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    Stator tooth and winding conductor designs for electric machines
    1.
    发明授权
    Stator tooth and winding conductor designs for electric machines 有权

    公开(公告)号：US11942822B2

    公开(公告)日：2024-03-26

    申请号：US17560404

    申请日：2021-12-23

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： Mohammad F. Momen ,  Edward L. Kaiser

    IPC: H02K1/16 ,  B60K1/00 ,  H02K1/276 ,  H02K7/00 ,  H02K21/14

    CPC classification number: H02K1/165 ,  B60K1/00 ,  H02K1/276 ,  H02K7/006 ,  H02K21/14 ,  H02K2201/03

    Abstract: Presented are electric machines with optimized stator tooth geometries and multi-gauge stator conductors, methods for making/using such electric machines, and motor vehicles equipped with such electric machines. An electric machine includes a housing, a rotor assembly rotatably attached to the housing, and a stator assembly coaxial with and separated by an airgap from the rotor assembly. The rotor assembly includes one or more magnets mounted to a rotor core. The stator assembly includes a stator core with multiple axially elongated, circumferentially spaced stator slots, multiple radially aligned stator teeth interleaved between and separating the slots, and multiple electromagnetic windings wound through the slots. Each stator tooth has an elongated tooth body with a tooth head at a radial end of a tooth root, which attaches to a cylindrical hub of the stator core. The tooth head has an axial cross-section with a trapezoidal crown integral with a rectangular tip.

    Electric device and a stator assembly for the electric device
    2.
    发明授权
    Electric device and a stator assembly for the electric device 有权

    公开(公告)号：US10340761B2

    公开(公告)日：2019-07-02

    申请号：US14669879

    申请日：2015-03-26

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： Paul F. Turnbull ,  Edward L. Kaiser ,  Matthew D. Laba ,  Khwaja M. Rahman ,  Rolf Blissenbach

    IPC: H02K3/28 ,  H02K3/50

    Abstract: An electric device and a stator assembly for the electric device includes a stator core defining a plurality of slots spaced from each other. The stator assembly includes a plurality of bar conductors disposed in each of the slots and arranged to present a first winding path, a second winding path and a third winding path. A first set of the bar conductors of the first, second and third winding paths are configured to receive current in a parallel circuit arrangement. The stator assembly also includes a plurality of electrical jumpers electrically connected to a predetermined number of the bar conductors such that an amount of current flowing through the first winding path and the third winding path is substantially the same and an amount of current flowing through the second winding path is different from the amount of current flowing through the first and third winding paths.

    DISTRIBUTED CONNECTION RING ASSEMBLY FOR STATOR ASSEMBLY
    3.
    发明申请
    DISTRIBUTED CONNECTION RING ASSEMBLY FOR STATOR ASSEMBLY 审中-公开

    公开(公告)号：US20180241277A1

    公开(公告)日：2018-08-23

    申请号：US15439025

    申请日：2017-02-22

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： Xiaohui Du ,  Robert T. Dawsey ,  Edward L. Kaiser ,  Paul Buchholz

    IPC: H02K5/22 ,  H02K3/52 ,  H02K3/28

    CPC classification number: H02K5/225 ,  H02K3/28 ,  H02K3/50 ,  H02K3/521 ,  H02K2203/09

    Abstract: A distributed connection ring assembly can be used in a stator assembly and can integrate a neutral connector and jumping winding connections in an overmolded assembly for insulation. The stator assembly including a stator core defining a plurality of slots spaced apart from each other, a plurality of bar conductors disposed in each of the slots, and a distributed connection ring assembly secured to the jumping winding connections. The distributed connection ring assembly includes an overmolded neutral connector. The distributed connection ring assembly also includes a plurality of overmolded couplers circumferentially spaced apart from one another. The overmolded couplers are coupled to the overmolded neutral connector. Each of the plurality of overmolded couplers includes a support body and a plurality of stator conductors partially disposed inside the support body. The stator conductors are electrically connected to the jumping winding connections.

    Stator assembly with winding sets having hairpins from multiple hairpin layers
    4.
    发明授权
    Stator assembly with winding sets having hairpins from multiple hairpin layers 有权
    具有绕组的定子组件具有来自多个发夹层的发夹

    公开(公告)号：US09520753B2

    公开(公告)日：2016-12-13

    申请号：US13949294

    申请日：2013-07-24

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： Khwaja M. Rahman ,  Edward L. Kaiser ,  Sinisa Jurkovic ,  Peter J. Savagian

    IPC: H02K3/28 ,  H02K3/04

    CPC classification number: H02K3/28 ,  H02K3/04

    Abstract: A stator assembly includes a plurality of stator slots defining multiple slot layers. The assembly includes a plurality of hairpins each having a respective first leg positioned in one of the multiple slot layers and a respective second leg positioned in another of the multiple slot layers. Each hairpin is configured to allow a current to flow from the respective first leg to the respective second leg. The plurality of hairpins is divided into multiple hairpin layers. The hairpins form multiple winding sets, such as first, second, third and fourth winding sets. Each of the winding sets at least partially includes the hairpins from at least two of the multiple hairpin layers. The multiple slot layers may include six slot layers. The multiple hairpin layers may include six hairpin layers. Thus, at least one of the hairpin layers may be “shared” by two winding sets.

