Modular transverse flux electrical machine assembly

• US 9,559,558 B2
• Filed: 09/20/2013
• Issued: 01/31/2017
• Est. Priority Date: 09/24/2012
• Status: Active Grant

• Current Assignee: Eocycle Technologies Inc.
• Original Assignee: Eocycle Technologies Inc.
• Inventors: Nadeau, Raphael, Massicotte, Daniel, Adams, Eric, Cote, Simon, Fortin, Patrice, Bernier-Synnott, Jean-Francois
• Primary Examiner(s): Andrews, Michael
• Application Number:
  US14/033,035
• Publication Number:
  US 20140084737A1
• Time in Patent Office: 1,229 Days
• Field of Search: 310/198, 310/254.1, 310/257, 310/112, 310/126, 310/164
• US Class Current: 1/1
• CPC Class Codes: H02K 1/145 having an annular coil, e.g. of the claw-pole type
• CPC Class Codes: H02K 1/185 to outer stators
• CPC Class Codes: H02K 15/02 of stator or rotor bodies
• CPC Class Codes: H02K 15/022 with salient poles or claw-shaped poles
• CPC Class Codes: H02K 15/066 inserted perpendicularly to the axis of the slots or inter-polar channels
• CPC Class Codes: H02K 15/12 Impregnating, heating or drying of windings, stators, rotors or machines
• CPC Class Codes: H02K 21/145 having an annular armature coil with homopolar co-operation H02K21/20
• CPC Class Codes: H02K 2213/12 Machines characterised by the modularity of some components
• 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: H02K 7/1838 Generators mounted in a nacelle or similar structure of a horizontal axis wind turbine
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/53143 Motor or generator

Abstract

A modular stator portion adapted to be used in a transverse flux electrical machine (TFEM) includes a plurality of phase modules adapted to be axially secured together with a plurality of securing members. The phase modules of at least en embodiment thereof are substantially identical and interchangeable. Each pair of axially adjacent phase modules are adapted to be angularly located in respect with each other to set a phase shift. A phase module and a kit of phase modules sized and designed to assemble a modular stator are also encompassed by the present application.

Claims

1. A rotatable transverse flux electrical machine (TFEM) comprising:

a modular stator including a plurality of axially assembled phase modules, each phase module comprising

a pair of opposed halves including a plurality of core-receiving spaces radially extending through the halves toward an axial center of the halves, each halve including a half portion of a core-receiving space, the half portion of a core-receiving space in a first halve being angularly offset with corresponding half portion of the core-receiving space in a second halve when both opposed halves are assembled together;

a plurality of cores secured between the pair of opposed halves inside respective phase modules, each of the cores being U-shaped with a pair of legs thereof, the pair of legs being angularly offset in the pair of opposed halves;

a coil operatively disposed between the pair of legs of the cores inside each phase modules, wherein the pairs of legs of the cores are radially and proximally extending through the pair of opposed halves; and

resin securing the plurality of cores and the coil between the pair of halves,

and, the TFEM further comprising

a rotor rotatably axially located in relation with the modular stator portion.

2. The rotatable transverse flux electrical machine (TFEM) of claim 1, wherein the plurality of phase modules is substantially identical.

3. The rotatable transverse flux electrical machine (TFEM) of claim 1, further comprising a cooperating positioning mechanism adapted to angularly locate adjacent phase modules axially assembled together.

4. The rotatable transverse flux electrical machine (TFEM) of claim 1, wherein the plurality of phase modules is two phase modules axially assembled together with an intervening phase shift generally set at 90°

[electrical] between adjacent phase modules to provide a two-phase symmetrical electric current overlapping over a complete 360°

electrical cycle.

5. The rotatable transverse flux electrical machine (TFEM) of claim 1, wherein the plurality of phase modules is three phase modules axially assembled together with an intervening phase shift generally set about 120°

[electrical] between adjacent phase modules to provide a three-phase symmetrical electric current overlapping over a complete 360°

electrical cycle.

6. The rotatable transverse flux electrical machine (TFEM) of claim 1, wherein the plurality of phase modules is axially secured together by opposed support portions.

