Ring wound stator having variable cross section conductors

• US 5,304,883 A
• Filed: 09/03/1992
• Issued: 04/19/1994
• Est. Priority Date: 09/03/1992
• Status: Expired due to Term

• Current Assignee: Alliedsignal Inc. (Honeywell International Inc.)
• Original Assignee: Alliedsignal Inc. (Honeywell International Inc.)
• Inventors: Denk, Joseph
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): TSO, EDWARD H
• Application Number:
  US07/939,788
• Time in Patent Office: 593 Days
• Field of Search: 310/180, 310/127, 310/258, 310/259, 310/260, 310/219, 310/223, 310/201, 310/194, 310/192, 310/58, 310/164, 310/267, 310/52, 310/193
• US Class Current: 310/180
• CPC Class Codes: H02K 1/12 Stationary parts of the magnetic circuit
• CPC Class Codes: H02K 2203/15 Machines characterised by cable windings, e.g. high-voltage cables, ribbon cables
• CPC Class Codes: H02K 3/04 Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
• CPC Class Codes: H02K 3/46 Fastening of windings on the stator or rotor structure
• CPC Class Codes: H02K 9/227 Heat sinks
• CPC Class Codes: Y10S 174/19 in a dynamo-electric machine

Abstract

Flux density in the air gap of an electrical machine is increased by varying the cross sectional area of conductors wound on the stator. Conductors of smaller cross sectional area are located within the air gap and conductors of larger cross sectional area are located outside the air gap. Because the smaller conductor allows the air gap to be reduced, air gap flux density is increased.

Claims

1. An electrical machine, comprising:

magnet means for providing magnetic flux;

flux collector means for providing a flux return path for said magnetic flux, said magnet means and flux collector means defining a magnetic air gap therebetween; and

windings around said flux collector means, a first portion of said windings being located within said magnetic air gap, and a second portion of said windings being located outside said magnetic air gap, said windings of said first portion having a smaller cross-sectional area than said windings of said second portion.

2. The machine of claim 1, wherein said magnet means includes a two pole permanent magnet.

3. The machine of claim 1, wherein said flux collector means includes a ring of magnetically permeable material.

4. The machine of claim 3, wherein said ring is toothless.

5. The machine of claim 3, wherein said ring has a plurality of radially inner axially extending and regularly circumferentially arrayed tooth portions, said tooth portions interposing circumferentially between successive turns of said windings of said first portions thereof, whereby said ring is toothed.

6. The machine of claim 1, further including a housing for said flux collector means and said magnet means, said housing providing an airtight chamber for said flux collector means and said windings, said housing further providing inlet and outer ports to said chamber.

7. The machine of claim 1, wherein said windings of said first portion form single layer.

8. The machine of claim 1, wherein said windings of said second portion are low current density conductors.

9. The machine of claim 8, wherein said low current density conductors are elongated bars of electrically conductive material.

10. The machine of claim 1, wherein said windings of said first portion are high current density conductors.

11. The machine of claim 10, wherein said high current density conductors are multiple stranded Litz cable.

12. The machine of claim 1, wherein said machine is a polyphase machine and wherein said windings are segmented into half phase sectors.

13. The machine of claim 12, further comprising means for isolating said half phase sectors at their phase boundaries.

14. The machine of claim 13, wherein said isolating means includes phase-to-phase barriers disposed between said half phase sectors.

15. An electrical machine, comprising:

a magnet;

a flux collector ring encircling said magnet, opposing surfaces of said flux collector ring and said magnet defining a magnetic air gap; and

windings that are toroidally wound around said flux collector ring, a first portion of said windings being located within said magnetic air gap, and a second portion of said windings being located outside said magnetic air gap, said windings of said first portion having a smaller cross-sectional area than said windings of said second portion.

16. The machine of claim 15, wherein said machine is a polyphase machine and wherein said windings are segmented int o half phase sectors.

17. The machine of claim 16, further comprising means for isolating said half phase sectors.

18. The machine of claim 17, wherein said flux ring is toothless, and wherein said isolating means further includes:

a bobbin encasing said flux collector ring;

an inner sleeve member received concentrically within said flux collector ring;

an outer sleeve member surrounding said flux collector ring;

a first set of barriers disposed between said first portion of windings and keyed into said inner sleeve member and said bobbin; and

a second set of barrier disposed between said second portion of windings and keyed into said bobbin and said outer sleeve member.

19. The machine of claim 15, wherein said windings of said first portion are high current density conductors and wherein said windings of said second portion are low current density conductors.

20. The machine of claim 19, wherein said high current density conductors include multiple stranded Litz cables, and wherein said low current density conductors include electrically conductive bars.

21. The machine of claim 15, wherein said windings of said first portion form single layer.

22. An electrical machine, comprising a housing;

a rotor, journalled for rotation within said housing, including a two pole permanent magnet; and

a stator including;

a flux collector ring encircling said magnet, opposing surfaces of said flux collector ring and said magnet defining a magnetic air gap; and

windings that are toroidally wound around said flux collector ring, said windings including a single layer of high current density conductors located within said magnetic air gap and low current density conductors connected between said high current density conductors, said high current density conductors having a smaller cross-sectional area than said low current density conductors.

23. The machine of claim 22, wherein said machine is a polyphase machine and wherein said windings are segmented into half phase sectors.

24. The machine of claim 23, wherein said flux ring is toothless and wherein said stator further includes isolating means for isolating said half phase sectors, said isolating means including:

a bobbin encasing said flux collector ring;

an inner sleeve member received concentrically within said flux collector ring;

an outer sleeve member surrounding said flux collector ring;

a first set of barriers disposed between said high current density conductors and keyed into said inner sleeve and said bobbin; and

a second set of barrier disposed between said low current density conductors and keyed into said bobbin and said outer sleeve.

25. The machine of claim 22, wherein said housing includes means for providing an airtight chamber for said flux collector ring and said windings, said housing further providing inlet and outer ports that are in fluid communication with said chamber.

26. A ring wound stator, comprising:

a flux return ring having an inner surface and an outer surface; and

electrical windings toroidally wound around said ring, a first portion of said windings being in communication with said inner surface, a second portion of said windings being in communication with said outer surface, said windings of said first portion having a smaller cross-sectional area than said windings of said second portion.

27. The machine of claim 26, wherein said windings of said first portion are high current density conductors and wherein said windings of said second portion are low current density conductors.

28. The machine of claim 27, wherein said high current density conductors include multiple stranded Litz cables, and wherein said low current density conductors include electrically conductive bars.