of the outer positioning ring, which are in particular configured to have a longer radial stroke than other moving fingers of the outer positioning ring.

[0039] In this case, the radial offset takes place towards the longitudinal axis of the stator.

[0040] The longer radial travel of these phase moving fingers allows the radial inward shifting of the inner legs of certain electrical conductors, in particular the inner legs of the phase input and / or output electrical conductors, relative to the other inner legs which remain circumferentially aligned.

[0041] These movable phase fingers make it possible to shift certain electrical conductors called phase input and / or output conductors inwards and place them on a third layer, in particular an innermost layer.

[0042] The radial inward offset may be more or less pronounced. The inclination of the inner legs may include a curved portion having a large radius of curvature or a smaller radius of curvature, which means that the curved portion is then located closer to the sheet metal pack.

[0043] In one embodiment, before their deformation in the method of the invention, the length of the welding portions of the inner legs of the phase input and / or output electrical conductors may be different, in particular greater, than the length of the welding portions of the inner legs of the other electrical conductors. Alternatively, the lengths may be equal.

[0044] In one embodiment, the phase movable fingers are configured to push the phase input and / or output electrical conductors inward.

[0045] The method may comprise the following additional step (d): (d) circumferentially deform the welding portions of the electrical conductors, with at least two different pitches, in particular three different pitches.

[0046] In one embodiment, the welding portions of the inner legs of the electrical conductors can be deformed at a first pitch PL. At least a portion of the welding portions of the outer legs of the electrical conductors can be deformed at a second pitch P2. All of the welding portions of the outer legs of the electrical conductors radially offset in step (c) can be deformed. The other welding portions of the outer legs of the electrical conductors can be deformed at a third pitch P3.

[0047] The third step P3 may be less than the first and second steps PI and P2.

[0048] In the method according to the invention, step (d) of circumferential deformation may comprise a step (dl) of positioning a third deformation ring, which may be crenellated, and may comprise as many crenellations as there are notches in the stator. This third deformation ring may in particular deform the welding portions of the inner legs of the electrical conductors at a first pitch PL

[0049] In an exemplary embodiment, it comprises 63 notches, for a stator comprising 63 slots and 6 poles. This third deformation crown makes it possible to deform the 63 welding portions of the inner legs of the electrical conductors to a first PI pitch.

[0050] The circumferential deformation step (d) may comprise a step (d2) of positioning a first deformation ring, which may comprise at least one window for receiving a tab of a second deformation ring.

[0051] The first deformation ring may be crenellated, and may comprise a number of notches equal to the number of notches in the stator, from which the number of notches in the second deformation ring described below is deduced.

[0052] This first deformation crown can deform in particular at least part of the welding portions of the outer legs of the electrical conductors at a second pitch P2, as well as all the welding portions of the outer legs of the electrical conductors radially offset in step (c).

[0053] In an exemplary embodiment, it comprises 42 notches, for a stator comprising 63 notches and 6 poles. This first deformation crown makes it possible to deform 42 welding portions of the outer legs of the electrical conductors at a second pitch P2.

[0054] The first deformation crown may also comprise notches which also make it possible to deform all the welding portions of the outer legs of the electrical conductors radially offset in step (c), in particular six notches for six welding portions radially offset in step (c).

[0055] The position of said notches may depend on the winding diagram of the stator.

[0056] Then, step (d) of circumferential deformation may comprise a step (d3) of positioning a second deformation crown.

[0057] The second deformation ring may be configured to be nested in the first deformation ring, being in particular configured to move therein, in particular in rotation.

[0058] The second deformation ring may in particular comprise tabs each received in a window of the first deformation ring, in particular four windows and four tabs.

[0059] The legs can move in the windows as the second deformation ring rotates in the first deformation ring.

[0060] This second deformation crown can deform in particular the other welding portions of the outer legs of the electrical conductors at a third pitch P3.

[0061] The legs can be crenellated.

[0062] In an exemplary embodiment, the second deformation ring comprises 15 notches distributed over 4 legs, for a stator comprising 63 notches and 6 poles. This second deformation ring makes it possible to deform the other welding portions outer legs of the electrical conductors at a third pitch P3.

[0063] Thus, thanks to the configuration of the deformation crowns, a lower angle of inclination can be obtained for these electrical conductors, which thus have a shorter pitch in the resulting stator.

[0064] The circumferential deformation step (d) may include a step (d4) of repositioning the inner and outer positioning rings against the stator mass, in particular with a helical movement of the outer positioning ring.

[0065] The outer positioning ring can descend in a helix in order to follow the inclination of certain electrical conductors called phase input and / or output conductors which are placed on a third layer, in particular the outermost layer.

[0066] The inner positioning ring can descend parallel to the longitudinal axis of the stator.

[0067] During this repositioning movement, the movable fingers of the inner and outer positioning rings can be in the retracted position.

[0068] Once the inner and outer positioning rings are returned to position, the movable fingers can be placed in the gripping position with the electrical conductors.

[0069] This movement makes it possible to obtain protection of the insulators at the outlet of the notch during the following step. Thus, the maintenance of the insulators at the outlet of the notch to support them during step (d) of circumferential deformation is improved.

[0070] The circumferential deformation step (d) may comprise a step (d5) of simultaneously rotating at least two of the first, second and third deformation rings, with at least two different pitches.

[0071] In particular, the second deformation ring can be rotated relative to the first deformation ring.

[0072] Thus, all the welding portions of the stator are deformed simultaneously, with the appropriate pitch for each.

[0073] The first and second deformation rings can be rotated in a first direction, but not at the same pitch, while the third deformation ring can be rotated in a second direction opposite to the first direction.

[0074] After rotation, the welding portions of the phase input and / or output electrical conductors are radially aligned with welding portions of other electrical conductors.

[0075] In a further step (e), the deformation crowns can be removed, and then the inner and outer positioning crowns are also removed.

[0076] The external positioning ring may advantageously include notches for receiving certain phase input and / or output electrical conductors, in particular six notches, which makes it possible to prevent its withdrawal movement from being prevented by the phase input and / or output electrical conductors.

[0077] In an alternative embodiment, the rotation of the first, second and third deformation rings is simultaneous for the three deformation rings.

[0078] Alternatively, the rotation of the three deformation crowns may not be simultaneous. It may take place successively.

[0079] In an alternative embodiment, the rotation of the first deformation ring may precede the rotation of the other deformation rings. It may or may not precede the radial shifting of step (c). Thus, in one embodiment, the radial shifting step (c) may take place before the circumferential shifting step (b).

[0080] In an alternative embodiment, the positioning rings may not be configured to allow circumferential shifting. Radial shifting may be performed as described below, using claws.

[0081] In the example described above, the phase input and / or output electrical conductors are pushed outwards. Alternatively, they may be pulled outwards, for example by means of pliers or another gripping tool, such as independent claws. Said claws may be configured to allow the outward deformation of these welding portions. This variant embodiment may in particular be implemented with phase input and / or output electrical conductors extending longitudinally beyond the other electrical conductors, being longer than the latter.

[0082] As a further variant, the phase input and / or output electrical conductors may be pushed inwards. In this case, the inner legs of the electrical conductors are circumferentially offset by half a tooth pitch relative to the outer legs, then the inner legs of certain electrical conductors are radially offset inwards, in particular the inner legs of the phase input and / or output electrical conductors, in particular six inner legs.

[0083] Such a configuration can make it possible to generally improve the accessibility of the tool assembly. In addition, this configuration can make it possible to avoid using an internal crown with movable fingers because accessibility from the outside is complete. Finally, this configuration makes it possible to obtain better compactness, and thus a reduction in the raw materials required for the connector, when it is desired to position the phase connector on a large diameter stator.

[0084] At least one electrical conductor, or a majority of the electrical conductors, introduced into the slots, are U-shaped. They may be shaped into a pin prior to their introduction into the slots. All the U-shaped electrical conductors may be shaped, simultaneously or successively, and then introduced into the stator mass simultaneously or successively.

[0085] The shaping may include a first step of assembling the strands of the same electrical conductor.

[0086] The same U-shaped electrical conductor can be arranged in two different non-consecutive notches of the stator mass of the stator. In the case where an electrical conductor is U-shaped, it can be welded to two other electrical conductors on the same side of the machine. Together

[0087] The invention also relates to a set of tools, in particular for the manufacture of a stator of a rotating electrical machine, for implementing the method as described above.

[0088] The invention also relates, independently or in combination with the above, to a set of tools, in particular for the manufacture of a stator of a rotating electrical machine, in particular for the implementation of the method as described above, which comprises: a plurality of deformation crowns, in particular three deformation crowns, including a second deformation crown which is configured to be nested in a first deformation crown, being in particular configured to move therein, in particular in rotation.

[0089] The first deformation ring may comprise at least one window for receiving a tab of the second deformation ring. The first deformation ring may comprise in particular four windows. The second deformation ring may comprise in particular four tabs.

[0090] The window(s) of the first deformation ring may have a circumferential extent longer than the leg(s) of the second deformation ring, which may allow the movement, in particular in rotation, of the second deformation ring in the first deformation ring.

