Strip wound dynamoelectric machine core

• US 4,365,180 A
• Filed: 06/25/1981
• Issued: 12/21/1982
• Est. Priority Date: 06/25/1981
• Status: Expired due to Fees

• Current Assignee: General Motors Corporation (Motors Liquidation Co. GUC Trust)
• Original Assignee: General Motors Corporation (Motors Liquidation Co. GUC Trust)
• Inventors: Licata, Joseph P., Ricker, Dennis J.
• Primary Examiner(s): Gonzales, John
• Application Number:
  US06/277,275
• Time in Patent Office: 544 Days
• Field of Search: 310/42, 310/216, 310/218, 310/254, 310/259, 310/261, 310/179, 29/596, 29/598, 29/605, 29/609
• US Class Current: 310/216.008
• CPC Class Codes: H02K 1/26 Rotor cores with slots for windings
• CPC Class Codes: H02K 15/026 Wound cores
• CPC Class Codes: Y10T 29/49012 Rotor

Abstract

A strip of toothed arcuate segments connected end-to-end is wound around a mandrel to form a core structure for a dynamoelectric machine. The length of the arcuate segments is such that the junctions between axially adjacent segments are sandwiched between solid portions of core material.

Claims

1. A wound core for a dynamoelectric machine comprising a strip of core material including a continuous array of pole teeth wound in helically overlapping and abutting relation about a longitudinal axis to provide a generally annular core of stacked helical laminations in which the pole teeth of successive laminations are longitudinally aligned to define core poles, the improvement wherein:

the strip of core material is formed in a series of arcuate segments connected end-to-end by integral portions of core material providing yieldable hinge joints between the ends of adjacent segments whereby such strip can be cut out from a sheet of core material with minimal material waste, the yieldable hinge joints each being generally located at the apex of an opening separating the ends of adjacent segments so that as the strip of core material is wound about said longitudinal axis, adjacent segments pivot relatively inward about the yieldable hinge joints thereby closing the opening separating the ends of adjacent segments so as to bring such segment ends into substantial juxtaposition, whereby stressing of the strip of core material is largely confined to the area of the yieldable hinge joints, tending to minimize the electrical losses associated with such stressing of the core material.

2. A wound core for a dynamoelectric machine comprising a strip of core material including a continuous array of pole teeth wound in helically overlapping and abutting relation about a longitudinal axis to provide a generally annular core of stacked helical laminations in which the pole teeth of successive laminations are longitudinally aligned to define core poles, the improvement wherein:

the strip of core material is formed in a series of arcuate segments connected end-to-end by integral portions of core material providing yieldable hinge joints between the ends of adjacent segments whereby such strip can be cut out from a sheet of core material with minimal material waste, the yieldable hinge joints each being generally located at the apex of an opening separating the ends of adjacent segments so that as the strip of core material is wound about said longitudinal axis adjacent segments pivot relatively inward about the yieldable hinge joints thereby closing the opening separating the ends of adjacent segments so as to bring such segments into substantial juxtaposition, and

the respective arcuate segments being of such lengths that within the fully wound core the stressed hinge joints and the inherent air gaps between the juxtaposed ends of adjacent segments do not coincide longitudinally from one helical lamination to the next adjacent helical laminations thereby tending to increase the mechanical strength of the core and decrease the electrical losses associated with such inherent air gaps and tending to distribute throughout the core the electrical losses associated with such stressed hinge joints and such inherent air gaps.

3. A wound core for a dynamoelectric machine comprising a strip of core material including a continuous array of pole teeth wound in helically overlapping and abutting relation about a longitudinal axis to provide a generally annular core of stacked helical laminations in which the pole teeth of successive laminations are longitudinally aligned to define core poles, the improvement wherein:

the strip of core material is formed in a series of arcuate segments connected end-to-end by integral portions of core material providing yieldable hinge joints between the ends of adjacent segments whereby such strip can be cut out from a sheet of core material with minimal material waste, the yieldable hinge joints each being generally located at the apex of an opening separating the ends of adjacent segments so that as the strip of core material is wound about said longitudinal axis adjacent segments pivot relatively inward about the yieldable hinge joints thereby closing the opening separating the ends of adjacent segments so as to bring such segments into substantial juxtaposition, and

the respective arcuate segments being of such lengths that within the fully wound core the stressed hinge joints and the inherent air gaps between juxtaposed ends of adjacent segments are abutted on each side by solid substantially unstressed core material so that the abutting solid core material tends to shunt magnetic flux around said stressed joints and inherent air gaps to significantly reduce electrical losses associated therewith.

