Automotive alternator stator assembly with rectangular continuous wire
First Claim
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1. A stator core assembly for an alternator of the type having a rotor assembly which presents a rotating, alternating polarity magnetic field, the stator core assembly of the type 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) at least two electrical conductors designated as conductor A and conductor B, 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 pair of the conductors A and B define one layer, by the following winding steps;
c) a first lead of conductor A placed into the slot number 1 with the conductor A first lead extending from the stator lead side end, d) a first lead of the conductor B placed into slot number n+1 with the conductor B first lead extending from the stator lead side end, e) the conductor A placed into the slot number n+1 thereby forming an end loop on the non-lead side end and lying in the slot number n+1 radially shifted inwardly from the conductor B, wherein the pair of the conductors A and B lying in the same slot define a layer L, f) the conductor A placed into the slot number 2n+1 thereby forming an end loop on the lead side, g) the conductor B shifted into the slot number 2n+1 thereby forming an end loop on the non-lead side and lying in the slot number 2n+1 radially shifted inwardly from the conductor A, h) the conductors A and B positioned as provided in the preceding c) through g) for all the slots numbered through m+1−
n, thereby forming a first layer L, and i) the conductor A extending from the slot number m+1−
n on the lead side end thereby defining a conductor A second lead, and the conductor B extending from the slot number 1 thereby defining a conductor B second lead.
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Abstract
A stator assembly for an electric machine, for example, for an automotive alternator. The stator assembly 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.
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Citations
21 Claims
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1. A stator core assembly for an alternator of the type having a rotor assembly which presents a rotating, alternating polarity magnetic field, the stator core assembly of the type 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:
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a) at least two electrical conductors designated as conductor A and conductor B, 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 pair of the conductors A and B define one layer, by the following winding steps;
c) a first lead of conductor A placed into the slot number 1 with the conductor A first lead extending from the stator lead side end, d) a first lead of the conductor B placed into slot number n+1 with the conductor B first lead extending from the stator lead side end, e) the conductor A placed into the slot number n+1 thereby forming an end loop on the non-lead side end and lying in the slot number n+1 radially shifted inwardly from the conductor B, wherein the pair of the conductors A and B lying in the same slot define a layer L, f) the conductor A placed into the slot number 2n+1 thereby forming an end loop on the lead side, g) the conductor B shifted into the slot number 2n+1 thereby forming an end loop on the non-lead side and lying in the slot number 2n+1 radially shifted inwardly from the conductor A, h) the conductors A and B positioned as provided in the preceding c) through g) for all the slots numbered through m+1−
n, thereby forming a first layer L, andi) the conductor A extending from the slot number m+1−
n on the lead side end thereby defining a conductor A second lead, and the conductor B extending from the slot number 1 thereby defining a conductor B second lead. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of forming a stator core assembly for an alternator of the type having a rotor assembly which presents a rotating, alternating polarity magnetic field, the stator core assembly of the type 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 method comprising the steps of:
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a) providing at least two electrical conductors designated as conductor A and conductor B, b) winding the conductors 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 pair of the conductors A and B define one layer, by the following winding steps;
c) the winding including placing a first lead of conductor A into the slot number 1 with the conductor A first lead extending from the stator lead side end, d) the winding including placing a first lead of the conductor B into slot number n+1 with the conductor B first lead extending from the stator lead side end, e) the winding including shifting the conductor A to the slot number n+1 thereby forming an end loop on the non-lead side end and lying in the slot number n+1 radially shifted inwardly from the conductor B, wherein the pair of the conductors A and B lying in the same slot define a layer L, f) the winding including shifting the conductor A to the slot number 2n+1 thereby forming an end loop on the lead side, g) the winding including shifting the conductor B to the slot number 2n+1 thereby forming an end loop on the non-lead side and lying in the slot number 2n+1 radially shifted inwardly from the conductor A, h) repeating winding steps c) through g) for all the slots numbered through m+1−
n, thereby forming a first layer L,i) repeating steps a) through d) for additional layers L, and j) completing the winding by having the conductor A extending from the slot number m+1−
n on the lead side end thereby defining a conductor A second lead, and having the conductor B extending from the slot number 1 thereby defining a conductor B second lead. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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Specification
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Current AssigneeVisteon Global Technologies Incorporated (Visteon Corporation)
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Original AssigneeVisteon Global Technologies Incorporated (Visteon Corporation)
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InventorsNeet, Kirk E.
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Granted Patent
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Time in Patent OfficeDays
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Field of Search
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US Class Current310/180
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