[0091] The plurality of deformation rings may comprise a third deformation ring, which may comprise regular notches, all regularly distributed around its circumference.

[0092] The deformation crowns are generally circular in shape. In particular, they are not made in independent sectors.

[0093] The deformation crowns can be manufactured for example by machining or by molding, or by additive manufacturing, known as 3D printing.

[0094] The deformation crowns may each comprise longitudinal slots to receive the welding portions of the electrical conductors.

[0095] Each welding portion of an electrical conductor can be received in a slot of one of the deformation rings. Each slot can receive a single welding portion of an electrical conductor.

[0096] The leg(s) of the second deformation crown may be crenellated.

[0097] The different deformation rings may be concentric around the longitudinal axis of the stator. In one embodiment, each deformation ring may comprise a different number of notches.

[0098] For example, a deformation ring, in particular the third deformation ring, may comprise as many notches as there are notches in the stator.

[0099] For example, a deformation ring, in particular the second deformation ring, may comprise a number of notches less than the number of notches in the stator, being for example equal to 15.

[0100] For example, a deformation ring, in particular the first deformation ring, may comprise a number of notches equal to the number of notches in the stator from which the number of notches in the second deformation ring is deduced.

[0101] All the notches of the first deformation crown may have the same circumferential width and / or the same height along the longitudinal axis of the stator and / or the same radial depth.

[0102] All the notches of the second deformation crown may have the same circumferential width and / or the same height along the longitudinal axis of the stator and / or the same radial depth.

[0103] All the notches of the third deformation crown may have the same circumferential width and / or the same height along the longitudinal axis of the stator and / or the same radial depth.

[0104] The assembly may comprise at least one outer ring for positioning the electrical conductors, the outer positioning ring comprising a plurality of movable fingers.

[0105] The movable fingers extend radially, they are each movable along a radial axis of the stator.

[0106] The outer positioning ring can have as many movable fingers as there are teeth on the stator.

[0107] The movable fingers may be conical in shape, in particular with a chamfered and / or radiated end.

[0108] The movable fingers are movable between a retracted position and a position grip with the electrical conductors. They can slide like pistons in the outer positioning ring.

[0109] In the retracted position, the movable fingers do not hinder the movement of the outer positioning ring relative to the stator. In particular, the outer positioning ring may be movable in translation along the longitudinal axis of the stator.

[0110] In the gripping position, the movable fingers are each engaged between two consecutive electrical conductors. They can help to promote their alignment, in particular during a translational movement along the longitudinal axis of the stator of the external positioning ring. In addition, they can allow their deformation by twisting, in particular over a circumferential distance of half a tooth pitch.

[0111] In one embodiment, all of the movable fingers of the outer positioning ring may be identical to each other.

[0112] The outer positioning ring may include notches for receiving certain phase input and / or output electrical conductors, in particular six notches.

[0113] These notches can allow the placement of the phase input and / or output electrical conductors on a third layer, in particular the outermost layer.

[0114] In one embodiment, the outer positioning ring comprises six notches each capable of receiving an electrical input and / or output phase conductor.

[0115] Some or all of the movable fingers of the outer positioning ring may each have a shoulder, which may allow the electrical conductors to be wedged.

[0116] In particular, the movable fingers present at the level of the aforementioned notches may comprise such a shoulder.

[0117] The shoulder can allow the electrical conductors to be held, as well as the insulation of said electrical conductor to be held.

[0118] The shoulders can help to maintain any insulators placed on the electrical conductors and protect them.

[0119] The assembly may comprise at least one inner ring for positioning the electrical conductors, the inner positioning ring comprising a plurality of movable fingers.

[0120] The movable fingers extend radially, they are each movable along a radial axis of the stator.

[0121] The inner positioning crown can have as many movable fingers as than teeth on the stator.

[0122] The movable fingers may be cylindrical, in particular with a chamfered and / or radiated end.

[0123] The movable fingers are movable between a retracted position and a gripping position with the electrical conductors. They can slide like pistons in the inner positioning ring.

[0124] In the retracted position, the movable fingers do not hinder the movement of the inner positioning ring relative to the stator. In particular, the inner positioning ring may be movable in translation along the longitudinal axis of the stator.

[0125] In the gripping position, the movable fingers are each engaged between two consecutive electrical conductors. They can help to promote their alignment, in particular during a translational movement along the longitudinal axis of the stator of the inner positioning ring. In addition, they can allow their deformation by twisting, in particular over a circumferential distance of half a tooth pitch.

[0126] The inner crown may have a disc shape.

[0127] The movable fingers of the inner positioning ring may comprise phase movable fingers configured to have a longer radial stroke than the other movable fingers, in particular four or six.

[0128] These movable phase fingers make it possible to shift certain electrical conductors called phase input and / or output conductors outwards or inwards and place them on a third layer, in particular the outermost layer.

[0129] Thus the internal positioning crown can comprise movable fingers with two possible radial strokes, a shorter one for most of them, and a longer one for some of them, in particular six of them.

[0130] The assembly may be configured such that the outer positioning ring and the inner positioning ring may be moved up and down and up and down relative to the stator along a longitudinal axis thereof.

[0131] Furthermore, the assembly may be configured such that the outer positioning ring and the inner positioning ring may be moved in rotation relative to each other. In particular, one of the two rings may be moved in rotation relative to the other and relative to the stator, while the other ring may remain fixed relative to the stator. In one embodiment, it is the outer positioning ring that is configured to be moved in rotation relative to the inner positioning ring and relative to the stator, while the inner positioning ring may remain fixed relative to the stator.

[0132] The tool assembly comprises crowns of simple shape, which are configured to have simple kinematics.

[0133] In an alternative embodiment, the assembly may be devoid of an inner positioning ring. It may only comprise an outer positioning ring. Stator

[0134] The invention also relates to a stator of a rotating electrical machine obtained by implementing the method as described above.

[0135] The invention also relates, independently or in combination with the above, to a stator for a rotating electrical machine, comprising a stator mass comprising notches arranged between teeth, electrical conductors being housed in the notches, at least a portion of the electrical conductors, or even a majority of the electrical conductors, being in the shape of a U-shaped or I-shaped pin, each comprising inner and outer legs extending axially respectively in first A and second R notches, at least one of the inner and outer legs of the electrical conductors extending outside the notches by a weld portion inclined relative to a plane perpendicular to a longitudinal axis of the stator to overhang the stator mass circumferentially at the level of a notch or a tooth, this notch or tooth being separated from the first A or the second R notch respectively by a number NI and / or N2 of teeth,at least a portion of the electrical conductors each having a welding portion that is the innermost relative to the longitudinal axis of the stator, or even a majority, better still all the electrical conductors each having a welding portion that is the innermost relative to the longitudinal axis of the stator, at least a portion of the electrical conductors each having a welding portion the outermost relative to the longitudinal axis of the stator, or even a majority, better all the electrical conductors each having a welding portion the outermost relative to the longitudinal axis of the stator, said innermost welding portions or said outermost welding portions being inclined with the same inclination relative to the plane perpendicular to the longitudinal axis of the stator, the others of the outermost welding portions of the electrical conductors or of the innermost welding portions being inclined with at least two, or even three or four, different inclinations relative to the plane perpendicular to the longitudinal axis of the stator, at least one welding portion of an input and / or output phase electrical conductor being radially aligned with welding portions of other electrical conductors.

[0136] The invention also relates, independently or in combination with the above, to a stator for a rotating electrical machine, in particular obtained by implementing the method as described above, which comprises a stator mass comprising notches formed between teeth, electrical conductors being housed in the notches, at least a portion of the electrical conductors, or even a majority of the electrical conductors, being in the shape of a U-shaped or I-shaped pin, each comprising inner and outer legs extending axially, in particular respectively in first A and second R notches, at least one of the inner and outer legs of the electrical conductors extending outside the notches by a weld portion inclined relative to a plane perpendicular to a longitudinal axis of the stator to overhang the stator mass circumferentially at the level of a notch or a tooth,this notch or tooth being in particular separated from the first A or the second R notch respectively by a number NI and / or N2 of teeth, , at least a portion of the electrical conductors each having a welding portion that is the innermost relative to the longitudinal axis of the stator, or even a majority, better still all the electrical conductors each having a welding portion that is the innermost relative to the longitudinal axis of the stator, said innermost welding portions being inclined with the same inclination relative to the plane perpendicular to the longitudinal axis of the stator, the outermost welding portions of the electrical conductors being inclined with at least two, or even three or four, different inclinations relative to the plane perpendicular to the longitudinal axis of the stator, at least one welding portion of an input and / or output phase electrical conductor being radially aligned with welding portions of other electrical conductors.

[0137] Each welding portion of the phase input electrical conductors may be radially aligned with welding portions of other electrical conductors.

[0138] In particular, the welding portions of the phase input electrical conductors may not be offset by half a tooth relative to welding portions of other electrical conductors.

[0139] The welding portions of the electrical conductors may be arranged in several layers relative to the longitudinal axis of the stator, in particular in three layers, at least two layers comprising a different number of welding portions of electrical conductors.

