Motor stator having transposed winding layers

• US 7,365,468 B2
• Filed: 07/20/2004
• Issued: 04/29/2008
• Est. Priority Date: 07/20/2004
• Status: Active Grant

• Current Assignee: BluWav Systems LLC (Magna International Incorporated)
• Original Assignee: BluWav Systems LLC (Magna International Incorporated)
• Inventors: Rahman, Ziaur
• Primary Examiner(s): MULLINS, BURTON S
• Application Number:
  US10/893,876
• Publication Number:
  US 20060017347A1
• Time in Patent Office: 1,379 Days
• Field of Search: 310/180, 310184-185, 310/194, 310/198, 310202-203, 310/188, 310/208, 336187-188, 242432-433, 296/05
• US Class Current: 310/184
• CPC Class Codes: H02K 3/18 Windings for salient poles
• 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 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

An electric motor is provided with a multi-layered winding stator core configuration. A plurality of individual layers of wire strands are successively formed on each stator pole of a pole pair. Each winding layer is fabricated of the same relatively thin wire gauge. A first layer is applied directly on a pole and each successive layer is assembled on top of the last previous layer. Each layer of one pole of the pole pair is connected in series with a layer of the other pole of the pole pair to obtain a number of individual series coil connections equal in number to the number of layers. As inductance and resistance characteristics of the layers differ from each other as the layers increase in distance from each pole, layers from one pole of the pole pair are connected to respective layers different in order from that of the other pole pair.

Claims

1. A method of winding a stator core of an electric machine having at least one pole pair, the method comprising the steps of:

winding in successive order a predetermined number of individual layers of coiled wire strands on each pole of the pole pair so that each successive layer overlays a preceding layer radially from the respective pole; and

connecting in series each of said layers of a first pole of the pole pair with a layer of a second pole of the pole pair to obtain individual series coil connections on the pole pair equal in number to said number of layers, the connections inversely connecting an order of the first pole layers to an order of the second pole layers.

2. The method as recited in claim 1, wherein the stator comprises a plurality of pole pair segments that are separated and ferromagnetically isolated from each other, and said steps of winding and connecting are applied to each of the plurality of pole pair segments.

3. The method as recited in claim 1, wherein:

said winding step comprises assembling a first layer directly on a pole and assembling each successive layer on top of a last previous layer, and said connecting step comprises joining a layer formed on the first pole to a layer formed on the second pole to obtain a transposition of layer connections.

4. The method as recited in claim 3, comprising the additional step of connecting all of the series connections of the pole pair in parallel.

5. A machine stator comprising:

a plurality of pole pairs, each pair having a plurality of coil layers wound on each pole of a core, said layers successively overlaying each other in position about the pole, the layers of a first said pole connected to layers of a second said pole in inverse order to the position of the respective layers about the poles,

wherein each core has a pair of poles, and

wherein each of the plurality of pole pairs comprises a ferromagnetic core segment that is ferromagnetically isolated from each of the other pole pairs.

6. A machine stator comprising:

a core having a pair of poles;

a plurality of coil layers wound on each pole of said core, said layers successively overlaying each other in position about the pole, the layers of a first said pole connected to layers of a second said pole in inverse order to the position of the respective layers about the poles.

7. The machine stator as recited in claim 6, wherein the number of layers on each pole is the same and the connected layers form individual series circuits equal in number to the number of layers.

8. The machine stator as recited in claim 7, wherein each of the plurality of coil layers of both poles comprises the same number of coil turns.

9. The machine stator as recited in claim 7, wherein each of the series circuits comprises a layer from each pole and the series circuits are connected in parallel.

10. A machine stator comprising a plurality of pole pairs, each pair having a plurality of coil layers configured and connected as recited in claim 6.

11. The machine stator as recited in claim 10, wherein each of the plurality of pole pairs comprises a ferromagnetic core segment that is ferromagnetically isolated from each of the other pole pairs.

12. The machine stator as recited in claim 6, wherein each layer for a pole pair is connected to the same electric phase.

13. The machine stator as recited in claim 6, wherein each successive layer overlays an outside perimeter of a preceding layer.

14. A method of winding a stator core of an electric machine having at least one pole pair, the method comprising the steps of:

winding in successive order a predetermined number of individual layers of coiled wire strands on each pole of the pole pair segment so that each successive layer overlays the preceding layer; and

connecting in series each of said layers of a first pole of the pole pair with a layer of a second pole of the pole pair to obtain individual series coil connections on the pole pair equal in number to said number of layers in inverse order to the position of the respective layers about the poles, wherein the machine stator comprises a plurality of pole pair segments that are separated and ferromagnetically isolated from each other, and said steps of winding and connecting are applied to each of the plurality of pole pair segments.

15. A machine stator comprising:

a plurality of pole pairs, each pair having a plurality of coil layers wound on each pole of a core, said layers successively overlaying each other in position about the pole, the layers of a first said pole connected to layers of a second said pole in inverse order to the position of the respective layers about the poles,

wherein each core has a pair of poles, and

wherein each of the plurality of pole pairs comprises a ferromagnetic core segment that is ferromagnetically isolated from each of the other pole pairs.