WINDING CONSTRUCTION FOR HIGH EFFICIENCY MACHINE

• US 20140125167A1
• Filed: 11/06/2012
• Published: 05/08/2014
• Est. Priority Date: 11/06/2012
• Status: Active Grant

• Current Assignee: LC Advanced Motor Technology Corporation
• Original Assignee: LCDrives Corp.
• Inventors: Marvin, Russel Hugh, Johnson, Thomas R.
• Granted Patent: US 9,379,585 B2
• Time in Patent Office: Days
• US Class Current: 310/64
• CPC Class Codes: H02K 15/045 Form wound coils
• CPC Class Codes: H02K 3/18 Windings for salient poles
• CPC Class Codes: H02K 3/24 with channels or ducts for cooling medium between the conductors
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine

Abstract

A permanent magnet motor, generator or the like that is constructed with a concentrated winding and edge form wound stator coils. This achieves less eddy current losses in the windings as well as a much higher power density than conventional techniques.

Claims

1. A rotary electric machine comprising a stator having a circumaxially spaced series of axially extending discrete teeth defining a similar series of circumaxially spaced winding slots therebetween, a plurality of stator coils at least partially disposed respectively in the slots, each of said stator coils being configured and wound as a concentrated winding, wherein windings are comprised of at least two generally concentric coils that are of edge wound construction.

2. A rotating electric machine as set forth in claim 1 wherein a cooling manifold is located between said teeth and said windings.

3. A rotating electric machine as set forth in claim 2 wherein there is at least one pair of wedges that compress the windings against the cooling manifold.

4. A rotating electric machine as set forth in claim 2 wherein the insulation layer between the cooling manifold and the winding is at least partially comprised of material that has a thermal conductivity of at least 1 W/mK.

5. A rotating electric machine as set forth in claim 1 wherein each of the coils is built as a separate unit and then electrically connected together in the assembly.

6. A rotating electric machine as set forth in claim 5 wherein wire is wound at least two in hand and connections between adjacent coils are made separately on each wire strand and insulated from each other.

7. A rotating electric machine as set forth in claim 1 wherein the wire in insulated prior to bending.

8. A rotating electric machine as set forth in claim 1 wherein the insulation contains at least one layer of polyamide-imide.

9. A rotating electric machine as set forth in claim 1 where for said coils, the wire on 3 sides of each turn are generally planar for at least some of the turns on said coil.

10. A rotating electric machine as set forth in claim 1 wherein rigid insulators are provided and incorporate features that accommodate wider coils in the corners than in the slot.

11. A rotating electric machine as set forth in claim 1 wherein at least some of the coils are connected electrically in parallel.

12. A rotating electric machine as set forth in claim 2 wherein said cooling manifold incorporates a step that approximately the same height as the thickness of one coil layer.

13. A rotating electric machine as set forth in claim 1 wherein at least one layer of insulation with a thermal conductivity of at least 1 W/mK separates edge wound coils.

14. A method for building edge wound coils from wire that is pre-coated with electrical insulation, said method consisting of clamping wire into a spindle assembly comprising a spindle, edge guide and clamp that constrain the width of the wire;

and then rotating the spindle;

edge guide; and

clamp at the same time to create a bend in the wire.

15. A method for building edge wound coils as set forth in claim 14 wherein said wire consists of two or more strands of rectangular wire adjacent to each other.

16. A method for building edge wound coils as set forth in claim 14 wherein wire tension is controlled while the spindle rotates.

17. A method for building stator assemblies from rectangular wire that consists of manufacturing a plurality of edge wound coils by clamping wire into a spindle assembly that constrains the width of the wire, rotating the spindle assembly to create a bend in the wire and repeating as many times as necessary;

and nesting said coils inside each other as well as inserting cooling manifolds and stator teeth inside coils;

clamping coils to nest tightly against said cooling manifolds;

then inserting the winding assembly into the stator outside lamination and securing in place;

completing any mechanical, fluid and electrical interconnections that are to be done before vacuum pressure impregnation, and then vacuum pressure impregnation of the stator assembly.

18. A method for building edge wound coils as set forth in claim 17 wherein the wire consists of two or more strands of rectangular wire adjacent to each other.

19. A method for building edge wound coils as set forth in claim 17 wherein wire tension is controlled while the spindle rotates.

20. A method for building edge wound coils as set forth in claim 17 wherein said wire is pre-coated with electrical insulation.

21. A method for building edge wound coils as set forth in claim 17 wherein the coils are compressed together with wedges after insertion into the outside lamination.

22. A method for building edge wound coils as set forth in claim 17 wherein securing in place of said winding assembly consists of driving at least one set of wedges in place.