Segmented lamination cores and an apparatus and method of making
AssigneeDelphi Technologies, Inc.
InventorsRobert Anthony Lawrence, Gerald R. Stabel
Life of this patent
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Abstract
A segmented core for an electric machine includes segments stamped from coated electric steel. The segments each have a first end, a second end, and winding openings. A predetermined number of segments are placed end-to-end to form layers. The layers are stacked such that each of the layers is staggered from adjacent layers by a predetermined rotation angle. The winding openings of each of the layers are in vertical alignment with the winding openings of the adjacent layers. The stack of layers is secured to form the segmented core.
Claims23
A segmented core for an electric machine, comprising:
- a plurality of segments being stamped from a coated electric steel, said plurality of segments each having a first end, a second end, and a plurality of winding openings;
- a plurality of layers each being formable by placing a predetermined number of segments end-to-end such that said first end of one of said plurality of segments is adjacent said second end of another of said plurality of segments;
- a stack of said plurality of layers, each of said layers being staggered from adjacent layers by a predetermined rotation angle such that said plurality of winding openings of each of said layers are in vertical alignment with said plurality of winding openings of said adjacent layers;
- and
- means for securing said stack of said plurality of layers.
An apparatus for manufacturing a segmented core for an electric machine, comprising:
- a stacking head having a magazine, a stripper blade and a stripper blade actuator, said magazine being sized, dimensioned and positioned to receive a plurality of segments stacked one on top of the other in said magazine, said segments being stamped from a coated electric steel and each having an annular length and winding openings;
- a dial having an arbor and means for rotating said dial, said arbor having an outer diameter approximately equal to an inner diameter of said segmented core and having radially extending blades being sized, positioned and dimensioned to be engageable with said winding openings;
- a support table supporting said stacking head and said dial, said support table having rollers disposed about said arbor at an outer diameter of said segmented core;
- and means for controlling said stripper blade actuator and said rotating means,
- said stripper blade actuator being controllable to extend said stripper blade into one of said plurality of segments at a bottom of said magazine to strip said segment from said magazine into said arbor such that said winding openings engage said blades and being controllable to retract said stripper blade,
- said rotating means being controllable to rotate said dial a first predetermined angular distance and a second predetermined angular distance, said first predetermined angular distance being equal to said annular length and said second predetermined angular distance being equal to half of said annular length,
- said controlling means being programmable to form a plurality of layers from said plurality of segments by rotating said dial said first predetermined angular distance, extending said stripper blade, and retracting said stripper blade until one of said plurality of layers is complete, and
- said controlling means being programmable to stagger said plurality of layers by rotating said dial said second predetermined angular distance between each completed layer.
A method of making a segmented core for an electric machine, comprising:
- stamping lamination segments from a blank of coated electrical steel, said lamination segments each having a first end, a second end, and winding openings;
- forming layers from said lamination segments by placing a predetermined number of lamination segments end-to-end such that said first end of one of said lamination segments is adjacent said second end of another of said lamination segments;
- stacking said layers in a staggered fashion by rotating adjacent layers a predetermined rotation angle such that said winding openings of each of said layers are in vertical alignment with said winding openings of said adjacent layers;
- and
- securing said stack of layers to form said segmented core.
Dependencies are inferred from the claim text.