Winding assemblies for electrical machines
First Claim
1. A winding assembly for an electrical machine having an axis, the winding assembly having an inner region situated radially outward of the axis and an outer region situated radially outward of the inner region, the winding assembly comprising:
- a first winding having a first portion situated in the outer region;
a second winding having a second portion situated in the outer region;
a third winding having a third portion situation in the outer region; and
a conduit electrically coupled directly to the first and third portions via at least one wave soldered connection, wherein the first and third portions form an acute angle with respect to the axis, and the second portion is situated in the acute angle.
1 Assignment
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Accused Products
Abstract
Winding assemblies of electrical machines, such as electric motors, are provided which include a connector scheme having at least one conduit that is electrically coupled via a wave soldered connection directly to at least two windings which are not axially adjacent. The conduit can include a common connector and/or a phase connector. The connector scheme can additionally or alternatively include a power connector that is electrically coupled via wave soldering directly to a single winding, and adapted to be electrically coupled to a power source. The winding assemblies of the invention can additionally provide a number of constructions which allow for minimally sized air gaps.
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Citations
83 Claims
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1. A winding assembly for an electrical machine having an axis, the winding assembly having an inner region situated radially outward of the axis and an outer region situated radially outward of the inner region, the winding assembly comprising:
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a first winding having a first portion situated in the outer region;
a second winding having a second portion situated in the outer region;
a third winding having a third portion situation in the outer region; and
a conduit electrically coupled directly to the first and third portions via at least one wave soldered connection, wherein the first and third portions form an acute angle with respect to the axis, and the second portion is situated in the acute angle. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A winding assembly for an electrical machine having an axis and at least first and second phases, the winding assembly having an inner region situated radially outward of the axis and an outer region situated radially outward of the inner region, the winding assembly comprising:
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first and second windings defining in part the first phase, at least a portion of the second winding being adjacent to at least a portion of the first winding;
a connector electrically coupled directly to the first and second windings via a wave soldered connection;
a third winding defining in part the second phase; and
a rigid conduit electrically coupled directly to the first and third windings, a majority of the rigid conduit being situated in the inner region. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31)
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32. A winding assembly for an electrical machine having an axis and at least a first phase, the winding assembly having an inner region situated radially outward of the axis and an outer region situated radially outward of the inner region, the winding assembly comprising:
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a first plurality of windings electrically coupled via at least one wave soldered connection in the outer region to form a first portion of the first phase, the first portion having a first IN terminal and a first OUT terminal;
a second plurality of windings electrically coupled via at least one wave soldered connection in the outer region to form a second portion of the first phase, the second portion having a second IN terminal and a second OUT terminal; and
a rigid conduit electrically coupled directly to the first OUT terminal and the second IN terminal, wherein the first OUT terminal and the second IN terminal form an acute angle with respect to the axis, and the second OUT terminal is situated in the acute angle. - View Dependent Claims (33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46)
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47. A winding assembly for an electrical machine having an axis and at least a first phase, the winding assembly having an inner region situated radially outward of the axis and an outer region situated radially outward of the inner region, the winding assembly comprising:
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a winding defining in part the first phase, the winding having an outer portion situated in the outer region;
a connector having an outer portion situated in the outer region and an inner portion situated in the inner region, the outer portion of the connector being electrically coupled directly to the outer portion of the winding via a wave soldered connection, and the inner portion being adapted to electrically couple the first phase to a power source associated with the electrical machine. - View Dependent Claims (48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58)
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59. A winding assembly for an axial air gap electrical machine having an axis, a rotor adapted to rotate about the axis, a stator, and an air gap between the rotor and the stator, the winding assembly having a first side adjacent to the air gap, a second side opposite the first side, an inner region situated radially outward of the axis, a middle region situated radially outward of the inner region, and an outer region situated radially outward of the middle region, the winding assembly comprising:
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a first winding having a first edge adjacent to the air gap, the first edge having a first notch;
a second winding having a second edge adjacent to the air gap, the second edge having a second notch; and
a conduit electrically coupled directly to the first and second windings via at least one wave soldered connection in the outer region, wherein a majority of the conduit is situated in a recess at least partially defined by the first notch and the second notch, and wherein the recess extends to the periphery of the winding assembly. - View Dependent Claims (60, 61, 62, 63, 64, 65, 66, 67)
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68. A winding assembly for an axial air gap electrical machine having an axis, a rotor adapted to rotate about the axis, a stator, and an air gap between the rotor and the stator, the winding assembly having a first side adjacent to the air gap, a second side opposite the first side, an inner region situated radially outward of the axis, a middle region situated radially outward of the inner region, and an outer region situated radially outward of the middle region, the winding assembly comprising:
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a first winding having a first edge adjacent to the air gap, the first edge having a first notch between two opposed ends of the first edge;
a second winding having a second edge adjacent to the air gap, the second edge having a second notch between two opposed ends of the second edge; and
a conduit electrically coupled directly to the first and second windings, wherein a majority of the conduit is situated in a recess at least partially defined by the first notch and the second notch. - View Dependent Claims (69, 70, 71, 72, 73, 74, 75, 76, 77)
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78. A winding assembly for an axial air gap electrical machine having an axis, a rotor adapted to rotate about the axis, a stator, and an air gap between the rotor and the stator, the winding assembly having a first side adjacent to the air gap and a second side opposite the first side, the winding assembly comprising:
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a first winding having a first edge adjacent to the air gap;
a second winding having a second edge adjacent to the air gap, the first and second edges defining a plane having a first surface facing the air gap and a second surface opposite the first surface;
a conduit electrically coupled directly to the first and second windings, wherein a majority of the conduit is situated axially adjacent to the first surface, and wherein the conduit has a height defined in the axial direction; and
a magnetically permeable element situated between the first and second windings, wherein at least a portion of the magnetic permeable element extends axially through the plane at least as far as the height of the electrical conduit. - View Dependent Claims (79, 80, 81, 82, 83)
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Specification