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公开(公告)号：US12170460B2
公开(公告)日：2024-12-17
申请号：US17749380
申请日：2022-05-20
Applicant: BorgWarner Inc.
Abstract: A stator for an electric machine comprises a stator core and a winding positioned on the stator core. The stator core includes a plurality of teeth defining a plurality of slots. The winding is comprised of a plurality of segmented conductors connected together to provide a plurality of parallel paths per phase for the winding, each conductor comprising (i) an end loop provided on a crown end of the stator core, (ii) two legs extending through the slots, and (iii) two leg ends extending out of the slots on a connection end of the stator core, each leg end having a twist portion. The legs of the conductors are arranged in layers in the slots, wherein the layers include a total number of layers (L), L being greater than five and L/2 being an odd whole number. Each leg end extending from each of the layers has a common twist associated with the layer from which said leg extends. The common twist associated with at least half of the layers is a first twist, and the common twist associated with at least one of the layers is a second twist that is different from the first twist.
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公开(公告)号：US12149136B2
公开(公告)日：2024-11-19
申请号：US17716092
申请日：2022-04-08
Applicant: BorgWarner Inc.
Inventor： Gabriel Domingues , Joshua B. Lahrman , Matthew R. Conner , Kirk Neet , David A. Fulton
Abstract: A method and arrangement is disclosed herein for making a stator with 3D printed end turns. The stator includes a stator lamination stack with semi-closed slots. Straight I-pin wire segments are housed in the slots of the stator lam stack and form the in-slot segments of a stator winding arrangement. The end turns of the winding arrangement are provided by a conductive material that is 3D printed material at both axial ends of the straight I-pins. The end turns result in a winding arrangement with diamond coils that are inter-locked. The 3D printing of the end turns makes the winding arrangement possible, as the winding arrangement is configured such that it cannot be inserted into the lamination stack in a radial direction (i.e., via any slot openings at the inner diameter or outer diameter).
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公开(公告)号：US20240022131A1
公开(公告)日：2024-01-18
申请号：US18351926
申请日：2023-07-13
Applicant: BorgWarner Inc.
Inventor： Kirk Neet
IPC: H02K3/28
CPC classification number: H02K3/28
Abstract: An electric machine includes a stator core and a plurality of windings wound on the stator core. The plurality of windings include a first coil group arranged in a plurality of layers of the stator core and a second coil group arranged in the plurality of layers of the stator core. At least one connection conductor extends between the first coil group and the second coil group. The at least one connection conductor is provided in at least one extra-outer layer of the stator core.
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公开(公告)号：US20220393521A1
公开(公告)日：2022-12-08
申请号：US17749380
申请日：2022-05-20
Applicant: BorgWarner Inc.
Abstract: A stator for an electric machine comprises a stator core and a winding positioned on the stator core. The stator core includes a plurality of teeth defining a plurality of slots. The winding is comprised of a plurality of segmented conductors connected together to provide a plurality of parallel paths per phase for the winding, each conductor comprising (i) an end loop provided on a crown end of the stator core, (ii) two legs extending through the slots, and (iii) two leg ends extending out of the slots on a connection end of the stator core, each leg end having a twist portion. The legs of the conductors are arranged in layers in the slots, wherein the layers include a total number of layers (L), L being greater than five and L/2 being an odd whole number. Each leg end extending from each of the layers has a common twist associated with the layer from which said leg extends. The common twist associated with at least half of the layers is a first twist, and the common twist associated with at least one of the layers is a second twist that is different from the first twist.
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公开(公告)号：US20220376575A1
公开(公告)日：2022-11-24
申请号：US17749369
申请日：2022-05-20
Applicant: BorgWarner Inc.
Inventor： Kirk Neet , Tim Sailors
Abstract: A winding for a stator comprises (i) a plurality of first end turns provided on a first end of the stator core, (ii) straight portions extending through the slots, and (iii) a plurality of second turns provided on a second end of the stator core. The straight portions are arranged in layers in the slots in a number of layers. Each of the second end turns connects straight portions in two consecutive layers of two slots and is defined by a first common twist associated with one of the two consecutive layers and a second common twist associated with another of the two consecutive layers. The first common twist and the second common twist are identical for the second end turns in a first half of consecutive layers, and the first common twist and the second common twist are different for the second end turns in a second half of consecutive layers.
