Process for assembling an alternator stator with clips that allows radial insertion of square wire with small slot openings

Abstract

A stator assembly for an alternator in accordance with the present invention includes a generally cylindrically-shaped stator core having a plurality of core slots formed along the inner surface thereof and defined by a radial depth and wherein a stator coil is disposed. The core slots thereby define a plurality of teeth therebetween, which are connected to the stator core by a yoke portion. The core slots are shaped and extend between a first and a second end of the stator core. A plurality of clips closely fit into one of said core slots for lining each respective core slot. The clips have a pair of extending leg members connected to a back end and forming an aperture therebetween. The clips are formed from a magnetically permeable material. A stator winding includes substantially straight wire segments that are received by the clips formed of substantially straight wire segments. The substantially straight wire segments of the stator winding and the clips are electrically insulated from one another. At least one of the extending leg members is bent towards the other leg member over a portion of the at least one row of substantially straight wire segments in the clips, narrowing the aperture between the extending leg members. Each of the plurality of clips and said substantially straight wire segments are each inserted into one of the plurality of core slots. Slits are added in these clips to reduce eddy current loss.