[0140] The different layers of welding portions of electrical conductors are concentric around the longitudinal axis of the stator.

[0141] In one embodiment, each layer may comprise a different number of welding portions of electrical conductors.

[0142] For example, a layer, in particular the innermost layer, may comprise as many welding portions as there are notches in the stator.

[0143] For example, a layer, in particular the outermost layer, may comprise a number of welding portions equal to twice the number of phases of the stator winding, for example six in the case where the winding is three-phase.

[0144] For example, a layer, in particular an intermediate layer placed between the innermost layer and the outermost layer, may comprise a number of welding portions equal to the number of notches in the stator from which is deducted twice the number of phases of the stator winding, for example six in the case where the winding is three-phase.

[0145] Thus, the welding portions of electrical conductors are well aligned with each other, which can facilitate the welding of the electrical conductors and simplify the manufacture of the stator.

[0146] The number of layers may for example be different from 4.

[0147] The numbers NI and N2 can be equal or different.

[0148] The first A and second R notches are separated by a number Nd of teeth.

[0149] The number Nd of teeth is preferably the same for all conductors U-shaped electrical conductors of the stator. We can also speak of the number Nd of pitch teeth of an electrical conductor, which in the invention is the same for all the electrical conductors of the stator which are U-shaped. This facilitates the manufacture of the U-shaped pins, and simplifies the step of positioning them in the stator mass, in particular their insertion.

[0150] Given the constant spacing between the legs of all the electrical conductors, the invention makes it possible to reduce the height of the buns on the side opposite the welds, which is advantageous for minimizing the size of the machine and the quantity of material, in particular copper, required for the electrical conductors. This results in a better compactness of the stator, including when it is assembled, and therefore of the resulting machine, which can in particular be shorter. The rotor shaft can be shorter, the casing can be shorter, the integration of the machine into its environment of use can be facilitated. Finally, the overall mass of the machine can be minimized.

[0151] On the other hand, the spacing between each of the buns is more regular, which can make it possible to minimize the risks of contact between them, and thus make it possible to eliminate the step of covering them with insulation.

[0152] Furthermore, the invention makes it possible to reduce the number of pin shapes to be used in the same stator. Thus, the manufacture of the stator can be accelerated, with fewer manufacturing steps. This simplifies manufacturing, the space required as well as the tools to use.

[0153] Finally, the invention makes it possible to free up space on either side of the pins at the outlet of the notch, which can make it possible to position the connections to the other phases or to an inverter, in particular on the side of the stator yoke. The spacing between the pins at the outlet of the notch can be, in one embodiment, constant or substantially constant. This can facilitate the production of welds on the one hand, and the cooling of the electrical conductors on the other hand.

[0154] In the invention, NI can vary from Nd / 2 - 0.5 to Nd teeth, and N2 can vary from 0 to Nd / 2 +1.5 teeth.

[0155] In an exemplary embodiment, NI is equal to Nd or Nd + 1 and N2 is equal to 0 or 1.

[0156] In another exemplary embodiment, NI and N2 are equal or nearly equal. NI and N2 can each 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.

[0157] In the following, the outer and inner legs of an electrical conductor may be designated by the terms 'first and second legs'.

[0158] In one embodiment, the welding portion of the second leg of the electrical conductor is aligned with it. In this case, N2 is zero.

[0159] In the other cases where N2 is non-zero, each of the first and second legs of the electrical conductors can extend outside the notches by a welding portion inclined relative to a plane perpendicular to a longitudinal axis of the stator to overhang the stator mass circumferentially at the level of a notch or a tooth, this notch being separated from the first A or the second R notch respectively by a number NI and N2 of teeth, the numbers NI and N2 possibly being equal or different.

[0160] When NI and N2 are equal or nearly equal, the compactness of the stator can be further improved.

[0161] The two welding portions of each of the first and second legs of the electrical conductors may be oriented away from each other, which may in particular be the case when the winding is corrugated. Alternatively, they may be oriented in the same direction, which may in particular be the case when the winding is in series.

[0162] The invention also relates, according to another of its aspects, to a stator of a rotating electrical machine, comprising a stator mass comprising notches, electrical conductors housed in the notches, at least a portion of the electrical conductors, or even a majority of the electrical conductors, being in the shape of a U-shaped pin, each comprising first and second legs extending axially respectively in first A and second R notches, the first A and second R notches being separated by a number Np of notches. The number Np of notches is the same for all U-shaped electrical conductors of the stator.

[0163] We can also speak for the number Np of pitch notches of an electrical conductor, which in the invention is the same for all the electrical conductors of the stator which are in the form of a U-shaped pin. This makes it easier to manufacture the U-shaped pins, and simplifies the step of positioning them in the stator mass, in particular their insertion.

[0164] At least one of the first and second legs of the electrical conductors may extend out of the notches by a welding portion inclined relative to a plane perpendicular to a longitudinal axis of the stator to overhang the stator mass circumferentially at the level of a notch, this notch being separated from the first A or the second R notch respectively by a number NI and / or N2 of teeth. The numbers NI and N2 may be equal or different.

[0165] In one embodiment, NI may vary from Np / 2 - 0.5 to Np notches, and N2 may vary from 0 to Np / 2 + 0.5 notches. In one exemplary embodiment, NI is equal to Np and N2 is equal to 0. In another exemplary embodiment, N1 and N2 are equal, being equal to Np / 2 or Np / 2 + 0.5 or Np / 2 - 0.5.

[0166] In one embodiment, the welding portion of the second leg of the electrical conductor is aligned with it. In this case, N2 is zero.

[0167] In the other cases where N2 is non-zero, each of the first and second legs of the electrical conductors can extend outside the notches by a welding portion inclined relative to a plane perpendicular to a longitudinal axis of the stator to overhang the stator mass circumferentially at the level of a notch, this notch being separated from the first A or the second R notch respectively by a number NI and N2 of teeth, the numbers NI and N2 possibly being equal or different. Pin legs

[0168] At least a portion of the electrical conductors each have a welding portion that is the innermost relative to the longitudinal axis of the stator, or even a majority, better still all of the electrical conductors each have a welding portion that is the innermost relative to the longitudinal axis of the stator.

[0169] At least a portion of the electrical conductors each have a welding portion that is the outermost relative to the longitudinal axis of the stator, or even a majority, or better still all of the electrical conductors each have a welding portion that is the outermost relative to the longitudinal axis of the stator.

[0170] The inner portions are arranged closer to the rotor than the outer portions.

[0171] In the invention, the innermost welding portions are inclined with the same inclination relative to the plane perpendicular to the longitudinal axis of the stator. These innermost weld portions all run parallel to each other.

[0172] As regards the outermost welding portions, they are not necessarily all inclined with the same inclination relative to the plane perpendicular to the longitudinal axis of the stator. They may be inclined with at least two, or even three or four, different inclinations relative to the plane perpendicular to the longitudinal axis of the stator.

[0173] In one embodiment, the outermost welding portions of the electrical conductors are inclined with at least two, or even three or four, different inclinations relative to the plane perpendicular to the longitudinal axis of the stator.

[0174] The first leg may be arranged closer to the rotor than the second leg. This may be referred to as the inner leg. The second leg may be arranged closer to the stator yoke than the first leg. This may be referred to as the outer leg.

[0175] Alternatively, the first leg may be disposed closer to the stator yoke than the second leg, and the second leg may be disposed closer to the rotor than the first leg.

[0176] At least a portion of the electrical conductors may have a second leg extending out of the notch by a welding portion extending in the same radial plane as the second leg, or even being aligned with it. When only the first leg of the electrical conductors has an inclined welding portion, the manufacture of the stator is facilitated, insofar as the operations of tilting the pins can be simplified and accelerated. In this configuration, only one of the legs of the electrical conductor is inclined, so that it is possible to limit the deformations and stresses on the electrical conductors. In particular, it is possible to reduce the risks of electrical contact between the phases of the stator winding.

[0177] In one embodiment, only the first leg of the electrical conductors has an inclined welding portion. The welding portion of the second leg may be aligned with, extending in line with, and being straight with the second leg. When only the first leg of the electrical conductors has an inclined welding portion, the first leg may be disposed closer to the rotor than the second leg. Alternatively, the inclined first leg may be disposed closer to the stator yoke than the second leg.

[0178] At least a portion of the electrical conductors may have a second leg extending out of the notch by a welding portion forming a step relative to the notch, while extending in the same radial plane as the second leg. The step of the electrical conductor may make it possible to reach metallic elements of a phase connector. The metallic elements may be arranged radially externally relative to the electrical conductors to which they are connected. connected.

[0179] At least a portion of the electrical conductors may have a second leg extending out of the notch by a circumferentially extending weld portion.

[0180] At least a portion of the electrical conductors may have a second leg extending out of the notch by a weld portion extending out of a circumferential surface. These weld portions outside a circumferential surface may provide access to a phase connector that may be disposed around the weld portions, rather than above them, relative to a longitudinal axis of the stator.

[0181] The stator may comprise two electrical conductors per notch.

