MODULAR STATOR

• US 20200136482A1
• Filed: 10/31/2018
• Published: 04/30/2020
• Est. Priority Date: 10/31/2018
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Agapiou, John S., Campbell, John D., Rhoads, Frederick W., Wang, Hongliang, Schroth, James G., Perry, Thomas A.
• Granted Patent: US 11,095,197 B2
• Time in Patent Office: Days
• CPC Class Codes: H02K 1/16 Stator cores with slots for windings
• CPC Class Codes: H02K 15/024 with slots
• CPC Class Codes: H02K 15/064 Windings consisting of separate segments, e.g. hairpin windings H02K15/063 takes precedence
• CPC Class Codes: H02K 2213/12 Machines characterised by the modularity of some components
• CPC Class Codes: H02K 3/12 arranged in slots

Abstract

A modular stator includes a first stator module and a second stator module. The first stator module includes a plurality of first coil end regions and a plurality of first junctions. The second stator module includes a plurality of second coil end regions and a plurality of second junctions. The first stator module and the second stator module are joined at the plurality of first junctions and the plurality of second junctions.

Claims

1. A modular stator comprising:

a first stator module having a plurality of first coil end regions and a plurality of first junctions; and

a second stator module having a plurality of second coil end regions and a plurality of second junctions;

wherein the plurality of first junctions are joined to the corresponding plurality of second junctions.

2. The modular stator as defined in claim 1 wherein the plurality of first coil end regions and the plurality of first junctions are regions defined in a plurality of first hair pin wires which are at least partially disposed within the first stator core module, and the plurality of second coil end regions and the plurality of second junctions are regions defined in a plurality of second hair pin wires which are at least partially disposed within the second stator core module.

3. The modular stator as defined in claim 1 wherein the first stator module includes a first stator core and a first crown housing the plurality of first coil end regions, a plurality of first crown junctions extend from a first crown interfacing surface and the plurality of first crown junctions are joined with a plurality of first core junctions disposed on the first stator module.

4. The modular stator as defined in claim 3 wherein the second stator module includes a second stator core and a second crown housing the plurality of second coil end regions, a plurality of second crown junctions extend from a second crown interfacing surface, and the plurality of second crown junctions are joined with a plurality of second core junctions disposed on the second stator module.

5. The modular stator as defined in claim 2 wherein the first stator module includes a plurality of first hair pin wires disposed within a plurality of first stator module slots, each hair pin wire includes a coil end region.

6. The modular stator as defined in claim 5 wherein the second stator module includes a plurality of second hair pin wires disposed within a plurality of second stator module slots, each hair pin wire in the plurality of second hair pin wires includes a coil end region.

7. The modular stator as defined in claim 5 wherein a central fixture is disposed between the first stator module and the second stator module, the central fixture defining a plurality of junction apertures which are configured to align the plurality of first junctions and the plurality of second junctions, each junction aperture is configured to support a first junction and a corresponding second junction.

8. The modular stator as defined in claim 7 wherein the central fixture further defines at least one tooling passageway which is configured to enable a joining tool to access the first junction and the second junction which are aligned within each junction aperture.

9. The modular stator as defined in claim 8 wherein the central fixture is formed from a thermally insulating material.

10. The modular stator as defined in claim 9 wherein the central fixture is one of a monolithic component or a two-piece component wherein the two-piece component is formed by a removable inner coil and a removable outer coil.

11. The modular stator as defined in claim 3 wherein a first crown fixture is disposed between the first stator module and the first crown fixture, the first crown fixture defines a plurality of junction apertures which are configured to align the plurality of first junctions and the first crown junctions, each junction aperture is configured to support a first junction and a first crown junction.

12. The modular stator as defined in claim 11 wherein the first crown fixture further defines at least one tooling passageway which is configured to enable a joining tool to access the first junction and the first crown junction which are aligned within each junction aperture.

13. The modular stator as defined in claim 12 wherein the first crown fixture is formed from a thermally insulating material.

14. The modular stator as defined in claim 13 wherein the first crown fixture is one of a monolithic component or a two-piece component wherein the two-piece component is formed by a removable inner coil and a removable outer coil.