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Patent Agency Ranking
公开(公告)号：US11456652B2
公开(公告)日：2022-09-27
申请号：US17193072
申请日：2021-03-05
Applicant: BorgWarner Inc.
Inventor： James Murphy , Kirk Neet
Abstract: A wire forming apparatus comprises a first rack moveable relative to a second rack in a first direction, a plurality of first forming structures provided on the first rack, and a plurality of second forming structures provided on the second rack. Each of the plurality of first forming structures is configured to move in the first direction, is separated from an adjacent first forming structure, and is configured to move in a second direction closer to the adjacent first forming structure when the first rack moves relative to the second rack. Each of the plurality of second forming structures is configured to move in the first direction, is separated from an adjacent second forming structure, and is configured to move in the second direction closer to the adjacent second forming structure when the first rack moves relative to the second rack. The second direction is different from the first direction.
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公开(公告)号：US11316415B2
公开(公告)日：2022-04-26
申请号：US16537052
申请日：2019-08-09
Applicant: BorgWarner Inc.
Inventor： Kirk Neet
IPC: H02K15/085 , H02K15/00 , H02K15/04
Abstract: A method of installing a winding in a stator includes forming a first multi-conductor winding including a first plurality of terminal leads and a second plurality of terminal leads, forming a second multi-conductor winding including a third plurality of terminal leads and a fourth plurality of terminal leads, introducing the first multi-conductor winding into a plurality of stator slots of a stator body, introducing the second multi-conductor winding into the plurality of stator slots of the stator body radially inwardly of the first multi-conductor winding, and connecting the second plurality of terminal leads with the third plurality of terminal leads to form a twelve conductor stator winding.
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公开(公告)号：US20210305863A1
公开(公告)日：2021-09-30
申请号：US17345744
申请日：2021-06-11
Applicant: BorgWarner Inc.
Inventor： Kirk Neet
Abstract: A stator includes a cylindrical core with a plurality of longitudinally extending slots, a first winding set formed as a first cascaded wire in two radial layers of the slots, a second winding set formed as a second cascaded wire in two other radial layers of the slots, and a jumper connecting the first and second wires. A first winding set may have three cascaded phase wires in first and second layers of the slots, and a second winding set may have three cascaded phase wires in third and fourth layers of the slots. A winding set of a first phase may have a first cascaded wire in two radial layers of a first one of the slots, and a winding set of a second phase may have a second cascaded wire in two other radial layers of the first one of the slots.
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公开(公告)号：US11081943B2
公开(公告)日：2021-08-03
申请号：US16265108
申请日：2019-02-01
Applicant: BorgWarner Inc.
Inventor： Kirk Neet , Stephen Humphrey
Abstract: A method of forming a stator for an electric machine includes forming a first conductor and a second conductor into a plurality of bends having a first winding pitch, creating a winding layer by introducing the first conductor and the second conductor into a first pole of a stator with the second conductor being on top of the first conductor at a first end loop crossing zone. The winding pitch of the first conductor is changed to a second winding pitch and the winding pitch of the second conductor is changed to a third winding pitch. The first conductor is woven relative to the second conductor between the first pole and a second pole. The first conductor and the second conductor are introduced into the second pole of the stator with the first conductor being on top of the second conductor at a second end loop crossing zone.
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公开(公告)号：US20200244126A1
公开(公告)日：2020-07-30
申请号：US16258270
申请日：2019-01-25
Applicant: BorgWarner Inc.
Inventor： Kirk Neet , Tausif Husain
Abstract: An electric machine a stator having a stator core and windings positioned thereon. The stator core has a plurality of slots formed therein and a winding positioned in the plurality of slots. The winding includes at least four parallel paths distributed in slot sets of the stator core. Each slot set includes at least four contiguous slots including two left slots and two right slots. A first parallel path and a second parallel path are arranged in the two left slots for at least a first revolution of the winding around the core. The first parallel path and the second parallel path are arranged in the two right slots for at least a subsequent revolution of the winding around the core.
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