[0182] The electrical conductors may form a distributed winding. The winding may be corrugated or in series. The electrical conductors may form a fractional winding. The winding may be full-pitch. In one embodiment, the winding may be short-pitch. Multi-phase winding

[0183] The electrical conductors housed in the slots may form a multi-phase winding having at least a first phase a and a second phase b, an input electrical conductor A of the first phase a being located in a first slot (slot number 1), one or more electrical conductors of the second phase b being located in a second slot (slot number 2), the second slot immediately following the first slot when moving circumferentially around the axis of rotation of the machine, in the direction of circulation of the electric current around the axis of rotation of the machine

[0184] The input electrical conductor of the first phase is in this case located in a first notch just before a second notch receiving one or more electrical conductors of the second phase, when moving circumferentially around the axis of rotation of the machine, in the direction of circulation of the electric current around the axis of rotation of the machine.

[0185] Thus, the input electrical conductor of the first phase is located opposite the usual position, namely a position in which the first notch receiving the input electrical conductor of the first phase is immediately followed by a second notch receiving one or more electrical conductors of the same first phase, when moving circumferentially around the axis of rotation of the machine, in the direction of circulation of the electric current around the axis of rotation of the machine.

[0186] The input notch of a first phase may be followed by a notch housing electrical conductors of a second phase different from the first.

[0187] Thus, the number of notches between the input electrical conductor and the output electrical conductor of the same phase is reduced. The first input notch of a phase can be brought closer to a third output notch of this same phase. In other words, the number of notches separating the first input notch of a phase and the third output notch of the same phase can be smaller. Thus, the implementation of the invention makes it possible to reduce the tooth pitch of the electrical conductors which serve to connect the different winding paths which progress in the same direction around the axis of rotation of the machine, and the average length of each phase thanks to a better interleaving of the subsets of electrical conductors constituting the winding, measured circumferentially around the axis of rotation of the machine.Shortening the average length of a phase improves linear resistance and thermal performance, and reduces the mass of copper required.

[0188] It is also possible to obtain for the electrical conductors bun heads of lesser height, on the side opposite the welds. The quantity of copper required for the manufacture of the conductors is therefore reduced, which is economically advantageous. In addition, the insertion of the electrical conductors into the notches can be made easier.

[0189] Furthermore, an output electrical conductor of the first phase may be located in a first notch, one or more electrical conductors of the second phase being located in a second notch, the second notch immediately following the first notch when moving circumferentially around the axis of rotation of the machine, in the direction of circulation of the electric current around the axis of rotation of the machine.

[0190] The output electrical conductor of the first phase may be located in a first notch just before a second notch receiving one or more electrical conductors of the second phase, when moving circumferentially around the axis of rotation of the machine, in the direction of circulation of the electric current around the axis of rotation of the machine.

[0191] Thus, the output electrical conductor of the first phase is located opposite the usual position, namely a position in which the first notch receiving the output electrical conductor of the first phase is immediately followed by a second notch receiving one or more electrical conductors of the same first phase, when moving circumferentially around the axis of rotation of the machine, in the direction of circulation of the electric current around the axis of rotation of the machine.

[0192] The output notch of a first phase may be followed by a notch housing electrical conductors of a second phase different from the first.

[0193] The phase inputs can be offset by an angle of 30°, 60°, 90° or by an angle of 120° for example.

[0194] The second notch may comprise one or more electrical conductors of the same phase only.

[0195] The first input notch of a first phase may comprise one or more electrical conductors of the first phase only.

[0196] Alternatively, the first input notch of a first phase may comprise one or more electrical conductors of the first phase and one or more electrical conductors of the second phase. The electrical conductor(s) of the first phase may be placed on the yoke side or alternatively on the air gap side. The electrical conductor(s) of the second phase may be placed on the air gap side or alternatively on the yoke side. The phase inputs and outputs may be placed on the yoke side or alternatively on the air gap side.

[0197] At least one first electrical conductor housed in a first notch can be electrically connected to a second electrical conductor housed in a second notch, at the outlet of said notches.

[0198] All electrical conductors having a free end located at the same circumferential position around the axis of rotation of the machine, regardless of their radial position, can be electrically connected together.

[0199] The stator may comprise a phase connector comprising metal elements connected to electrical conductors of the stator. The metal elements may be arranged radially externally or internally relative to the electrical conductors to which they are connected. The metal elements connected to conductors of the stator windings may be held by an insulating support. Furthermore, the phase connector may have connection tabs to a power bus. The machine may thus be connected to an inverter, electrically connected to the connection tabs of the connector. Pins

[0200] At least some, if not a majority of, electrical conductors may be pin-shaped, U-shaped, or I-shaped. The pin may be U-shaped or straight, being I-shaped.

[0201] In one embodiment, all electrical conductors are U-shaped. Alternatively, all electrical conductors are I-shaped.

[0202] The pin and flat electrical conductors make it possible to increase the filling coefficient of the slot, making the machine more compact. Thanks to a high filling coefficient, the thermal exchanges between the electrical conductors and the stator mass are improved, which makes it possible to reduce the temperature of the electrical conductors inside the slots.

[0203] Furthermore, the manufacture of the stator can be facilitated thanks to the electrical conductors in the form of pins. Finally, since the pins do not require open notches, we can have closed notches which allow the pins to be held and we can therefore eliminate the step of inserting the stator shims.

[0204] Electrical conductors, or even a majority of the electrical conductors, extend axially in the notches. The electrical conductors can be introduced into the corresponding notches through one or both axial ends of the machine.

[0205] An I-shaped electrical conductor has two axial ends each placed at one of the axial ends of the stator. It passes through a single notch, and can be welded at each of its axial ends to two other electrical conductors, at the axial ends of the stator. The stator may for example have 6, 10, 12, 14, 18, 22 or 26 I-shaped electrical conductors, the other electrical conductors all being U-shaped.

[0206] The stator may be devoid of an I-shaped electrical conductor.

[0207] A U-shaped electrical conductor has two axial ends both placed at one of the axial ends of the stator. These two axial ends are defined by the two legs of the U. It passes through two different notches, and can be welded at each of its axial ends to two other electrical conductors, at the same axial side of the stator. The bottom of the U, that is to say the side of the U forming the bun or coil head, is arranged on the other axial side of the stator.

[0208] At least a portion of the electrical conductors, or even a majority of the electrical conductors, may be U-shaped.

[0209] In addition, the size of the electrical conductors at the coil heads is reduced. This facilitates the nesting of the electrical conductors.

[0210] The winding may be devoid of a U-shaped pin of a width different from Np. In certain embodiments of the prior art, there are U-shaped pins of at least three different widths. The width of a U-shaped pin is equal to the number of dental pitches + 1. The width of a U-shaped pin is defined by the number of notches separating the first and second legs of the U-shaped pin, including the two notches housing the two legs of the U-shaped pin in question. The first and second legs may be separated by a number of notches between 3 and 20, better between 6 and 16, being for example 6, 7, 8, 9 or 10 or 11 notches. Strands

[0211] In the invention, each electrical conductor may comprise one or more strands (wire or strand in English). By "strand" is meant the most basic unit for electrical conduction. A strand may be of round cross-section, in which case it may be referred to as a 'wire', or flat. The flat strands may be shaped into pins, for example U-shaped or I-shaped. Each strand is coated with an insulating enamel.

[0212] The fact that each notch can comprise several conductors and / or several strands makes it possible to minimize losses by induced currents, or AC Joule losses, which vary with the square of the supply frequency, which is particularly advantageous at high frequency and when the operating speed is high. Heat transfer to the cold source is also facilitated. This makes it possible to obtain better efficiency at high speed.

[0213] When the notches are closed, a reduction in leakage fluxes seen by the conductors can be achieved, resulting in a reduction in eddy current losses in the strands.

[0214] In one embodiment, each electrical conductor may comprise several pins, each forming a strand, as explained above. All the strands of the same electrical conductor may be electrically connected to each other at the outlet of the notch. The strands electrically connected to each other are placed in short circuit. The number of strands electrically connected together may be greater than or equal to 2, being for example between 2 and 12, being for example 3, 4, 6 or 8 strands.

[0215] Several strands can form a single electrical conductor. The same electric current of the same phase flows in all the strands of a single electrical conductor. All the strands of a single electrical conductor can be electrically connected to each other, in particular at the outlet of the notch. All the strands of a single electrical conductor can be electrically connected to each other at each of their two axial ends, in particular at the outlet of the notch. They can be electrically connected in parallel.

[0216] All strands of all electrical conductors having a free end located at the same circumferential position around the axis of rotation of the machine, regardless of their radial position, can be electrically connected to each other.

[0217] In one embodiment, each electrical conductor comprises a single strand. In another embodiment, each electrical conductor comprises three strands.

[0218] In the case where a notch comprises two electrical conductors, a notch can therefore accommodate two strands, or alternatively six strands, for example, distributed between the two electrical conductors.

[0219] Alternatively, a notch comprises four electrical conductors. Each electrical conductor may comprise two strands. The notch then accommodates eight strands, distributed between the four electrical conductors.

[0220] The strands may be positioned in the notch such that their circumferential dimension around the axis of rotation of the machine is greater than their radial dimension. Such a configuration allows for a reduction in eddy current losses in the strands.

