Stator assembly with cascaded winding and method of making same
First Claim
1. A stator assembly for a dynamoelectric machine, comprising:
- a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core, and a stator winding including a first set of first conductors and a second set of second conductors, wherein each first and second conductor includes a first lead, a plurality of slot segments interconnected with a plurality of end loop segments, the slot segments of the conductors being disposed within the slots of the stator core to define a plurality of concentric winding layers, wherein a first plurality of consecutive slot segments of each first conductor are disposed in a radially-outermost first layer of the stator winding, and at least one first additional slot segment of each first conductor immediately adjacent to the first plurality of consecutive slot segments of each first conductor is disposed in a second, radially-inward winding layer of the stator winding, and wherein at least one first slot segment of each second conductor is disposed in the first layer of the stator winding, and a first plurality of additional, consecutive slot segments of each second conductor is disposed within the second layer of the stator winding.
17 Assignments
0 Petitions
Accused Products
Abstract
A stator assembly for a dynamoelectric machine featuring a cascaded construction includes several conductors, each having a plurality of slot segments interconnected by plurality of end loop segments. The consecutive slot segments of a first conductor forms nearly all of a radially-outermost first layer of the stator winding, with the remaining portion of the radially-outermost winding layer being defined by a slot segment of a second conductor that is then inserted into the core to form nearly all of a second layer of the stator winding radially-inwardly of the first winding layer. The second winding layer is completed with an additional single slot segment of the first conductor.
-
Citations
33 Claims
-
1. A stator assembly for a dynamoelectric machine, comprising:
-
a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core, and a stator winding including a first set of first conductors and a second set of second conductors, wherein each first and second conductor includes a first lead, a plurality of slot segments interconnected with a plurality of end loop segments, the slot segments of the conductors being disposed within the slots of the stator core to define a plurality of concentric winding layers, wherein a first plurality of consecutive slot segments of each first conductor are disposed in a radially-outermost first layer of the stator winding, and at least one first additional slot segment of each first conductor immediately adjacent to the first plurality of consecutive slot segments of each first conductor is disposed in a second, radially-inward winding layer of the stator winding, and wherein at least one first slot segment of each second conductor is disposed in the first layer of the stator winding, and a first plurality of additional, consecutive slot segments of each second conductor is disposed within the second layer of the stator winding. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
-
-
15. A stator assembly for a dynamoelectric machine, comprising:
-
a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core, and a stator winding including a continuous first conductor and a continuous second conductor, wherein the conductors each includes in series a first lead, a plurality of slot segments interconnected by end loop segments, and a second lead, the conductors being disposed within the slots of the stator core to define a plurality of concentric conductor winding layers in which the conductors reside within a given winding layer for nearly one circumferential pass before shifting radially into an adjacent winding layer, wherein a first conductor includes a first plurality of consecutive slot segments disposed in the slots of the stator core for nearly one complete revolution around the stator core within a first winding layer, and a second conductor includes a second plurality of consecutive slot segments disposed in the slots of the stator core for nearly one complete revolution around the stator core within a second winding layer, wherein a first additional slot segment of the second conductor, disposed between the first lead of the second conductor and the first plurality of consecutive slot segments of the second conductor, is disposed in a slot of the stator core within the first winding layer, adjacent to the first plurality of consecutive slot segments of the first conductor, and wherein a first additional slot segment of the first conductor, adjacent to the first plurality of consecutive slot segments of the first conductor, is disposed in a slot of the stator core in the second winding layer, adjacent to the first plurality of consecutive slot segments of the second conductor. - View Dependent Claims (16, 17, 18)
-
-
19. A method of making a stator assembly having a cascaded stator winding about a stator core, the method comprising:
-
inserting a plurality of consecutive slot segments defined on a continuous first conductor and a first one of a plurality of slot segments defined on a continuous second conductor into a series of radial slots in the stator core to define one complete revolution of a radially-outermost first layer of the stator winding, and inserting an additional one of the consecutive slot segments defined on the first conductor and additional slot segments defined on the second conductor into the radial slots to define one complete revolution of a second layer of the stator winding immediately radially-inwardly of the first layer. - View Dependent Claims (20, 21)
-
-
22. A stator assembly for a dynamoelectric machine comprising:
-
a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core;
a stator winding including at least one conductor, wherein each of the at least one conductor includes a plurality of slot segments interconnected by a plurality of end loop segments, the slot segments being disposed within the slots of the stator core to define a plurality of concentric winding layers, and the plurality of end loop segments including a first type of end loop segment interconnecting two slot segments disposed in the same layer and a second type of end loop segment interconnecting one slot segment of one layer with one slot segment of a different layer, wherein fewer than 26% of the plurality of end loop segments are the second type of end loop segments. - View Dependent Claims (23, 24)
-
-
25. A stator assembly for a dynamoelectric machine comprising:
-
a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core;
a stator winding including at least one conductor, wherein each of the at least one conductor includes a plurality of slot segments interconnected by a plurality of end loop segments, the slot segments are disposed within the slots of the stator core to define a plurality of concentric winding layers, and the plurality of end loop segments of the stator include at least one end loop segment having at least two radial adjustments per end loop segment and wherein the number of inward radial adjustments equals the number of outward radial adjustments and at least one end loop segment having one more inward radial adjustment than outward radial adjustments per end loop segment. - View Dependent Claims (26, 27, 28, 29)
-
-
30. A stator assembly for an automotive alternator comprising:
-
a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core, and a stator winding including a first set of first conductors and a second set of second conductors, wherein each first and second conductor includes in a first lead and a plurality of slot segments interconnected with a plurality of end loop segments, the slot segments of the conductors being disposed within the slots of the stator core to define a plurality of concentric winding layers, wherein a first plurality of consecutive slot segments of each first conductor are disposed in a radially-outermost first layer of the stator winding and at least one additional slot segment of each first conductor immediately adjacent to the first plurality of consecutive slot segments of each first conductor is disposed in a second, radially-inward winding layer of the stator winding, wherein at least one additional slot segment of each second conductor is disposed in the first layer of the stator winding, and a first plurality of additional, consecutive slot segments of each second conductor is disposed within the second layer of the stator winding, and wherein the conductors of each set of conductors are organized into multiple phases defined by a fixed circumferential slot pitch, and the number of the multiple phases equals six.
-
-
31. A stator assembly for an automotive alternator, comprising:
-
a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core;
a stator winding including at least one conductor, wherein each of the at least one conductor includes a plurality of slot segments interconnected by a plurality of end loop segments, the slot segments being disposed within the slots of the stator core to define a plurality of concentric winding layers;
the plurality of end loop segments of the stator include at least one end loop segment of a first type which connects two slot segments disposed in the same layer and at least one end loop segment of a second type which connects two slot segments disposed in different layers; and
wherein the winding includes less than 26% of the end loop segments of the second type. - View Dependent Claims (32)
-
-
33. A stator assembly for an automotive alternator comprising:
-
a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core; and
a stator winding including at least one conductor, wherein each of the at least one conductor includes a plurality of slot segments interconnected by a plurality of end loop segments, the slot segments being disposed within the slots of the stator core to define a plurality of concentric winding layers, wherein at least 74% of the plurality of end loop segments being an end loop segment of a first type which has at least two radial adjustments with the number of inward radial adjustments being equal to the number of outward radial adjustments; and
wherein the plurality of end loop segments include at least one end loop segment having one more inward radial adjustment than outward radial adjustments per end loop segment, at least one end loop segment having only one radial adjustment per end loop segment, and at least one end loop segment having only two inward radial adjustments and only one outward radial adjustment for each end loop segment.
-
Specification