Automotive alternator stator assembly with rectangular continuous wire

• US 6,759,779 B2
• Filed: 10/07/2002
• Issued: 07/06/2004
• Est. Priority Date: 01/24/2002
• Status: Expired due to Fees

• Current Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Original Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Inventors: Neet, Kirk E.
• Primary Examiner(s): Nguyen, Tran N.
• Application Number:
  US10/265,529
• Publication Number:
  US 20030137204A1
• Time in Patent Office: 638 Days
• Field of Search: 310/179-180, 310/195, 310/198, 310/203, 310/205, 310/206, 310/208
• US Class Current: 310/180
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49011 Commutator or slip ring assembly
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49078 Laminated

Abstract

A stator assembly for an electric machine includes a metal core with windings installed into slots of the core. A pair of conductors of a continuous form is used for each phase of the machine. The windings are interlaced to alternate between radially inner and outer positions in each adjacent winding slot of the stator core.

Claims

1. A stator core assembly for an electric machine having a rotor assembly and a stator assembly, the stator assembly of the type having at least one phase and having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to the inside diameter but terminating short of the outside diameter, the core further defining a lead side and an opposite non-lead side, the stator core assembly further comprising:

a) two continuous electrical conductors per phase designated as conductor A and conductor B and being positioned into a predetermined pitch of the winding slots, and extending from the lead side and non-lead side of the core,

b) the conductors positioned into the winding slots where;

n=number of phases of the stator core assembly,

m=number of the winding slots in the stator core, with the winding slots numbered 1 through m,

L=number of layers of the conductors A and B in the winding slots, wherein a layer is defined as a portion of conductors A and B which are interleaved into two adjacent radial portions of the winding slots for one substantial revolution around the core,

c) a first lead of conductor A being located on one axial end of the core, thereby defining the lead side and extending from the outermost radial portion of slot number 1,

d) a first lead of conductor B being located on the lead side and extending from the outermost radial portion of slot number n+1,

e) conductor A extends circumferentially forward and is located into the slot number n+1 thereby forming an end loop on the non-lead side end and is radially shifted inwardly from conductor B and lying in the second outermost radial portion of slot number n+1,

f) conductor A further extends circumferentially forward and is located into the slot number 2n+1 thereby forming an end loop on the lead side end and is radially shifted outward and lying in the outermost radial portion of slot number 2n+1,

g) conductor B extends circumferentially forward and is located in the slot number 2n+1 thereby forming an end loop on the non-lead side end and is radially shifted inward from conductor A and is lying in the second outermost radial portion of slot number 2n+1,

h) conductor B extends circumferentially forward and is located in the slot number 3n+1 thereby forming an end loop on the lead side end and is radially shifted outward from conductor A and is lying in the outermost radial portion of slot number 3n+1,

i) conductors A and B continue to extend circumferentially forward around the core located in every Zn+1 slot, wherein Z is a whole number from 0 through m/n−

1, alternating between outermost and second outermost portions of the slots until conductor A is located in slot number m+1−

n and conductor B is located in slot number 1, thereby completing a first layer K1, wherein K designates each layer from 1 through L,

j) conductor A further extends circumferentially forward from slot number m+1−

n and is located in slot number 1 and is radially shifted inward and lying in the third outermost radial portion of the slot,

k) conductor B further extends circumferentially forward from slot number 1 and is located in slot number n+1 and is radially shifted inward and lying in the third outermost radial portion of the slot,

l) the pattern of conductors A and B continues as described in e) through k) is repeated for each additional layer K except the conductors alternate between 2K−

1 and 2K outermost portions of the slots for e) through i) and 2K+1 outermost portion of the slot for j) and k), and deleting steps j) and k) for the innermost layer K=L.

2. A stator core assembly for an electric machine according to claim 1 wherein conductor A terminates as a lead in the innermost portion of slot number m+1−

n and conductor B terminates as a lead in the innermost portion of slot number 1.

3. A stator core assembly for an electric machine according to claim 1 wherein the pattern of conductors A and B is repeated for each phase of the stator assembly and each phase is shifted circumferentially forward by one slot with respect to the previous phase.

4. A stator core assembly for an electric machine according to claim 3 wherein the conductors have a substantially rectangular cross-sectional shape.