[0221] A strand may have a width of between 1 and 5 mm, for example being of the order of 2.5 or 3 mm. The width of a strand is defined as its dimension in the circumferential direction around the axis of rotation of the machine.

[0222] A strand may have a height of between 1 and 5 mm, for example being of the order of 1.6 or 1.8 mm. The height of a strand is defined as its thickness in the radial dimension.

[0223] The electrical conductors can be made of copper or aluminum. Winding

[0224] A winding consists of a number of phases m offset in space in such a way that when they are supplied by a multi-phase current system, they produce a rotating field.

[0225] The electrical conductors may form a single winding, in particular with a whole or fractional pitch. By "single winding" is meant that the electrical conductors are electrically connected together in the stator, and that the connections between the phases are made in the stator, and not outside the stator, for example in a terminal box.

[0226] The electrical conductors may form a distributed winding. The winding is not concentrated or tooth wound.

[0227] The winding may be full pitch. Each slot only accommodates electrical conductors of the same phase and / or the width of an electrical conductor is equal to the number of slots divided by the number of poles.

[0228] Alternatively, the winding may have a shortened pitch. Slots may accommodate electrical conductors of different phases. In one embodiment, at least one slot accommodates an electrical conductor of the first phase and an electrical conductor of the second phase and / or the width of the majority of the electrical conductors is less than the number of slots divided by the number of poles.

[0229] The winding is in the invention whole or fractional. The winding can be whole with or without shortening, or in a fractional variant. In one embodiment, the electrical conductors form a fractional winding.

[0230] For a fractional winding, the number of slots per pole and per phase is fractional, that is to say that the ratio q defined by <?=Ne / (2pm) s’écrit sous la forme d’une fraction irréductible zln, zetn étant deux nombres entiers non nuis, n étant différent de 1, où Ne est le nombre d’encoches du stator, m le nombre de phases du bobinage et p le nombre de paires de pôles du stator.

[0231] The number of notches of the stator may be between 18 and 96, better between 30 and 84, being for example 18, 24, 27, 30, 36, 42, 45, 48, 54, 60, 63, 72, 78, 81, 92, 96, better being 60 or 63. The number of poles of the stator may be between 2 and 24, or even between 4 and 12, being for example 6 or 8.

[0232]

[0233]

[0234]

[0235]

[0236]

[0237]

[0238]

[0239] The combination of number of slots / number of stator poles can be chosen from the combinations in the following list, which is not exhaustive: 30 / 4, 42 / 4, 45 / 6, 48 / 8, 63 / 6, 60 / 8, 78 / 8, 84 / 8. In one embodiment, the combination of number of slots / number of stator poles is 60 / 8. In this case we have g=60 / (2*4*3)=5 / 2. In one embodiment, the combination number of slots / number of stator pole pairs is 63 / 6. In this case we have g=63 / (2*3*3)=7 / 2. More broadly, the combination between the number of slots Ne and the number of pole pairs p of the stator can be one of those checked in the following table 1, for a three-phase winding. P ' 5 5 •5 12 21 24 '27 53 53 55 55 47 45 4S si ■ 34 23 SS 55 55 55 72 32 TSi 31 S4 5? 5 SJ XXXXXXXX X. XXXXXZX XXXXXXX £5 XXXX ;MX 7 XXXXXXXXXXXXX X. XXXXXXXXXX ax I XX XX XXXXXXXXXXXXXXX' XXX 3 XX [Table 1] The number of phases in this case is three, but it does not go beyond the scope of the present invention if the number of phases is different, for example two, the machine then comprising a two-phase winding, or being for example 5, 6, 7, 9, 11 or 13. The winding is polyphase. The series connection of electrical conductors can be done in so-called corrugated winding or in so-called series winding. "Corrugated winding" means a winding in which the electrical conductors of the same phase and the same pole are electrically connected to each other in such a way that, for one winding path, the electric current of the phase flows in the electrical conductors while rotating around the axis of rotation of the machine always in one direction. For one winding path, the electrical conductors of the same phase and the same pole do not overlap when observed perpendicular to the axis of rotation of the machine. By "series winding" is meant a winding in which the electrical conductors of the same phase of the same pole are electrically connected to each other so that the electric current of the phase flows in the electrical conductors by rotating around the axis of rotation of the machine alternately in one direction then in the other. For a winding path, the electrical conductors of the same phase and the same pole overlap when observed perpendicular to the axis of rotation of the machine.

[0240] The winding may comprise a single winding path or several winding paths. In an "electrical conductor" the current of the same phase flows through each winding path. By "winding path" is meant all the electrical conductors of the machine which are traversed by the same electric current of the same phase. These electrical conductors may be connected together in series or in parallel or in series-parallel. In the case where there is a single path, the electrical conductors are connected in series. In the case where there are several paths, the electrical conductors of each path are connected in series, and the paths are connected in parallel.

[0241] At least one first electrical conductor housed in a first notch can be electrically connected to a second electrical conductor housed in a second notch, at the outlet of said notches.

[0242] By "electrically connected" is meant any type of electrical connection, in particular by welding, with different possible welding methods, in particular laser, induction, friction, ultrasound, vibration, or brazing, or by mechanical tightening, in particular by crimping, screwing or riveting for example. The welding step can be implemented by means of a heat source, in particular a laser or an electric arc, for example an electric arc produced by means of a tungsten electrode. The welding process using a tungsten electrode can be a TIG (in English "Tungsten Inert Gas") welding. In this welding process, the electric arc is produced from a tungsten electrode and a plasma. The use of a heat source makes it possible to melt the free ends of the strands without damaging the assembly of the strands of the conductor(s). A single heat source can be used to make the same weld.Alternatively, several heat sources can be used to make the same weld.

[0243] The first and second electrical conductors may be electrically connected at the outlet of the notches, that is to say that the electrical connection is formed on the electrical conductors just after their outlet from the two notches, at an axial end of the stator mass. The electrical connection may be made in a plane perpendicular to the axis of rotation of the machine. The plane of the electrical connection may be distant from the stator mass by approximately 30 to 70 mm, better still by approximately 40 to 60 mm.

[0244] The electrical conductors may be arranged in the notches in a distributed manner. By "distributed" it is meant that the outgoing and return electrical conductors are each housed in different and non-consecutive notches. At least one of the electrical conductors may pass successively through two non-consecutive notches.

[0245] The electrical conductors may be arranged in a row in the notches. By "row" is meant that the electrical conductors are not arranged in the notches loosely but in an orderly manner. They are stacked in the notches in a non-random manner, for example being arranged in a row of electrical conductors aligned in the radial direction.

[0246] The electrical conductors may have a generally rectangular cross-section, in particular with rounded edges. The circumferential dimension of an electrical conductor may correspond substantially to the width of a notch. Thus, a notch may have only one electrical conductor in its width. The width of the notch is measured in its circumferential dimension around the axis of rotation of the machine.

[0247] The electrical conductors may be adjacent to each other by their long sides, otherwise called the flat.

[0248] Optimizing the stacking can allow a greater quantity of electrical conductors to be placed in the notches.

[0249] The stator may comprise a sensor for measuring the temperature of the electrical conductors, for example a thermocouple. The sensor may be arranged in the notch, or alternatively at the welding portions.

[0250] At least one tooth, better all the teeth, may be of generally trapezoidal cross-section. At least one tooth, better all the teeth, may have edges that diverge away from the axis of rotation of the machine.

[0251] The stator mass can be made by stacking sheets. The teeth are connected to each other by bridges of material, and on the opposite side by a yoke. The closed notches can be made entirely by cutting into the sheets. Each sheet of the stack of sheets can be a single piece.

[0252] Each sheet is for example cut from a sheet of magnetic steel or containing magnetic steel, for example steel 0.1 to 1.5 mm thick. The sheets may be coated with an electrically insulating varnish on their opposite faces before they are assembled within the stack. Electrical insulation may also be obtained by heat treatment of the sheets, if necessary.

[0253] Alternatively, the stator mass may be manufactured from a compacted or agglomerated magnetic powder. Machine and rotor

[0254] The invention also relates to a rotating electrical machine, such as a synchronous motor or a synchronous generator, comprising a stator as defined above. The machine may be synchronous or asynchronous. The machine may be reluctance. It may constitute a synchronous motor.

[0255] The maximum rotational speed of the machine can be high, being for example su higher than 10,000 rpm, better higher than 12,000 rpm, being for example of the order of 14,000 rpm to 15,000 rpm, or even 20,000 rpm or 25,000 rpm. The maximum rotation speed of the machine may be lower than 100,000 rpm, or even 60,000 rpm, or even lower than 40,000 rpm, better still lower than 30,000 rpm.

[0256] The rotating electrical machine may comprise a rotor. The rotor may have permanent magnets, surface magnets or buried magnets. The rotor may be flux concentrating. It may comprise one or more layers of magnets arranged in an I, U or V shape. Alternatively, it may be a wound or squirrel cage rotor, or a variable reluctance rotor.

[0257] The diameter of the rotor may be less than 400 mm, better still less than 300 mm, and greater than 50 mm, better still greater than 70 mm, for example being between 100 and 200 mm.

