Method for manufacturing a stator assembly of an electrical machine

• US 10,523,096 B2
• Filed: 08/08/2017
• Issued: 12/31/2019
• Est. Priority Date: 01/13/2017
• Status: Active Grant

• Current Assignee: GE Aviation Systems LLC (GE Aerospace)
• Original Assignee: GE Aviation Systems LLC (GE Aerospace)
• Inventors: Huang, Hao, Jia, Xiaochuan, Mook, Joshua Tyler
• Primary Examiner(s): Pham, Emily P
• Application Number:
  US15/671,344
• Publication Number:
  US 20180205299A1
• Time in Patent Office: 875 Days
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: H02K 1/02 characterised by the magnetic material
• CPC Class Codes: H02K 1/14 Stator cores with salient poles
• CPC Class Codes: H02K 1/16 Stator cores with slots for windings
• CPC Class Codes: H02K 1/18 Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• CPC Class Codes: H02K 15/00 Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
• CPC Class Codes: H02K 15/028 for fastening to casing or support, respectively to shaft or hub
• CPC Class Codes: H02K 19/12 characterised by the arrangement of exciting windings, e.g. for self-excitation, compounding or pole-changing
• CPC Class Codes: H02K 3/04 Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/50 Fastening of winding heads, equalising connectors, or connections thereto
• CPC Class Codes: H02K 5/04 Casings or enclosures characterised by the shape, form or construction thereof
• CPC Class Codes: H02K 9/197 in which the rotor or stator space is fluid-tight, e.g. to provide for different cooling media for rotor and stator

Abstract

A method for manufacturing a stator assembly for an electrical machine includes printing a stator core. The method also includes printing a first part of a stator winding. In addition, the method includes coupling the first part of the stator winding to the stator core. The method also includes printing a second part of the stator winding onto the first part of the stator winding to form the stator assembly. In particular, coupling the first part of the stator winding to the stator core precedes printing the second part of the stator winding onto the first part of the stator winding.

Claims

1. A method for manufacturing a stator assembly for an electrical machine, the method comprising:

printing a stator core;

printing a first part of a stator winding;

coupling the first part of the stator winding to the stator core; and

printing a second part of the stator winding onto the first part of the stator winding to form the stator assembly,

wherein coupling the first part of the stator winding to the stator core precedes printing the second part of the stator winding onto the first part of the stator winding.

2. The method of claim 1, wherein printing the stator core comprises:

printing a first lamination sheet;

printing at least one spacer after printing the first lamination sheet; and

printing a second lamination sheet after printing the at least one spacer,

wherein the at least one spacer is positioned between the first lamination sheet and the second lamination sheet.

3. The method of claim 2, wherein the at least one spacer is formed from a first material having a high resistivity relative to a second material used to form both the first lamination sheet and the second lamination sheet.

4. The method of claim 2, wherein the first lamination sheet is a bottom lamination sheet of the stator core, wherein the bottom lamination sheet defines a plurality of slots, and wherein each slot of the plurality of slots defines at least one slot skew and at least one slot wedge.

5. The method of claim 1, wherein printing the stator core comprises printing a first projection, wherein printing the first part of the stator winding comprises printing a second projection, and wherein the first projection contacts the second projection when the first part of the stator winding is coupled to the stator core.

6. The method of claim 5, further comprising:

applying a varnish or epoxy to the stator assembly;

removing the first projection from the stator core after applying the varnish or epoxy; and

removing the second projection from the first part of the stator winding after applying the varnish or epoxy.

7. The method of claim 6, wherein applying the varnish or epoxy to the stator assembly comprises potting the epoxy to the stator assembly.

8. The method of claim 6, wherein applying the varnish or epoxy to the stator assembly comprises electrophoretically depositing the varnish or epoxy onto the stator assembly.

9. The method of claim 1, wherein coupling the first part of the stator winding to the stator core comprises inserting each coil of a plurality of coils into one slot of a plurality of slots defined by the stator core.

10. A method for manufacturing an electrical machine, the method comprising:

printing, by a three-dimensional (3D) printing process, a stator core;

printing, by the 3D printing process, a first part of a stator winding;

coupling the first part of the stator winding to the stator core;

after coupling the first part of the stator winding to the stator core, printing, by the 3D printing process, a second part of the stator winding onto the first part of the stator winding to form a stator assembly; and

printing, by the 3D printing process, a rotor assembly,

wherein the 3D printing process comprises fusing metal using laser energy or heat.

11. The method of claim 10, wherein printing the stator core comprises:

printing a first lamination sheet;

printing at least one spacer after printing the first lamination sheet; and

printing a second lamination sheet after printing the at least one spacer,

wherein the at least one spacer is positioned between the first lamination sheet and the second lamination sheet.

12. The method of claim 11, wherein the at least one spacer is formed from a first material having a high resistivity relative to a second material that is used to form both the lamination sheet and the second lamination sheet.

13. The method of claim 11, wherein the first lamination sheet is a bottom lamination sheet of the stator core, wherein the bottom lamination sheet defines a plurality of slots, and wherein each slot of the plurality of slots define at least one slot skew and at least one slot wedge.

14. The method of claim 10, wherein printing the stator core comprises printing, by the 3D printing process, a first projection, wherein printing the first part of the stator winding comprises printing, by the 3D printing process, a second projection, and wherein the first projection contacts the second projection when the first part of the stator winding is coupled to the stator core.

15. The method of claim 14, further comprising:

applying a varnish or epoxy to the stator assembly; and

removing the first projection from the stator core after applying the varnish or epoxy; and

removing the second projection from the first part of the stator winding after applying the varnish or epoxy.

16. The method of claim 15, wherein applying the varnish or epoxy to the stator assembly comprises potting the epoxy to the stator assembly.

17. The method of claim 15, wherein applying the varnish or epoxy to the stator assembly comprises electrophoretically depositing the varnish or epoxy onto the stator assembly.

18. The method of claim 10, wherein coupling the first part of the stator winding to the stator core comprises inserting each coil of a plurality of coils into one slot of a plurality of slots defined by the stator core.

19. The method of claim 10, wherein printing the first part of the stator winding comprises printing, by the 3D printing process, a wire.

20. The method of claim 19, wherein printing the wire comprises printing, by the 3D printing process, a hollow wire or a solid wire.