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公开(公告)号：US11356006B2
公开(公告)日：2022-06-07
申请号：US16774696
申请日：2020-01-28
发明人： Suresh Gopalakrishnan , Chandra S. Namuduri , Alexandru Rajala , Thomas W. Nehl , Xiaohui Du , Edward L. Kaiser
IPC分类号： H02K24/00 , H02K7/00 , B60L50/60 , B60L53/22 , H02K11/225
摘要： An electric machine includes a machine rotor circumscribed by a machine stator, and having a rotor shaft, rotor stack, and end cap which rotate about an axis. The end cap includes lobes equal in number to a number of pole pairs of the machine rotor. A position sensor assembly has a predetermined alignment with the machine rotor and stator. The sensor assembly includes a sensor rotor formed by the lobes and a sensor stator having a printed circuit board with conductive sine and cosine traces. Machine rotor rotation causes the sensor assembly to output an unmodulated sine and cosine signals to a controller, which then calculates a calibrated reference angle. A magnetic axis of an electrical phase of the machine is aligned with and bisects a peak of the sine trace. A direct axis of the machine rotor aligns with an edge of a lobe.
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公开(公告)号：US20210234447A1
公开(公告)日：2021-07-29
申请号：US16774696
申请日：2020-01-28
发明人： Suresh Gopalakrishnan , Chandra S. Namuduri , Alexandru Rajala , Thomas W. Nehl , Xiaohui Du , Edward L. Kaiser
IPC分类号： H02K24/00 , H02K7/00 , H02K11/225 , B60L50/60 , B60L53/22
摘要： An electric machine includes a machine rotor circumscribed by a machine stator, and having a rotor shaft, rotor stack, and end cap which rotate about an axis. The end cap includes lobes equal in number to a number of pole pairs of the machine rotor. A position sensor assembly has a predetermined alignment with the machine rotor and stator. The sensor assembly includes a sensor rotor formed by the lobes and a sensor stator having a printed circuit board with conductive sine and cosine traces. Machine rotor rotation causes the sensor assembly to output an unmodulated sine and cosine signals to a controller, which then calculates a calibrated reference angle. A magnetic axis of an electrical phase of the machine is aligned with and bisects a peak of the sine trace. A direct axis of the machine rotor aligns with an edge of a lobe.
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公开(公告)号：US11056943B2
公开(公告)日：2021-07-06
申请号：US16026430
申请日：2018-07-03
发明人： Khwaja M. Rahman , Xiaohui Du , Edward L. Kaiser
摘要： A stator assembly includes a plurality of stator slots having multiple respective slot layers and a plurality of hairpins. The plurality of hairpins have a respective first leg positioned in one of the multiple respective slot layers and a respective second leg positioned in another of the multiple respective slot layers. A first set of n adjacent slots of the plurality of stator slots is configured to accommodate the plurality of hairpins carrying a current in a first phase, n being an integer. The plurality of hairpins is configured in respective conductor layers (L1, L2 . . . ) having a plurality of respective turn locations defining n respective turn positions. The plurality of hairpins is configured to occupy the n respective turn positions an equal number of times such that the respective conductor layers (L1, L2 . . . ) are electrically balanced.
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公开(公告)号：US20180241277A1
公开(公告)日：2018-08-23
申请号：US15439025
申请日：2017-02-22
发明人： Xiaohui Du , Robert T. Dawsey , Edward L. Kaiser , Paul Buchholz
CPC分类号： H02K5/225 , H02K3/28 , H02K3/50 , H02K3/521 , H02K2203/09
摘要： 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.
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公开(公告)号：US10447108B2
公开(公告)日：2019-10-15
申请号：US15439025
申请日：2017-02-22
发明人： Xiaohui Du , Robert T. Dawsey , Edward L. Kaiser , Paul Buchholz
摘要： 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.
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公开(公告)号：US10141810B2
公开(公告)日：2018-11-27
申请号：US15056481
申请日：2016-02-29
发明人： Edward L. Kaiser , Paul Buchholz , Xiaohui Du
摘要： 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.
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公开(公告)号：US20170250588A1
公开(公告)日：2017-08-31
申请号：US15056481
申请日：2016-02-29
发明人： Edward L. Kaiser , Paul Buchholz , Xiaohui Du
CPC分类号： H02K5/225 , H02K1/16 , H02K3/12 , H02K3/50 , H02K2203/06 , H02K2203/09
摘要： 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.
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