[0258] The rotor may comprise a rotor mass extending along the axis of rotation and arranged around a shaft. The shaft may comprise torque transmission means for driving the rotor mass in rotation.

[0259] The rotor may be cantilevered or not.

[0260] The machine can be inserted alone in a housing or inserted in a box housing gear. In this case, it is inserted into a casing which also houses a gearbox. Brief description of the drawings

[0261] The invention may be better understood by reading the detailed description which follows, non-limiting examples of its embodiment, and by examining the attached drawing, in which:

[0262] [Fig.l] [Fig.l] is a schematic and partial perspective view of a stator produced in accordance with the invention.

[0263] [Fig. la] [Fig. la] is a schematic and partial perspective view of the stator of [Fig.l],

[0264] [Fig.2] [Fig.2] illustrates the manufacturing process of the stator of [Fig.l].

[0265] [Fig.3] [Fig.3] illustrates the manufacturing process of the stator of [Fig.l].

[0266] [Fig.4] [Fig.4] illustrates the manufacturing process of the stator of [Fig.l].

[0267] [Fig.5] [Fig.5] illustrates the manufacturing process of the stator of [Fig.l].

[0268] [Fig.6] [Fig.6] illustrates the manufacturing process of the stator of [Fig.l].

[0269] [Fig.6a] [Fig.6a] illustrates the manufacturing process of the stator of [Fig.l].

[0270] [Fig.6b] [Fig.6b] illustrates the manufacturing process of the stator of [Fig.l].

[0271] [Fig.6c] [Fig.6c] illustrates the manufacturing process of the stator of [Fig.l].

[0272] [Fig.7a] [Fig.7a] illustrates the manufacturing process of the stator of [Fig.l].

[0273] [Fig.7b] [Fig.7b] illustrates the manufacturing process of the stator of [Fig.l].

[0274] [Fig.7c] [Fig.7c] illustrates the manufacturing process of the stator of [Fig.l].

[0275] [Fig.8] [Fig.8] illustrates the manufacturing process of the stator of [Fig.l].

[0276] [Fig.8a] [Fig.8a] is a perspective view of a deformation crown used in the manufacturing process of the stator of [Fig.l].

[0277] [Fig.9] [Fig.9] illustrates the manufacturing process of the stator of [Fig.l].

[0278] [Fig.9a] [Fig.9a] is a perspective view of a deformation crown used in the manufacturing process of the stator of [Fig.l].

[0279] [Fig. 10] [Fig. 10] illustrates the manufacturing process of the stator of [Fig.l].

[0280] [Fig. 10a] [Fig. 10a] is a perspective view of a deformation crown used in the manufacturing process of the stator of [Fig.l].

[0281] [Fig. 11] [Fig. 11] illustrates the manufacturing process of the stator of [Fig.l].

[0282] [Fig.lia] [Fig.lia] illustrates the manufacturing process of the stator of [Fig.l].

[0283] [Fig. 11b] [Fig. 11b] illustrates the manufacturing process of the stator of [Fig.l].

[0284] [Fig. 12a] [Fig. 12a] illustrates an alternative embodiment of the method.

[0285] [Fig. 12b] [Fig. 12b] illustrates this variant embodiment of the method.

[0286] [Fig. 12c] [Fig. 12c] illustrates this variant embodiment of the method.

[0287] [Fig. 13] [Fig. 13] is a schematic and partial perspective view of an alternative embodiment. Detailed description

[0288] Figures 1 and 1a show a stator 2 of a rotating electrical machine 1 also comprising a rotor (not shown). The stator makes it possible to generate a rotating magnetic field to drive the rotor in rotation, in the case of a synchronous or asynchronous motor, and in the case of an alternator, the rotation of the rotor induces an electromotive force in the electrical conductors of the stator.

[0289] The examples illustrated below are schematic and the relative dimensions of the different constituent elements have not necessarily been respected.

[0290] The stator 2 comprises electrical conductors 22, which are arranged in notches 21 formed between teeth 23 of a stator mass 25. The notches 21 are closed. The notches 21 are closed on the air gap side by material bridges 27, each connecting two consecutive teeth of the stator mass 25, and on the opposite side by a yoke 29. The latter and the teeth 23 are in one piece. The electrical conductors 22 may be for the most part in the form of pins, namely U-shaped, and extending axially in the notches.

[0291] In the example described, all the electrical conductors 22 of the stator 2 are identical, all being U-shaped, with the same pitch Np for all the electrical conductors of the stator which are U-shaped. Each electrical conductor in U-shaped stator has first 22e and second 22f legs extending axially respectively in first A and second R notches. The first A and second R notches are separated by a number Np of notches and by a number Nd of teeth. The number Np of notches is the same for all U-shaped stator electrical conductors. In the example described, Np is 11. The number Nd of teeth is the same for all U-shaped stator electrical conductors. In the example described, Nd is 10.

[0292] The first legs 22e are inner and the second legs 22f are outer.

[0293] In the example described, a first electrical conductor housed in a first notch is electrically connected to a second electrical conductor housed in a second notch, at the outlet of said notches. The first and second notches are non-consecutive. In the example illustrated, they are separated by 12 other notches and by 11 teeth. Alternatively, the first and second notch are separated by 3, 4, 5, 6, 7, 8, 9, 10, 11 or 13 other notches, for example, and by 2, 3, 4, 5, 6, 7, 8, 9, 10, 12 or 13 teeth.

[0294] The electrical conductors are arranged in the slots in a distributed manner, and they form a distributed winding, which is in the example described fractional. In this example, the number of slots is 63. The number of stator poles is 6. Thus, the combination number of slots / number of stator poles is 63 / 6.

[0295] The electrical conductors form a fractional winding, for which the ratio q defined by <?=Ne / (2pm) s’écrit sous la forme d’une fraction irréductible zln, zetn étant deux nombres entiers non nuis, n étant différent de 1, où Ne est le nombre d’encoches du stator, m le nombre de phases du bobinage etp le nombre de paires de pôles du stator. On a alors q=63 / (3x6)=7 / 2 pour cette machine à 63 encoches et 6 pôles.

[0296] The electrical conductors 22 are made of copper or aluminum, or any other conductive material enameled or coated with any other suitable insulating coating.

[0297] The electrical conductors 22 are arranged in a row in the notches 21, in a row of aligned electrical conductors.

[0298] The electrical conductors may have a generally rectangular cross-section, in particular with rounded corners. In the example described, they are superimposed radially in a single row. The circumferential dimension of an electrical conductor corresponds substantially to the width of a notch. Thus, the notch only has one electrical conductor in its width. It may have several electrical conductors in its radial dimension. It has two in the example described.

[0299] Furthermore, the hairpin electrical conductors each have first 22nd and second 22f legs which extend outside the notches by a welding portion 22b inclined relative to a plane perpendicular to a longitudinal axis of the stator to overhang the stator mass circumferentially at the level of a notch, this notch being separated from the first A or the second R notch respectively by a number NI and / or N2 of teeth.

[0300] In the example described with reference to Figures 1 and 1a, the welding portion 22b of the second outer leg 22f of the electrical conductor 22 is aligned with the latter. In this case, N2 is zero. The first inner leg 22e is arranged closer to the rotor than the second leg 22f. The second outer leg 22f is arranged closer to the stator yoke than the first leg 22e. Thus, in this example, NI is 11.

[0301] For each electrical conductor, the innermost welding portion 22b relative to the longitudinal axis of the stator, which is arranged closer to the rotor, is inclined with the same inclination relative to the plane perpendicular to the longitudinal axis of the stator as the other innermost welding portions.

[0302] For each electrical conductor, the outermost welding portion relative to the longitudinal axis of the stator, which is arranged further from the rotor, is inclined with an inclination which may be different relative to the plane perpendicular to the longitudinal axis of the stator than the other outermost welding portions. The outermost welding portions are not necessarily all inclined with the same inclination relative to the plane perpendicular to the longitudinal axis of the stator. They may be inclined with at least two, or even three or four, different inclinations relative to the plane perpendicular to the longitudinal axis of the stator.

[0303] Furthermore, some electrical conductors have a second outer leg 22f extending outside the notch by a welding portion 22b forming a step relative to the notch, while extending in the same radial plane as the second leg. This welding portion 22b is radially even further from the axis of rotation of the machine. This step of the electrical conductor makes it possible to reach the metallic elements of the phase connector of the machine. These are the phase input and / or output electrical conductors.

[0304] It is thus obtained, as clearly visible in [Fig.1a], that at least one welding portion of an input and / or output phase electrical conductor is aligned radially with welding portions of other electrical conductors. Each welding portion of the phase input electrical conductors is in particular aligned radially with welding portions of other electrical conductors.

[0305] Furthermore, the welding portions of the electrical conductors are arranged in three layers relative to the longitudinal axis of the stator, each layer comprising a different number of welding portions of electrical conductors. The different layers of welding portions of electrical conductors are concentric around the longitudinal axis of the stator.

