US 12,283,857 B2
Production method for a hairpin coil
Thomas Baranowski, Würselen (DE); Maik Broda, Würselen (DE); Raphael Koch, Odenthal (DE); Marcel Mathissen, Übach-Palenberg (DE); Maira Magnani, Aachen (DE); Julius Maximilian Engelke, Aachen (DE); and Ferat Oezkan, Übach-Palenberg (DE)
Assigned to Ford Global Technologies, LLC, Dearborn, MI (US)
Filed by Ford Global Technologies, LLC, Dearborn, MI (US)
Filed on Aug. 19, 2021, as Appl. No. 17/406,803.
Claims priority of application No. 102020210575.8 (DE), filed on Aug. 20, 2020.
Prior Publication US 2022/0060075 A1, Feb. 24, 2022
Int. Cl. H02K 15/00 (2006.01); H02K 3/28 (2006.01); H02K 3/48 (2006.01)
CPC H02K 3/28 (2013.01) [H02K 3/48 (2013.01); H02K 15/0068 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A production method for manufacturing a hairpin coil, the production method comprising:
positioning a plurality of hairpin elements on a coil support such that conductor end portions of the plurality of hairpin elements to be connected protrude from the coil support and are arranged adjacent to one another as conductor end portion pairs, the conductor end portions of each of the conductor end portion pairs are aligned with each other one after the other in a circumferential direction about a center axis of a mask at a same radial distance from the center axis,
securing a relative position of the conductor end portions of each of the conductor end portion pairs, and
welding the respective conductor end portions of the conductor end portion pairs by friction welding with a friction surface of a welding tool moving in a frictional manner along the conductor end portion pairs, the relative position of the conductor end portions of each of the conductor end portion pairs being further secured during friction welding,
wherein the welding tool acts simultaneously on and friction welds the conductor end portions of all of the conductor end portion pairs.