    Abstract translation: 定子组件包括限定多个槽层的多个定子槽。 组件包括多个发夹，每个发夹具有定位在多个槽层中的一个中的相应的第一腿部和位于多个狭缝层中的另一个中的相应的第二腿部。 每个发夹构造成允许电流从相应的第一支腿流到相应的第二支腿。 多个发夹被分成多个发夹层。 发夹形成多个绕组，例如第一，第二，第三和第四绕组。 每个绕组至少部分地包括来自多个发夹层中的至少两个的发夹。 多个时隙层可以包括六个时隙层。 多个发夹层可以包括六个发夹层。 因此，发夹层中的至少一个可以由两个绕组组“共享”。

    Hairpin conductor for an electric motor stator and method of forming the hairpin conductor
    5.
    发明授权
    Hairpin conductor for an electric motor stator and method of forming the hairpin conductor 有权

    公开(公告)号：US12136856B2

    公开(公告)日：2024-11-05

    申请号：US17858214

    申请日：2022-07-06

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： John D. Campbell ,  Edward L. Kaiser ,  Elizabeth Pepper ,  Caroline Bolt

    IPC: H02K15/06 ,  H02K1/16 ,  H02K3/28 ,  H02K15/085

    Abstract: A hairpin conductor includes two wire segments each having respective first and second ends and a respective middle region. The segments are disposed in a side-by-side orientation such that their first ends are proximate each other and their second ends are proximate each other. The first ends are welded to each other and the second ends are welded to each other, or the middle regions are welded to each other, thereby providing a welded wire assembly, which is bent such that the two wire segments are bent equally to form the hairpin conductor. The hairpin conductor has a primary bend in the middle regions to form an apex thereat and first and second secondary bends in the two wire segments nearer to the apex than to the first and second ends to form respective first and second shoulders thereat. A method of forming the hairpin conductor is also presented.

    Connection support assembly for stator assembly
    7.
    发明授权
    Connection support assembly for stator assembly 有权

    公开(公告)号：US10141810B2

    公开(公告)日：2018-11-27

    申请号：US15056481

    申请日：2016-02-29

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： Edward L. Kaiser ,  Paul Buchholz ,  Xiaohui Du

    IPC: H02K1/16 ,  H02K3/12 ,  H02K3/50 ,  H02K5/22

    Abstract: A connection support assembly for a stator assembly can be used to secure electrical jumper wires of an electric machine. The connection support assembly includes a support body and a catch protruding from the support body. The catch defines an opening. The connection support assembly further includes a clip coupled to the support body. The clip includes a clip body and a pin protruding from the clip body. The pin extends through the opening of the catch in order to couple the clip to the support body and clamp at least some electrical jumper wires between the support body and the clip.

    ELECTRIC DEVICE AND A STATOR ASSEMBLY FOR THE ELECTRIC DEVICE
    10.
    发明申请
    ELECTRIC DEVICE AND A STATOR ASSEMBLY FOR THE ELECTRIC DEVICE 审中-公开
    电气设备和电气设备的定子组件

    公开(公告)号：US20160285334A1

    公开(公告)日：2016-09-29

    申请号：US14669879

    申请日：2015-03-26

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： Paul F. Turnbull ,  Edward L. Kaiser ,  Matthew D. Laba ,  Khwaja M. Rahman ,  Rolf Blissenbach

    IPC: H02K3/28 ,  H02K3/12

    CPC classification number: H02K3/28 ,  H02K3/50

    Abstract: An electric device and a stator assembly for the electric device includes a stator core defining a plurality of slots spaced from each other. The stator assembly includes a plurality of bar conductors disposed in each of the slots and arranged to present a first winding path, a second winding path and a third winding path. A first set of the bar conductors of the first, second and third winding paths are configured to receive current in a parallel circuit arrangement. The stator assembly also includes a plurality of electrical jumpers electrically connected to a predetermined number of the bar conductors such that an amount of current flowing through the first winding path and the third winding path is substantially the same and an amount of current flowing through the second winding path is different from the amount of current flowing through the first and third winding paths.

    Abstract translation: 电气装置的电气装置和定子组件包括限定彼此间隔开的多个狭槽的定子芯。 定子组件包括设置在每个狭槽中的多个条形导体，并布置成呈现第一绕组路径，第二绕组路径和第三绕组路径。 第一，第二和第三绕组路径的第一组条形导体被配置为以并联电路布置接收电流。 定子组件还包括电连接到预定数量的条形导体的多个电跳线，使得流过第一绕组路径和第三绕组路径的电流量基本相同，并且流过第二绕组路径的电流量 绕组路径不同于流过第一和第三绕组路径的电流量。

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