Process for annealing of helical wound cores used for automotive alternator applications

1. A method for manufacturing a helically wound alternator core, comprising the steps of:

stamping an electrical steel strip to create a lamination strip having a back-iron and projecting teeth;

helically winding the lamination strip by applying at least one force to the strip to bend the lamination strip to form the helically wound alternator core, said at least one force causing at least one area of plastic deformation resulting in internal stress and strain in at least said back-iron of the strip;

welding the helically wound alternator core; and

thereafter, annealing the welded helically wound alternator core in a neutral or decarburizing atmosphere at temperatures in a range of 1300° F. to 1600° F. which relieves the stress and strain and which causes recrystallization at said at least one area of plastic deformation caused by said at least one force which reduces electrical core loss.

2. The method of claim 1 wherein in addition to welding, the helically wound alternator core is also coined prior to said annealing, said coining ensuring consistent dimensions for slot openings or to add additional features on faces of the core or on edges leading into slots defined between teeth of the core.

3. The method of claim 1 wherein the helically winding comprises use of an inside pressure wheel which contacts an outer edge of said projecting teeth and exerts a force thereon, and also an outer pressure wheel which abuts against an outside edge of said back-iron, internal stress thus being created inside both said back-iron and said projecting teeth.

4. The method of claim 1 wherein said step of helically winding by bending the lamination strip comprises providing an outside pressure wheel contacting an outside edge of said back-iron and an inside pressure wheel having notches which receive a base portion of the teeth and apply a pressure to an inside edge of the back-iron, internal stress thus being created inside said back-iron.

5. The method of claim 1 wherein said projecting teeth are T-shaped.

6. The method of claim 1 wherein the electrical steel strip has a thickness in a range of 0.35 mm to 1.00 mm.

7. The method of claim 6 wherein the thickness is approximately 0.50 mm.

8. The method of claim 1 wherein said welding occurs at least two peripheral locations on the wound core.

9. The method of claim 8 wherein said two peripheral locations are defined by channel-like indentations where weld material for the respective weld is provided.

10. A method for manufacturing a helically wound alternator core, comprising the steps of:

stamping an electrical steel strip to create a lamination strip having a back-iron and projecting teeth;

helically winding the lamination strip by applying at least one force to the strip to bend the lamination strip to form the helically wound alternator core, said at least one force causing at least one area of plastic deformation resulting in internal stress and strain in at least said back-iron of the strip;

welding and coining the helically wound alternator core, said welding and coining also causing internal stress and strain in at least said back-iron; and

thereafter, annealing the welded helically wound alternator core in a neutral or decarburizing atmosphere at temperatures in a range of 1300° F. to 1600° F. which relieves the stress and strain and which causes recrystallization at said at least one area of plastic deformation caused by said at least one force which reduces electrical core less.