Segmented dual radial gap brushless PMDC motor/generator

A motor/generator comprising:

• (a) a rotor including a plurality of rotor segments, the plurality of rotor segments being operatively connected at opposite ends thereof to form a circular rotor ring, each one of the plurality of rotor segments including:
• (i) a substantially T-shaped rotor frame having a plurality of longitudinal slots formed therein;
• (ii) a plurality of magnets arranged in alternating magnetic polarity, each one of the plurality of magnets disposed within a respective one of the plurality of longitudinal slots;
• (b) a stator including a plurality of stator segments, the plurality of stator segments being operatively connected at opposite ends thereof to form a circular stator ring, each one of the plurality of stator segments including:
• (i) a stator frame including a base and a pair of opposed sidewalls extending upwardly from and substantially perpendicular to opposite ends of the base, the base and the pair of sidewalls defining a stator channel, a pair of shoulders extending inwardly from respective sidewalls;
• (ii) a plurality of bus bars disposed within the stator channel, the plurality of bus bars including a plurality of phase bus bars and at least one common bus bar;
• (iii) a plurality of stator induction modules being seated on the shoulder of the stator frame, each one of the plurality of stator induction modules including:
• (1) a coil having leads extending from opposite ends thereof and at least one turn formed therebetween, respective leads being in electrical communication with one of the plurality of phase bus bars and the common bus bar;
• (2) a lamination stack formed from a magnetically permeable material, the lamination stack having a bight section encircled by the coil and a pair of opposing legs extending upwardly from and substantially perpendicular to opposite ends of the bight section;
• (3) a molded polymer formed from a thermally, non-electrically conductive polymer, the molded polymer at least partially encapsulating the coil and the lamination stack;
• and
• wherein the rotor rotates above the stator such that the lamination stack of each stator induction module extends parallel to a respective magnet and provides a dual air gap between the lamination stacks and the respective magnet.

A wind turbine comprising:

• (a) a wind turbine rotor;
• (b) a rotor mechanically connected to the rotor in a direct drive application, the rotor including a plurality of rotor segments, the plurality of rotor segments being operatively connected at opposite ends thereof to form a circular rotor ring, each one of the plurality of rotor segments including:
• (i) a rotor frame having a top wall and a pair of opposed sidewalls extending downwardly from and substantially perpendicular to opposite ends of the top wall, the top wall and the sidewalls defining a rotor channel;
• (ii) a plurality of magnet modules arranged in alternating magnetic polarity, each one of the plurality of magnet modules including a metal band having a bight section, and a pair of opposing legs extending downwardly from and substantially perpendicular to opposite ends of the bight section, a pair of inwardly facing magnets being disposed on respective legs and positioned within the rotor channel;
• (c) a stator including a plurality of stator segments, the plurality of stator segments being operatively connected at opposite ends thereof to form a circular stator ring, each one of the plurality of stator segments including:
• (i) a stator frame including a base and a pair of opposed sidewalls extending upwardly from and substantially perpendicular to opposite ends of the base, the base and the pair of sidewalls defining a stator channel, a pair of shoulders extending inwardly from respective sidewalls;
• (ii) a plurality of bus bars disposed within the stator channel, the plurality of bus bars including a plurality of phase bus bars and at least one common bus bar;
• (iii) a plurality of stator induction modules being seated on the shoulder of the stator frame, each one of the plurality of stator induction modules including:
• (1) a coil having leads extending from opposite ends thereof and at least one turn formed therebetween, respective leads being in electrical communication with one of the plurality of phase bus bars and the common bus bar;
• (2) a molded polymer formed from a thermally, non-electrically conductive polymer, the molded polymer at least partially encapsulating the coil;
• wherein the rotor rotates above the stator such that the plurality of magnet modules encircles the stator induction modules and provides a dual air gap between the coils and the opposing magnets;
• and
• further wherein the rotor and the wind turbine rotor rotate simultaneously while the stator remains stationary.

In a motor/generator of the type having a plurality of motor segments and stator segments where the motor segments and stator segments form a circular motor/generator, the improvement comprising:

• a plurality of magnet modules arranged in alternating magnetic polarity, each one of the plurality of magnet modules including a metal band having a bight section and a pair of opposing legs extending downwardly from a substantially perpendicular the opposite ends of the bight section;
• and
• a stator frame further including a pair of shoulders extending inwardly from respective sidewalls;
• the stator frame including a base and a pair of opposed sidewalls extending upwardly from and substantially perpendicular to opposite ends of the base, the base and the sidewalls defining a stator channel.