[0306] In the example described, the innermost layer Int has as many welding portions as there are notches in the stator. The outermost layer Ext has a number of welding portions equal to twice the number of phases of the stator winding, here six with a three-phase winding. Finally, the intermediate layer Cen placed between the innermost layer and the outermost layer has a number of welding portions equal to the number of notches in the stator from which is deducted twice the number of phases of the stator winding, here six with the three-phase winding.

[0307] Thus, the welding portions 22b of electrical conductors are well aligned with each other, which can facilitate the welding of the electrical conductors 22 and simplify the manufacture of the stator.

[0308] The method of manufacturing the stator will now be described in detail, with reference to Figures 2 to 12c.

[0309] In a first step (a) of the manufacturing method, a stator mass 25 is provided, as visible in [Fig. 2], comprising a pack of magnetic sheets, the stator mass 25 comprising notches 21 formed between teeth 23, electrical conductors 22 being housed in the notches 21. All the electrical conductors are U-shaped, each comprising inner 22e and outer 22f legs, which extend in particular axially respectively in first A and second R notches. At least one of the inner 22e and outer 22f legs of the electrical conductors 22 extends outside the notches by a welding portion.

[0310] In a second step (b), the outer legs of the electrical conductors will be circumferentially offset by half a dental pitch relative to the inner legs. The second step (b) can be broken down into several sub-steps (bl) to (b4).

[0311] Step (b) of circumferentially shifting the outer legs of the electrical conductors by half a tooth pitch comprises a step (bl) of positioning two inner 31 and outer 32 positioning rings for the electrical conductors 22. The two inner 31 and outer 32 positioning rings are placed against the stator mass 25, just above the stack of sheets thereof, as seen in [Fig.2]. The inner ring 31 has a disc shape.

[0312] The two inner 31 and outer 32 positioning rings comprise, as described below, movable fingers 33 and 34 respectively, which extend radially and which are each movable along a radial axis of the stator. During the step (bl) of positioning the positioning rings, the movable fingers are in the retracted position in the positioning rings.

[0313] In a step (b2), the movable fingers 33 and 34 are removed, each of which is placed between two consecutive electrical conductors 22, sliding like pistons, as seen in [Fig.3]. The movable fingers 34 of the outer positioning ring 32 are placed between the outer legs 22f of the electrical conductors and the movable fingers 33 of the inner positioning ring 31 are placed between the inner electrical conductors 22e.

[0314] The outer positioning ring 32 has as many movable fingers 34 as there are teeth on the stator. They can all be identical to each other.

[0315] The inner positioning crown 31 also comprises as many movable fingers 33 as there are teeth on the stator. They can all be identical to each other.

[0316] In the gripping position, all the movable fingers 33, 34 are each engaged between two consecutive electrical conductors. They make it possible to promote their alignment, in particular during a translational movement along the longitudinal axis of the stator of the positioning rings 31, 32, described below.

[0317] In a step (b3), the positioning rings 31, 32 are moved in translation along the longitudinal axis of the stator, away from the stator mass 25, namely upwards in [Fig. 4]. Thus, the positioning rings are moved towards the ends of the welding portions 22b. In this translational movement, the movable fingers 33, 34 act as combs which allow the electrical conductors to be properly aligned.

[0318] In a step (b4), the outer positioning ring is rotated by a given angle around the longitudinal axis of the stator, as illustrated in [Fig.5]. The angle is here equal to half a tooth pitch. In this rotational movement, the movable fingers make it possible to twist the outer legs 22f by half a tooth pitch relative to the inner legs 22e.

[0319] In particular, the outer positioning ring 32 is moved in rotation relative to the inner positioning ring 31 and relative to the stator, while the inner positioning ring 31 remains fixed relative to the stator.

[0320] In a step (c) illustrated in [Fig.6], the six outer legs 22f of the phase input and / or output electrical conductors are radially shifted outwards and placed on a third layer, namely the outermost layer Ext.

[0321] For this purpose, phase moving fingers 35 are removed from the inner positioning ring 31, which are configured to have a longer radial stroke than the other moving fingers 33 of the inner positioning ring 31.

[0322] The movable fingers of the inner positioning ring 31 thus comprise movable phase fingers 35 configured to have a longer radial stroke than the other movable fingers 33, here six movable phase fingers 35. The inner positioning ring thus comprises movable fingers with two strokes possible radials, a shorter one for most of them 33, and a longer one for some of them 35, notably six of them.

[0323] The longer radial travel of these movable phase fingers allows the radial shift outwards, away from the longitudinal axis of the stator, of the outer legs 22f of the phase input and / or output electrical conductors, relative to the other outer legs which remain circumferentially aligned.

[0324] Furthermore, the outer positioning ring 32 comprises notches 38 for receiving the phase input and / or output electrical conductors. These notches 38 allow the placement of the phase input and / or output electrical conductors on the third outermost layer Ext.

[0325] Some or all of the movable fingers of the outer positioning ring may each comprise a shoulder 36, as illustrated in [Fig.6a], which may allow the electrical conductors to be wedged. In particular, the movable fingers present at the level of the aforementioned notches may comprise such a shoulder.

[0326] The radial offset outwards may be more or less accentuated. The inclination of the outer legs may comprise a curved portion having a large radius of curvature, as illustrated in [Fig.6b], or a smaller radius of curvature, as illustrated in [Fig.6c], which means that the welding portion is then located closer to the sheet metal pack.

[0327] Before their deformation in the method of the invention, the length of the welding portions of the outer legs of the phase input and / or output electrical conductors may be greater than the length of the welding portions of the outer legs of the other electrical conductors, as illustrated in Figures 7a to 7c.

[0328] The method then comprises the following additional step (d): (d) circumferentially deforming the welding portions of the electrical conductors, with at least two different pitches, in particular three different pitches. This step (d) can be broken down into several sub-steps (dl) to (d5) and is implemented using three concentric deformation rings 41, 42, 43, including a second deformation ring 42 which is configured to be nested in a first deformation ring 41, being configured to move therein in rotation.

[0329] In a step (dl), the third deformation ring 43 is first put into position, as illustrated in [Fig.8]. This third deformation ring 43 will deform in particular the welding portions of the inner legs of the electrical conductors at a first step PL

[0330] The third deformation ring 43 is of generally circular and crenellated shape, comprising in particular as many crenellations as there are notches in the stator to receive the welding portions of the electrical conductors. The crenellations 49 are regular, all being regularly distributed around its circumference.

[0331] In the example described, it comprises 63 notches 49, as visible in [Fig.8a], for a stator comprising 63 notches and 6 poles. This third deformation crown makes it possible to deform the 63 welding portions of the inner legs of the electrical conductors at a first pitch PI.

[0332] In a step (d2), the first deformation ring 41 is positioned, as illustrated in [Fig.9]. This first deformation ring 41 will deform a part of the welding portions of the outer legs 22f of the electrical conductors at a second pitch P2, as well as all the welding portions of the outer legs of the electrical conductors radially offset in step (c).

[0333] This first deformation ring 41 is of generally circular and crenellated shape, comprising a number of notches 49 equal to the number of notches in the stator from which the number of notches in the second deformation ring 42 described below is deduced.

[0334] In the example described, it comprises 42 notches 49, for a stator comprising 63 notches and 6 poles. This first deformation ring 41 makes it possible to deform 42 welding portions of the outer legs of the electrical conductors at a second pitch P2.

[0335] The first deformation crown also comprises notches 48 which also make it possible to deform all the welding portions of the outer legs of the electrical conductors radially offset in step (c), in particular six notches 48 for six welding portions radially offset in step (c).

[0336] It also comprises windows 45 for receiving tabs 46 of the second deformation ring 42. The windows 45 of the first deformation ring have a longer circumferential extent than the tabs 46 of the second deformation ring 42, which can allow the rotational movement of the second deformation ring in the first deformation ring.

[0337] In a step (d3), the second deformation ring 42 is positioned, as illustrated in [Fig. 10]. This second deformation ring 42 can deform in particular the other welding portions of the outer legs of the electrical conductors at a third pitch P3.

[0338] The second deformation ring 42 is configured to be nested in the first deformation ring 41, and to move therein in rotation.

[0339] The second deformation ring 42 is of generally circular and crenellated shape, comprising in particular tabs 46 each received in a window 45 of the first deformation ring 4L. The tabs 46 can move in the windows 45 when the second deformation ring 42 moves in rotation in the first deformation ring 4L. The tabs 46 are crenellated, comprising crenellations 49.

[0340] In the example described, the second deformation crown comprises 15 notches 49 distributed over 4 legs 46, for a stator comprising 63 notches and 6 poles.

[0341] In a step (d4), the inner 31 and outer 32 positioning rings are returned to position against the stator mass. The outer positioning ring 32 descends in a helix in order to follow the inclination of the phase input and / or output electrical conductors which are placed on the third outermost layer Ext. The inner positioning 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 the retracted position.

[0342] Once the inner and outer positioning rings are back in position, the movable fingers can be returned to the gripping position with the electrical conductors. This movement provides protection for the insulators at the notch outlet during the next step.

[0343] In a step (d5), the first, second and third deformation rings 41, 42, 43 are driven in simultaneous rotation, with different pitches, as illustrated in [Fig.11].