7. The rotatable transverse flux electrical machine (TFEM) of claim 1, wherein the phase modules are axially secured together with a plurality of axially securing members.

8. A modular stator adapted to be used in a rotatable transverse flux electrical machine (TFEM), the modular stator comprising:

a plurality of axially assembled self-containing phase modules, each phase module comprising

a pair of opposed halves including a plurality of core-receiving spaces radially extending through the halves toward an axial center of the halves, each halve including a half portion of a core-receiving space, the half portion of a core-receiving space in a first halve being angularly offset with corresponding half portion of the core-receiving space in a second halve when both opposed halves are assembled together;

a plurality of cores secured between the pair of opposed halves inside respective phase modules, each of the cores being U-shaped with a pair of legs thereof, the pair of legs being angularly offset in the pair of opposed halves;

a coil operatively disposed between the pair of legs of the cores inside each phase modules, wherein the pairs of legs of the cores are radially and proximally extending through the pair of opposed halves; and

resin securing the plurality of cores and the coil between the pair of halves and wherein the modular stator is configured to operatively receive therein a rotor axially located in relation with the modular stator portion.

9. The modular stator of claim 8, wherein the plurality of phase modules is substantially identical.

10. The modular stator of claim 8, further comprising a cooperating positioning mechanism adapted to angularly locate adjacent phase modules axially assembled together.

11. The modular stator of claim 8, wherein the plurality of phase modules is two phase modules axially assembled together with an intervening phase shift generally set at 90°

[electrical] between adjacent phase modules to provide a two-phase symmetrical electric current overlapping over a complete 360°

electrical cycle.

12. The modular stator of claim 8, wherein the plurality of phase modules is three phase modules axially assembled together with an intervening phase shift generally set about 120°

[electrical] between adjacent phase modules to provide a three-phase symmetrical electric current overlapping over a complete 360°

electrical cycle.

13. The modular stator of claim 8, wherein the plurality of phase modules is axially secured together by opposed support portions.

14. The modular stator of claim 8, wherein the phase modules are axially secured together with a plurality of axially securing members.

15. A kit for assembling a modular stator in a rotatable transverse flux electrical machine (TFEM), the kit comprising:

a plurality of phase modules sized and designed to be axially assembled together, each phase module comprising

a pair of opposed halves including a plurality of core receiving-spaces radially extending through the halves toward an axial center of the halves, each halve including a half portion of a core-receiving space, the half portion of a core-receiving space in a first halve being angularly offset with corresponding half portion of the core-receiving space in a second halve when both opposed halves are assembled together;

a plurality of cores operatively disposed between the pair of opposed halves inside each phase module, each of the cores being U-shaped with a pair of legs thereof, the pair of legs being angularly offset in the pair of opposed halves;

a coil operatively disposed between the pair of legs of the cores inside each phase modules, wherein the pairs of legs of the cores are radially and proximally extending through the pair of opposed halves; and

resin securing the plurality of cores and the coil between the pair of halves,

the plurality of phase modules, once assembled, being adapted to receive therein a rotor rotatably and axially located in respect with the assembled phase modules.

16. The kit of claim 15, wherein the plurality of phase modules is substantially identical.

17. The kit of claim 15, further comprising a cooperating positioning mechanism adapted to angularly locate adjacent phase modules axially assembled together.

18. The kit of claim 15, wherein, when the plurality of phase modules is two phase modules, the two phase modules are adapted to be axially assembled together with an intervening phase shift generally set at 90°

[electrical] between adjacent phase modules to provide a two-phase symmetrical electric current overlapping over a complete 360°

electrical cycle, and, when the plurality of phase modules is three phase modules, the three phase modules are adapted to be axially assembled together with an intervening phase shift generally set about 120°

[electrical] between adjacent phase modules to provide a three-phase symmetrical electric current overlapping over a complete 360°

electrical cycle.

19. The kit of claim 15, wherein the plurality of phase modules is axially secured together by opposed support portions.

20. The kit of claim 15, wherein the phase modules are axially secured together with a plurality of axially securing members.