Composite stator for axial flux electric machines and methods of assembling the same
AssigneeRegal Beloit Australia Pty Ltd
InventorsDean James Patterson, Mark Thiele, Greg Heins, Matthew J. Turner
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Abstract
A stator for an axial flux machine includes a back iron, a plurality of stator teeth extending from the back iron, and a plurality of tooth tips attached to the stator teeth. The back iron and the stator teeth include a first material. Each stator tooth has a first end proximate the back iron and a second end. Each tooth tip is attached to the second end of a different stator tooth. The tooth tips include a second material different than the first material.
Claims16
A stator comprising:
- an annular back iron for an axial flux machine, said annular back iron defining an axis of rotation therethrough, said annular back iron comprising a first material;
- and
- a plurality of stator module packs annularly disposed around said annular back iron, each stator module pack of said plurality of stator module packs including:
- a housing defining an enclosed volume;
- a plurality of stator teeth attached to said housing and disposed in the enclosed volume, said plurality of stator teeth extending axially from said annular back iron and annularly disposed around said annular back iron, each stator tooth of said plurality of stator teeth having a first end proximate said annular back iron and a second end, said plurality of stator teeth comprising said first material;
- and
- a plurality of tooth tips attached to said plurality of stator teeth, each tooth tip of said plurality of tooth tips attached to said second end of a different stator tooth of said plurality of stator teeth, said plurality of tooth tips comprising a second material different than said first material.
A method of assembling a stator having an annular back iron of a first material, the method comprising:
- arranging a plurality of stator module packs annularly around the annular back iron, each stator module pack of the plurality of stator module packs including a housing defining an enclosed volume and a plurality of stator teeth attached to housing and disposed in the enclosed volume, the plurality of stator teeth extending axially from the annular back iron, each stator tooth of the plurality of stator teeth having a first end proximate the annular back iron and a second end, the plurality of stator teeth comprising the first material, adjacent stator teeth of the plurality of stator teeth defining a slot with a substantially constant width from the first end to the second end of each adjacent stator tooth;
- winding stator windings on each stator tooth without needle winding;
- and
- attaching a plurality of tooth tips to the plurality of stator teeth, wherein each tooth tip of the plurality of tooth tips is attached to the second end of a different stator tooth of the plurality of stator teeth, the plurality of tooth tips comprising a second material different than the first material.
Dependencies are inferred from the claim text.