5. A stator core assembly for an electric machine according to claim 3 wherein the conductors have a substantially square cross-sectional shape.

6. A stator core assembly for an electric machine according to claim 3 wherein the conductors have a substantially elliptical cross-sectional shape.

7. A stator core assembly for an electric machine according to claim 3 wherein the conductors, including any insulation on the conductors, have a width of a dimension to be closely received by the winding slots, including any insulation on the slots.

8. A stator core assembly for an electric machine according to claim 3 wherein n≧

1.

9. A stator core assembly for an electric machine according to claim 3 wherein n=6.

10. A stator core assembly for an electric machine according to claim 3 wherein L=3.

11. A stator core assembly for an electric machine according to claim 3 wherein the two conductors A and B are series connected.

12. A stator core assembly for an electric machine according to claim 3 wherein the two conductors A and B are parallel connected.

13. A stator core assembly for an electric machine according to claim 3 wherein the end loops of the conductors on the lead and non-lead side ends are twisted;

they axially extend away from the core, circumferentially shift to a first position, shift radially at least one conductor radial width to a second position, lower back toward the core and circumferentially shift toward and enter the next predetermined slot.

14. A stator core assembly for an electric machine according to claim 3 wherein all end loops on the non-lead side shift radially inward and circumferentially forward and all end loops on the lead side, except the end loops in the radial shift areas, shift radially outward and circumferentially forward, and within the radial shift areas between each layer, one end loop of conductor A and one end loop of conductor B on the lead side for every phase shift radially inward and circumferentially forward.

15. A stator core assembly for an electric machine according to claim 3 wherein the conductors are aligned in one radial row within each slot.

16. A stator core assembly for an electric machine having a rotor assembly and a stator assembly, the stator assembly of the type having at least one phase and having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to the inside diameter but terminating short of the outside diameter, the stator core assembly further comprising:

a) two continuous electrical conductors per phase designated as conductor A and conductor B and being positioned into a predetermined pitch of the winding slots, and extending as end loops from both sides of the core,

b) wherein all end loops on one side of the core, shift radially inward and circumferentially forward, and all end loops on the opposite side of the core, that are not within the radial shift areas, shift radially outward and circumferentially forward, and all end loops on the opposite side of the core that are within the radial shift areas, between the layers, one end loop of conductor A and one end loop of conductor B, for each phase, shift radially inward and circumferentially forward.

17. A stator core assembly for an electric machine according to claim 16 wherein the conductors are aligned in one radial row in each slot.

18. A stator core assembly for an electric machine according to claim 17 wherein the two conductors alternate radial positions within each slot.

19. A stator core assembly for an electric machine according to claim 18 wherein for each phase, the conductors A and B consist of multiple layers, wherein for each layer K, the conductors alternate between a 2K−

1 and 2K outermost portions of the slot.

20. A stator core assembly for an electric machine of the type having a rotor assembly and a stator assembly, the stator assembly of the type having at least one phase and having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to the inside diameter but terminating short of the outside diameter, the stator core assembly further comprising:

a) two continuous electrical conductors per phase designated as conductor A and conductor B and being positioned into a predetermined pitch of the winding slots, and extending as end loops from both sides of the core,

b) conductors aligned in one radial row in each slot,

c) wherein for each phase, the conductors A and B traverse around the core in layers, alternating radial slot portions with respect to each other, except within a radial shift areas between the layers, one conductor will lie radially inward of the other conductor for three consecutive slots.

21. A stator core assembly for an electric machine having a rotor assembly and a stator assembly, the stator assembly of the type having at least one phase and having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to the inside diameter but terminating short of the outside diameter, the core further defining a lead side and an opposite non-lead side, the stator core assembly further comprising:

a) two continuous electrical conductors per phase designated as conductor A and conductor B and being positioned into a predetermined pitch of the winding slots, and extending from the lead side and non-lead side of the core

b) each phase comprised of multiple layers wherein the layers are aligned radially with respect to each other, and

c) the conductors aligned in one radial row in each slot

“

d) wherein for each phase, the conductors A and B traverse around the core in layers, alternating radial slot portions with respect to each other, except within a radial shift areas between the layers, one conductor will lie radially inward of the other conductor for three consecutive slots.