[0344] In particular, the second deformation ring is rotated relative to the first deformation ring. [Fig.11a] illustrates the starting position of the first and second deformation rings, and [Fig.11b] their arrival position. The first and second deformation rings are rotated in a first direction, but not at the same pitch, while the third deformation ring is rotated in a second direction opposite to the first direction.

[0345] By the rotational movements of the deformation crowns, the welding portions of the inner legs of the electrical conductors are deformed at a first pitch PL. A part of the welding portions of the outer legs of the electrical conductors is deformed at a second pitch P2. All the welding portions of the outer legs of the electrical conductors offset radially in step (c) are deformed, as well as the other welding portions of the outer legs of the electrical conductors at a third pitch P3. The third pitch P3 is less than the first and second pitches PI and P2.

[0346] After rotation, the welding portions of the phase input and / or output electrical conductors are radially aligned with welding portions of other electrical conductors.

[0347] In an additional step (e), the deformation crowns are removed, then the inner and outer positioning crowns are also removed.

[0348] In the example just described, the rotation of the first, second and third deformation crowns is simultaneous for the three deformation crowns.

[0349] In the example just described, the phase input and / or output electrical conductors are pushed outwards.

[0350] Alternatively, as illustrated in Figures 12a to 12c, they can be pulled outwards. The tool assembly can for this purpose comprise a clamp or another gripping tool, such as independent claws 50. Said claws 50 can be configured to allow the outward deformation of these welding portions. This alternative embodiment can in particular be implemented with phase input and / or output electrical conductors extending longitudinally beyond the other electrical conductors, being longer than the latter.

[0351] In another embodiment, the phase input and / or output electrical conductors are pushed inwards. In this case, as illustrated in [Fig. 13], the inner legs 22e of the electrical conductors have been circumferentially offset by half a tooth pitch relative to the outer legs 22f, then the six inner legs 22e of the phase input and / or output electrical conductors have been radially offset inwards.

Claims

Claims

1. Method for manufacturing a stator (2) of a rotating electrical machine (1), comprising the following steps: (a) providing a stator mass (25), in particular comprising a pack of magnetic laminations, the stator mass (25) comprising notches (21) formed between teeth (23), electrical conductors (22) being housed in the notches (21), at least a portion of the electrical conductors, or even a majority of the electrical conductors, being in the shape of a U-shaped or I-shaped pin, each comprising inner (22e) and outer (22f) legs, which extend in particular axially respectively in first (A) and second (R) notches, at least one of the inner (22e) and outer (22f) legs of the electrical conductors (22) extending outside the notches by a welding portion, (b) circumferentially offsetting the outer legs (22f) of the electrical conductors by half a tooth pitch relative to the inside legs (22nd),and (c) radially shifting respectively inwardly or outwardly respectively the inner legs (22e) or the outer legs (22f) of certain electrical conductors, in particular the outer legs (22f) of certain electrical conductors, in particular the legs of the phase input and / or output electrical conductors, in particular six legs, the step (b) of circumferentially shifting the inner legs (22e) or the outer legs (22f) of the electrical conductors by a half tooth pitch comprising a step (bl) of positioning two inner (31) and outer (32) crowns for positioning the electrical conductors, in which in the radial shift step (c) the phase movable fingers (35) are removed from the inner positioning crown.,

2. Method according to the preceding claim, the step (b) of circumferentially shifting the outer legs (22f) of the electrical conductors by half a dental pitch comprising a step (bl) of positioning two inner (31) and outer (32) crowns for positioning the electrical conductors.

3. Method according to the preceding claim, in which in step (c) of radial shifting the phase moving fingers (35) of the crown in- inner positioning ring are configured to have a longer radial stroke than other movable fingers (33) of the inner positioning ring (31).

4. Method according to claim 2, in which in step (c) of radial shifting, phase moving fingers (35) are removed from the outer positioning ring, which are in particular configured to have a longer radial stroke than other moving fingers (33) of the outer positioning ring (32).

5. Method according to any one of the preceding claims, comprising the following additional step (d): (d) circumferentially deforming the welding portions of the electrical conductors (22), with at least two different pitches, in particular three different pitches.

6. Method according to the preceding claim, the step (d) of circumferential deformation comprising a step (d2) of positioning a first deformation crown (41), which may comprise at least one window (45) for receiving a tab (46) of a second deformation crown (42).

7. Method for manufacturing a stator (2) of a rotating electrical machine (1), comprising the following steps: (a) providing a stator mass (25), in particular comprising a pack of magnetic laminations, the stator mass (25) comprising notches (21) formed between teeth (23), electrical conductors (22) being housed in the notches (21), at least a portion of the electrical conductors, or even a majority of the electrical conductors, being in the shape of a U-shaped or I-shaped pin, each comprising inner (22e) and outer (22f) legs, which extend in particular axially respectively in first (A) and second (R) notches, at least one of the inner (22e) and outer (22f) legs of the electrical conductors (22) extending outside the notches by a welding portion, (b) circumferentially offsetting the outer legs (22f) of the electrical conductors by half a tooth pitch relative to the inside legs (22nd),and (c) radially shifting respectively inwardly or outwardly respectively the inner legs (22e) or the outer legs (22f) of certain electrical conductors, in particular the outer legs (22f) of certain electrical conductors, in particular, the legs of the phase input and / or output electrical conductors, in particular six legs, (d) circumferentially deforming the welding portions of the electrical conductors (22), with at least two different pitches, in particular three different pitches, the circumferential deformation step (d) comprising a step (d2) of positioning a first deformation ring (41), which may comprise at least one window (45) for receiving a tab (46) of a second deformation ring (42), the circumferential deformation step (d) comprising a step (d4) of repositioning against the stator mass the inner and outer positioning rings (31, 32).

8. Method according to one of the two preceding claims, the second deformation crown (42) being configured to be nested in the first deformation crown (41), being in particular configured to move therein, in particular in rotation.

9. Method according to one of the four preceding claims, the step (d) of circumferential deformation comprising a step (d4) of repositioning against the stator mass the inner and outer positioning rings (31, 32), with a helical movement of the outer positioning ring (32).

10. Method according to the preceding claim, the step (d) of circumferential deformation comprising a step (d5) of simultaneously rotating at least two of the first, second and third deformation rings (41, 42, 43), with at least two different pitches.

11. Tool assembly, in particular for implementing the method according to any one of the preceding claims, comprising a plurality of deformation rings (41, 42, 43), in particular three deformation rings, including a second deformation ring (42) which is configured to be nested in a first deformation ring (41), being in particular configured to move therein, in particular in rotation, the assembly comprising at least one inner positioning ring (31) for the electrical conductors, the inner positioning ring comprising a plurality of movable fingers (33).

12. Assembly according to the preceding claim, the deformation crowns (41, 42, 43) each comprising longitudinal notches (49) to receive the welding portions of the electrical conductors (22).

13. Assembly according to one of the two preceding claims, comprising at least one external positioning ring (32) for the electrical conductors, the external positioning ring (32) comprising a plurality of movable fingers (34).

14. Assembly according to the preceding claim, the external positioning ring (32) comprising notches (38) for receiving certain phase input and / or output electrical conductors, in particular four or six notches (38).

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

16. Stator (2) of a rotating electrical machine (1), comprising a stator mass (25) comprising notches (21) formed between teeth (23), electrical conductors (22) being housed in the notches (21), at least a portion of the electrical conductors, or even a majority of the electrical conductors, being in the shape of a U-shaped or I-shaped pin, each comprising inner (22e) and outer (22f) legs extending axially respectively in first (A) and second (R) notches, at least one of the inner (22e) and outer (22f) legs of the electrical conductors (22) extending outside the notches by a weld portion inclined relative to a plane perpendicular to a longitudinal axis of the stator to overhang the stator mass circumferentially at the level of a notch or a tooth, this notch or tooth being separated from the first (A) or the second (R) notch. second (R) notch respectively by a number N1 and / or N2 of teeth,at least a portion of the electrical conductors each having an innermost welding portion relative to the longitudinal axis of the stator, or even a majority, better all the electrical conductors each having an innermost welding portion relative to the longitudinal axis of the stator, at least a portion of the electrical conductors each having an outermost welding portion relative to the longitudinal axis of the stator, or even a majority, better all the electrical conductors each having an outermost welding portion relative to the Ion- axis, horizontal of the stator, said innermost welding portions (22b) or said outermost welding portions (22b) being inclined with the same inclination relative to the plane perpendicular to the longitudinal axis of the stator, the others of the outermost welding portions of the electrical conductors (22) or of the innermost welding portions (22b) being inclined with at least two, or even three or four, different inclinations relative to the plane perpendicular to the longitudinal axis of the stator, at least one welding portion of an input and / or output phase electrical conductor (22) being radially aligned with welding portions of other electrical conductors.

17. Stator according to the preceding claim, the welding portions (22b) of the electrical conductors being arranged in several layers (Int, Ext, Cen) relative to the longitudinal axis of the stator, in particular in three layers, at least two layers comprising a different number of welding portions of electrical conductors.

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