4. A wound core for a dynamoelectric machine comprising a strip of core material including a continuous array of pole teeth wound in helically overlapping and abutting relation about a longitudinal axis to provide a generally annular core of stacked helical laminations in which the pole teeth of successive laminations are longitudinally aligned to define core poles, the improvement wherein:

the strip of core material is formed in a series of arcuate segments connected end-to-end by integral portions of core material providing yieldable hinge joints between the ends of adjacent segments whereby such strip can be cut out from a sheet of core material with minimal material waste, the yieldable hinge joints each being generally located at the apex of an opening separating the ends of adjacent segments so that as the strip of core material is wound about said longitudinal axis adjacent segments pivot relatively inward about the yieldable hinge joints thereby closing the opening separating the ends of adjacent segments so as to bring such segments into substantial juxtaposition, and

each segment being terminated at its respective ends by complementary partial pole teeth and including at least one solid whole pole tooth positioned between such partial pole teeth so that as the strip of core material is wound and the openings separating the ends of adjacent segments are closed, the complementary partial pole teeth at the ends of such adjacent segments are brought into substantial juxtaposition, the respective arcuate segments having such lengths and such spacings between pole teeth that within the fully wound core the stressed hinge joints and inherent air gaps between juxtaposed partial pole teeth in each helical lamination are sandwiched in the axial direction between whole solid pole teeth of adjacent helical laminations thereby tending to increase the mechanical strength of the core and to decrease the electrical losses associated with such inherent air gaps and tending to distribute throughout the core the electrical losses associated with such stressed hinge joints and such inherent air gaps.

5. A wound core for a dynamoelectric machine comprising a strip of core material including a continuous array of radially outward extending pole teeth wound in helically overlapping and abutting relation about a longitudinal axis to provide a generally annular core of stacked helical laminations in which the pole teeth of successive laminations are longitudinally aligned to define core poles, the improvement wherein:

the strip of core material is formed in a series of arcuate segments being terminated at their respective ends by complementary partial pole teeth and including at least one whole pole tooth positioned between such partial pole teeth, said arcuate segments being connected end-to-end at the outer radial end points of said partial pole teeth by integral portions of core material providing yieldable hinge joints between the ends of adjacent segments, the yieldable hinge joints being generally located at the apex of an opening separating the ends of adjacent segments so that as said strip of core material is wound about said longitudinal axis, adjacent segments pivot relatively inward about said yieldable hinge joints thereby closing the opening separating the ends of adjacent segments so as to bring such segment ends into substantial juxtaposition so that the tips of said pole teeth do not move relative to each other as said strip is wound around said axis, whereby the spacing between the tips of radially adjacent poles is determined solely by the spacing between pole teeth tips in said segments.

6. In a method of making a wound core for a dynamoelectric machine comprising the steps of cutting out from a flat sheet of core material a strip including a continuous array of pole teeth and winding such strip of core material about a longitudinal axis in helically overlapping and abutting relation to make a laminated annular core in which the pole teeth of successive helical laminations are longitudinally aligned to provide core poles, the improvement wherein:

the strip of core material is formed in a series of arcuate segments connected end-to-end by integral portions of core material providing yieldable hinge joints between the ends of adjacent segments whereby such strip is cut out from a sheet of core material with minimal material waste, the yieldable hinge joints each being generally located at the apex of an opening separating the ends of adjacent segments so that as the strip of core material is wound about said longitudinal axis adjacent segments pivot relatively inward about the yieldable hinge joints, closing the opening separating the ends of adjacent segments so as to bring such segment ends into substantial juxtaposition.