Abstract: An electric machine includes a stator having a stator core, rotor core and/or magnetic core comprising a plurality of slots. Each of the plurality of slots includes a spacer, a conductor, and encapsulated slot insulation. The spacer is configured to suspend the conductor away from the stator core by a dielectric distance without occupying all of the space between the conductor and the stator core. The encapsulated slot insulation includes an encapsulation material configured to flow in a liquid state around the perimeter of the conductor filling in the space between the conductor and the stator core. The encapsulation material cures to hold the spacer and the conductor in place. The encapsulated material typically has higher thermal conductivity properties than a conventional slot liner, increasing the performance of the motor.

Abstract: An electric machine includes a stator having a stator core, rotor core and/or magnetic core comprising a plurality of slots. Each of the plurality of slots includes a spacer, a conductor, and encapsulated slot insulation. The spacer is configured to suspend the conductor away from the stator core by a dielectric distance without occupying all of the space between the conductor and the stator core. The encapsulated slot insulation includes an encapsulation material configured to flow in a liquid state around the perimeter of the conductor filling in the space between the conductor and the stator core. The encapsulation material cures to hold the spacer and the conductor in place. The encapsulated material typically has higher thermal conductivity properties than a conventional slot liner, increasing the performance of the motor.

Abstract: The present disclosure provides a brushless permanent magnet machine which includes an essentially circular shaped rotor, and a pair of magnets arranged in the rotor. The magnets are each U-shaped and have a thickness direction extending along a contour of the corresponding magnet between the opposite poles of the corresponding magnet, respectively. The magnets are each composed of a non-rare earth material having a lower coercivity than a rare earth material. A direction of magnetization of each of the pair of magnets is parallel to the thickness direction of the corresponding magnet. The present disclosure also provides a method of manufacturing such a brushless permanent magnet machine.

Abstract: A rotor for a permanent magnet electric motor includes a rotor core having a generally cylindrical shape with an outer circumferential surface and a rotational axis and a plurality of magnet insertion hole arrangements formed in the rotor core and arranged circumferentially at a preset angular interval about the rotational axis. Each hole arrangement has a radially inward side, a radially outward side, and two ends that are respectively spaced apart from the circumferential surface by respective bridge regions formed by the rotor core. The material of the bridge regions is metallurgically transformed by having its grain structure changed, e.g., by heating the material to at least its Curie temperature, whereby the material possesses greater magnetic reluctance than the material of adjacent portions of the rotor core.

Abstract: The present disclosure provides a brushless permanent magnet machine which includes an essentially circular shaped rotor, and a pair of magnets arranged in the rotor. The magnets are each U-shaped and have a thickness direction extending along a contour of the corresponding magnet between the opposite poles of the corresponding magnet, respectively. The magnets are each composed of a non-rare earth material having a lower coercivity than a rare earth material. A direction of magnetization of each of the pair of magnets is parallel to the thickness direction of the corresponding magnet. The present disclosure also provides a method of manufacturing such a brushless permanent magnet machine.

Abstract: A rotor for a permanent magnet electric motor includes a rotor core having a generally cylindrical shape with an outer circumferential surface and a rotational axis and a plurality of magnet insertion hole arrangements formed in the rotor core and arranged circumferentially at a preset angular interval about the rotational axis. Each hole arrangement has a radially inward side, a radially outward side, and two ends that are respectively spaced apart from the circumferential surface by respective bridge regions formed by the rotor core. The material of the bridge regions is metallurgically transformed by having its grain structure changed, e.g., by heating the material to at least its Curie temperature, whereby the material possesses greater magnetic reluctance than the material of adjacent portions of the rotor core.

Abstract: A stator of an electrical machine operable as a motor or a generator, applicable to a radial-axial type machine. The stator includes a plurality of stator segments disposed circumferentially about an axis. Each segment has a generally wedge shaped core and a winding wound around the core. The winding is bent to have portions that are disposed on multiple planes. The core includes an elongated wedge tip portions aligned parallel to the axis and an outer radial face opposite to the tip portion. The multiple planes include at least one plane substantially normal to the axis and at least one plane tangential to the radial face.

Abstract: A rotor includes a cylindrical rotor core having an outer circumferential surface and a plurality of magnet insertion holes formed in the rotor core and arranged circumferentially at a preset angular interval about the rotational axis of the rotor core. Each hole extends in a direction parallel to the rotational axis and has a cross section of a generally elongated slit. The elongated slit is curved concave relative to the circumferential surface and has a radially inward side, a radially outward side, and two ends that are respectively spaced apart from the circumferential surface by two bridges, wherein each bridge has thinner and thicker portions that are respectively positioned near the radially inward and outward sides. One or more permanent magnets are inserted in each hole and arranged to transfer centrifugal forces acting on the magnets during operation to portions of the bridges.

Abstract: A stator of an electrical machine operable as a motor or a generator, applicable to a radial-axial type machine. The stator includes a plurality of stator segments disposed circumferentially about an axis. Each segment has a generally wedge shaped core and a winding wound around the core. The winding is bent to have portions that are disposed on multiple planes. The core includes an elongated wedge tip portions aligned parallel to the axis and an outer radial face opposite to the tip portion. The multiple planes include at least one plane substantially normal to the axis and at least one plane tangential to the radial face.

Abstract: A rotor includes a cylindrical rotor core having an outer circumferential surface and a plurality of magnet insertion holes formed in the rotor core and arranged circumferentially at a preset angular interval about the rotational axis of the rotor core. Each hole extends in a direction parallel to the rotational axis and has a cross section of a generally elongated slit. The elongated slit is curved concave relative to the circumferential surface and has a radially inward side, a radially outward side, and two ends that are respectively spaced apart from the circumferential surface by two bridges, wherein each bridge has thinner and thicker portions that are respectively positioned near the radially inward and outward sides. One or more permanent magnets are inserted in each hole and arranged to transfer centrifugal forces acting on the magnets during operation to portions of the bridges.

Abstract: An polyphase machine includes a stator having a plurality of parallel stator windings, a plurality of phase voltage terminals, each of the stator windings fastened to a corresponding phase voltage terminal, and at least one neutral terminal, each of the stator windings forming a common ground fastened to the neutral terminal. At least one of the stator windings is fastened to the corresponding phase voltage terminal or neutral terminal by a connection that does not involve a heat induced joining method. In an exemplary embodiment, the connection includes a lead wire protruding from the stator winding and terminated with a connector, such as a ring lug, fastened to the respective terminal with a mechanical fastener, such as a rivet or threaded rivet. A method for connecting stator windings in a polyphase machine is also provided.

Abstract: A brushless permanent magnet electric motor or generator having a hollow rotor, is provided with apertures in ends of the rotor. The apertures allow air to flow through the center of the hollow rotor and remove heat from the rotor. Vanes or blades can be fixed to the shaft within the rotor or fixed to ends of the rotor to force air through an interior of the hollow rotor. Ends of the rotor can be shaped to form fan blades that draw air through the interior of the rotor. Air flowing through the rotor can be recirculated by flowing back through passageways formed between the stator and the motor/generator casing, through passages through the stator, and/or back through an air gap between the stator and the rotor.