Method of forming cascaded stator winding
First Claim
Patent Images
1. A method of forming a cascaded stator winding comprising:
- providing a stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof;
forming a plurality of A conductors;
forming a plurality of B conductors;
arranging the plurality of A and B conductors into a wire pack;
rolling the wire pack into a cylindrical shape having an outer dimension which allows it to be placed within the stator core;
placing the wire pack within the stator core; and
expanding the wire pack radially outward such that the slot segments of the wire pack are inserted within the core slots of the stator core.
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Abstract
A method of forming a stator for an electric machine having a cascaded winding includes the steps of: providing a stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, forming a plurality of A conductors and a plurality of B conductors, arranging the A and B conductors into a wire pack, rolling the wire pack into a cylindrical shape and inserting the wire pack within the stator core, and expanding the wire pack radially outward such that the wire pack is inserted within the slots of the stator core.
82 Citations
20 Claims
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1. A method of forming a cascaded stator winding comprising:
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providing a stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof;
forming a plurality of A conductors;
forming a plurality of B conductors;
arranging the plurality of A and B conductors into a wire pack;
rolling the wire pack into a cylindrical shape having an outer dimension which allows it to be placed within the stator core;
placing the wire pack within the stator core; and
expanding the wire pack radially outward such that the slot segments of the wire pack are inserted within the core slots of the stator core. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A method of forming a cascaded stator winding comprising:
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providing a stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, and having a circumferential width of the core slots at the inner diameter of the stator core;
providing a plurality of conductors having a circumferential width narrower than the circumferential width of the core slots just prior to insertion;
forming a plurality of six A conductors such that each A conductor includes a plurality layers having a plurality of slot segments alternately connected at first and second ends by a plurality of end loop segments, wherein at least half of the end loop segments each include a first sloped portion and a second sloped portion that meet at an apex portion, wherein the slot segments of each layer are radially aligned with one another, the first sloped portion of the end loop segment is radially aligned with the slot segments, and the second sloped portion of the end loop segment is radially offset from the slot segments and the first sloped portion. forming a plurality of six B conductors such that each B conductor includes a plurality of layers having a plurality of slot segments alternately connected at first and second ends by a plurality of end loop segments, wherein at least half of the end loop segments each include a first sloped portion and a second sloped portion that meet at an apex portion, wherein the slot segments of each layer are radially aligned with one another, the second sloped portion of the end loop segment is radially aligned with the slot segments, and the first sloped portion of the end loop segment is radially offset from the slot segments and the second sloped portion. sequentially loading a plurality of A conductors into the magazine with each subsequent A conductor shifted one pitch in a first direction of the previous A conductor and having at least half of the slot segments disposed in the outer portion of the magazine;
sequentially loading a plurality of B conductors into the magazine, with each subsequent B conductor shifted one pitch in a second direction of the previous B conductor, wherein the second direction is opposite of the first direction and having at least half of the slot segments disposed in the inner portion of the magazine;
rolling the wire pack into a cylindrical shape having a plurality of radial aligned layers and having an outer dimension which allows it to be placed within the stator core;
placing the wire pack within the stator core;
expanding the wire pack radially outward such that the slot segments of the wire pack are inserted within the core slots of the stator core;
bonding the conductors to themselves and to the slot liners;
connecting the leads of the A conductors of a particular phase and B conductors of the same particular phase, for each phase, thereby forming neutral ends and positive ends for each phase and a winding having a plurality of electrical turns;
- View Dependent Claims (19, 20)
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Specification