Stator winding having cascaded end loops

• US 6,882,077 B2
• Filed: 05/22/2003
• Issued: 04/19/2005
• Est. Priority Date: 12/19/2002
• Status: Expired due to Term

• Current Assignee: BorgWarner Incorporated
• Original Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Inventors: Neet, Kirk E.
• Primary Examiner(s): LE, DANG D
• Application Number:
  US10/443,441
• Publication Number:
  US 20040119362A1
• Time in Patent Office: 698 Days
• Field of Search: 310201-208
• US Class Current: 310/208
• CPC Class Codes: H02K 15/0478 Wave windings, undulated windings when on diagonally wound hollow coils H02K15/0492
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/24 with channels or ducts for cooling medium between the conductors

Abstract

An alternator stator having cascaded end loop segments includes a multi-phase stator winding that is adapted to be placed in a plurality of circumferentially spaced axially-extending core slots in a surface of a stator core. The stator winding includes a plurality of straight segments alternately connected at the first and second ends of the stator core by a plurality of end loop segments to form the winding. The end loop segments include first and second sloped portions meeting at an apex portion. Each of the end loop segments includes a radial outward adjustment and a radial inward adjustment and forms a cascaded winding pattern.

Claims

1. A stator for a dynamoelectric machine, comprising:

a generally cylindrically-shaped stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, said core slots extending between a first and a second end of said stator core; and

a stator winding including at least one layer of continuous conductors having a plurality of phases, each of said phases having a plurality of substantially straight segments disposed in said core slots, said straight segments alternately connected at said first and second ends of said stator core by a plurality of end loop segments, each of said straight segments of said at least one layer being in a same radial distance from a central axis of said stator core, said straight segments and said end lop segments having a substantially equal cross sectional area,

wherein said end loop segments form a cascaded winding pattern.

2. The stator according to claim 1 wherein at least one of said end loop segments includes a first sloped portion substantially co-radial with said at least one layer and a second sloped portion substantially non-co-radial with said at least one layer, said first and second sloped portions connected by an apex portion thereof.

3. The stator according to claim 1 wherein at least one of said end loop segments includes a radial adjustment portion to form said cascaded winding pattern.

4. The stator according to claim 1 including at least two layers and wherein at least one of said layers is shifted a predetermined number of slots from at least one of another said layers.

5. The stator according to claim 4 wherein said end loop segments of a one of said layers extend radially outwardly in a counterclockwise direction on said first axial end of said stator core and said end loop segments of another one of said layers extend radially outwardly in a clockwise direction on said first axial end of said stator core.

6. A stator for a dynamoelectric machine, comprising:

a generally cylindrically-shaped stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, said core slots extending between a first and a second end of said stator core; and

a stator winding including at least one layer of continuous conductors having a plurality of phases, each of said phases having a plurality of substantially straight segments disposed in said core slots, said straight segments alternately connected at said first and second ends of said stator core by a plurality of end loop segments, each of said straight segments of said at least one layer being in a same radial distance from a central axis of said stator core,

wherein each of said end loop segments includes a first sloped portion substantially co-radial with said at least one layer and a second sloped portion substantially non-co-radial with said at least one layer, said first and second sloped portions connected by an apex portion thereof, and

wherein a one of said first sloped portion, said second sloped portion, and said apex portion of each of said end loop segments includes a radial outward adjustment and a one of said first sloped portion, said second sloped portion, and said apex portion of each of said end loop segments includes a radial inward adjustment to form a cascaded winding pattern.

7. The stator according to claim 6 wherein said outward radial adjustment is a first radial extension at said apex portion and said radial inward adjustment is a second sloping radial extension adjacent a one of said straight segments.

8. The stator according to claim 6 wherein said stator core slots have a substantially rectangular volume.

9. The stator according to claim 6 wherein each of said straight segments has a first substantially rectangular cross-sectional shape and said end loop segments have a second substantially rectangular cross-sectional shape.

10. The stator according to claim 9 wherein an area of said first cross-sectional shape is equal to an area of said second cross-sectional shape.

11. The stator according to claim 6 wherein said straight segments of adjacent phases are disposed in said core slots at an equal pitch around the circumference of said stator core.

12. The stator according to claim 6 wherein the width of said straight segments, including any insulation, fit closely to the width of said core slots, including any insulation.

13. The stator according to claim 6 wherein said stator winding includes at least two layers of conductors.

14. The stator according to claim 13 wherein each of said phases of said at least two layers are formed from a single continuous conductor.

15. The stator according to claim 14 wherein said at least two layers are connected by a reversing end loop.

16. The stator according to claim 13 wherein the conductors of said at least two layers are aligned in one radial row in each slot.

17. The stator according to claim 13 wherein a portion of said end loop segments of said conductors of said at least two layers, lay radially outward by one wire width for the outermost layer.

18. The stator according to claim 6 wherein an interior surface of said stator core slots is substantially parallel to said central axis of said stator core.

19. The stator according to claim 18 wherein a one of said radial outward adjustment and said radial inward adjustment is adjacent a one of said first and second end of said stator core.

20. The stator according to claim 18 wherein a radially angled surface is formed in said interior surface of a predetermined number of said core slots.

21. The stator according to claim 20 wherein said radially angled surfaces are adjacent said first end on a number of consecutive core slots equal to the number of said plurality of phases and said radially angled surfaces of circumferentially adjacent core slots are adjacent said second axial end.

22. The stator according to claim 21 wherein a one of said radial outward adjustment and said radial inward adjustment is mated to said angled surface in said core slots.

23. A dynamoelectric machine, comprising:

a housing;

a shaft rotatably supported by said housing;

a rotor supported by and adapted to rotate with said shaft; and

a stator fixedly disposed in said housing adjacent said rotor, said stator comprising;

a generally cylindrically-shaped stator core having a plurality of circumferentially spaced axially-extending core slots in a surface thereof, said core slots extending between a first and a second end of said stator core; and

a stator winding including at least one layer of continuous conductors having a plurality of phases, each of said phases having a plurality of substantially straight segments disposed in said core slots, said straight segments alternately connected at said first and second ends of said stator core by a plurality of end loop segments, each of said straight segments of said at least one layer being in a same radial distance from a central axis of said stator core,

wherein each of said end loop segments includes a first sloped portion substantially co-radial with said at least one layer and a second sloped portion substantially non-co-radial with said at least one layer, said first and second sloped portions connected by an apex portion thereof, and

wherein a one of said first sloped portion, said second sloped portion, and said apex portion of each of said end loop segments includes a radial outward adjustment and another one of said first sloped portion, said second sloped portion, and said apex portion of each of said end loop segments includes a radial inward adjustment to form a cascaded winding pattern.