Electric machines with energizable and non-energizerable U-shaped stator segments
AssigneeGreen Ray Technologies LLC
InventorsRamon Anthony Caamaño, Hector Luis Moya, Jeffrey Wayne Harris, Robert R. Ferber
Life of this patent
Estimating the term…
Abstract
A method of making a stator module for use in a stator assembly of an electric machine includes temporarily supporting a plurality of stator segments in a desired orientation using a temporary support. The desired orientation of the stator segments is a relative orientation of the stator segments within the stator module. A mold is placed around the plurality of stator segments and the mold is filled with a potting material to form a stator module such that the potting material supports the stator segments in their desired orientation. The temporary support is removed.
Claims9
A rotating electric machine comprising:
- a rotor assembly supported for rotation about a rotational axis, the rotor assembly including a plurality of rotor poles, the rotor poles being supported for rotation along a rotor pole circular path about the rotational axis with a desired rotor pole spacing between adjacent rotor poles;
- and
- a stator assembly comprising:
- a plurality of independently energizable stator segments, each stator segment including a magnetic core that defines a plurality of stator poles for magnetically interacting with the rotor poles, the stator segments being positioned adjacent to the rotor pole circular path such that the stator poles face the rotor pole circular path with a desired stator pole spacing between adjacent stator poles, the stator segments also being positioned adjacent to only a portion of the rotor pole circular path such that there is at least one stator pole gap between at least two stator poles that is greater than the desired stator pole spacing;
- and
- a stator pole face enlarging piece, the stator pole face enlarging piece being attached to the stator pole portions of the tape wound magnetic core piece to enlarge the surface area of the stator pole face and allow at least portions of the ends of at least some of the multiple layers of thin film soft magnetic tape material to form portions of the stator pole face,
- wherein the stator pole face enlarging piece fully surrounds the stator pole portions of the tape wound magnetic core piece and is made from a pressed powder magnetic material with a uniform thickness perpendicular to the stator pole face, with at least one non-energizable termination magnetic core positioned within the stator pole gap and adjacent to one of the stator segments such that the termination core provides an additional magnetic flux return path for magnetic flux associated with the energizing of the adjacent stator segment, said termination core not including coils and not being an active electromagnetic assembly being shorter than an adjacent stator segment.
A magnetic core for use in a stator assembly of an electric machine having a rotor with a plurality of rotor poles, the magnetic core comprising:
- a tape wound magnetic core piece formed from multiple layers of thin film soft magnetic tape material of a desired tape width and tape thickness, the tape wound magnetic core piece defining at least portions of a plurality of stator poles adapted to magnetically interacting with the rotor poles of the electric machine, each stator pole having a pole face adapted to face the rotor of the electric machine, each stator pole face including at least portions of the ends of at least some of the multiple layers of thin film soft magnetic tape material;
- and
- a stator pole face enlarging piece, the stator pole face enlarging piece being attached to the stator pole portions of the tape wound magnetic core piece to enlarge the surface area of the stator pole face and allow at least portions of the ends of at least some of the multiple layers of thin film soft magnetic tape material to form portions of the stator pole face,
- wherein the stator pole face enlarging piece fully surrounds the stator pole portions of the tape wound magnetic core piece and is made from a pressed powder magnetic material with a uniform thickness perpendicular to the stator pole face, with
- at least one non-energizable termination magnetic core positioned within the stator assembly and adjacent to a stator segment such that the termination core provides an additional magnetic flux return path for magnetic flux associated with the energizing of the adjacent stator segment, said termination core not including coils and not being an active electromagnetic assembly.
Dependencies are inferred from the claim text.