Abstract: A rotor is provided for use in an electric motor. The rotor includes a shaft assembly rotatable about an axis. The rotor also includes a plurality of magnets arranged arcuately about the shaft assembly, and a plurality of pole segments arranged arcuately about the shaft assembly. The pole segments alternate with the magnets, such that each of the magnets is at least in part interposed between adjacent pole segments. The pole segments interlock with the coupling element.

Abstract: A rotor is provided for use in an electric motor. The rotor includes a shaft assembly rotatable about an axis. The rotor also includes a plurality of magnets arranged arcuately about the shaft assembly, and a plurality of pole segments arranged arcuately about the shaft assembly. The pole segments alternate with the magnets, such that each of the magnets is at least in part interposed between adjacent pole segments. The pole segments interlock with the coupling element.

Abstract: A motor or generator assembly including a motor or generator machine and mounting structure supporting the machine on an appliance is provided. The machine presents an axially extending, radially outermost circumferential face and a pair of axially spaced apart, radially projecting axial margins. The mounting structure includes a pair of at least substantially radially extending plates and a base configured for connection to the appliance. The plates extend at least in part adjacent respective ones of the axial margins and at least in part define a machine-receiving space therebetween. The machine is mounted on the brackets so as to be positioned at least in part in the machine-receiving space. The base is positioned at least substantially radially outside the circumferential face of the machine and presents a pair of axially spaced apart side faces, with each of the plates being secured against a respective one of the side faces.

Abstract: A rotor is provided for use in an electric motor. The rotor includes a shaft assembly rotatable about an axis, a plurality of magnets arranged arcuately about the shaft assembly, and a plurality of pole segments arranged arcuately about the shaft assembly. The pole segments alternate with the magnets, such that each of the magnets is at least in part interposed between adjacent pole segments. The pole segments are magnetically isolated from each other. Furthermore, the shaft assembly is electrically isolated from the pole segments.

Abstract: A motor or generator assembly including a motor or generator machine and mounting structure supporting the machine on an appliance is provided. The machine presents an axially extending, radially outermost circumferential face and a pair of axially spaced apart, radially projecting axial margins. The mounting structure includes a pair of at least substantially radially extending plates and a base configured for connection to the appliance. The plates extend at least in part adjacent respective ones of the axial margins and at least in part define a machine-receiving space therebetween. The machine is mounted on the brackets so as to be positioned at least in part in the machine-receiving space. The base is positioned at least substantially radially outside the circumferential face of the machine and presents a pair of axially spaced apart side faces, with each of the plates being secured against a respective one of the side faces.

Abstract: An electrical motor has been developed having an epoxy, which encapsulates a stator winding to protect the stator winding from the humid and damp atmosphere associated with a cooling tower. The electrical motor includes a stator core, a stator winding configured about the stator core, and an epoxy encapsulating at least an end portion of the stator winding, the epoxy enabling the stator winding to be isolated from an atmosphere surrounding a fan within in a cooling tower operated by the electrical motor in which the stator core and the stator winding are positioned.

Abstract: An electrical motor has been developed having an epoxy, which encapsulates a stator winding to protect the stator winding from the humid and damp atmosphere associated with a cooling tower. The electrical motor includes a stator core, a stator winding configured about the stator core, and an epoxy encapsulating at least an end portion of the stator winding, the epoxy enabling the stator winding to be isolated from an atmosphere surrounding a fan within in a cooling tower operated by the electrical motor in which the stator core and the stator winding are positioned.

Abstract: A stator assembly has discrete stacks of laminations. A plurality of nonmagnetic containment structures define pockets. The stacks are at least partially received in the pockets and coupled to one another by the containment structure. The containment structures are moveable between a first configuration in which the stacks are separate from one another and a second configuration in which yokes of adjacent stacks are in physical contact with one another. In a method of making a stator assembly, a plurality of stator segments are positioned so each is received in one of a plurality of pockets in a containment structure. Coils are wound around each stator segment while the containment structure prevents the stator segment from having direct physical contact with another stator segment. The containment structure is reconfigured to bring the wound stator segments into contact with one another, thereby forming a closed magnetic circuit.

Abstract: A stator assembly has discrete stacks of laminations. A plurality of nonmagnetic containment structures define pockets. The stacks are at least partially received in the pockets and coupled to one another by the containment structure. The containment structures are moveable between a first configuration in which the stacks are separate from one another and a second configuration in which yokes of adjacent stacks are in physical contact with one another. In a method of making a stator assembly, a plurality of stator segments are positioned so each is received in one of a plurality of pockets in a containment structure. Coils are wound around each stator segment while the containment structure prevents the stator segment from having direct physical contact with another stator segment. The containment structure is reconfigured to bring the wound stator segments into contact with one another, thereby forming a closed magnetic circuit.

Abstract: A stator segment for a stator assembly includes a stack of substantially identical laminations and a containment structure receiving a portion of the stacked laminations. The containment structure includes a flexible hinge element. The containment structure can include a first containment structure member having a first pocket for receiving a portion of the stack of substantially identical laminations and a second containment structure member having a second pocket for receiving a different portion of the stack of substantially identical laminations than the first pocket. In some embodiments, the stack of substantially identical laminations includes two ends and a middle portion extending between the ends. The containment structure can include a first containment structure member for capping one end of the stack of substantially identical laminations and a second containment structure member for capping the other end of the stack of substantially identical laminations.

Abstract: A stator for an electric machine includes stator teeth with powder coat insulation covering a portion of each tooth. An end cap with a routing element is positioned on one side of the stator. Wire extends around and contacts the powder coat insulation on the stator teeth and is routed via the routing element.

Abstract: A stator segment for a stator assembly has a stack of substantially identical laminations and a containment structure receiving a portion of the stacked laminations. The containment structure includes a flexible hinge element.

Abstract: A stator assembly that may be rounded into an annular form is disclosed that includes a plurality of stator segments where each stator segment defines a yoke portion and a stator tooth and a containment structure configured to position the stator segments relative to one another such that the stator segments do not physically touch one another and such that no magnetic circuit between adjacent stator segments is formed. Also disclosed is a method for forming a segmented stator, involving the steps of positioning a plurality of stator segment in a containment structure such that no magnetic circuit between adjacent stator segments is formed, forming a winding coil about at least some of the stator segments; and deforming the containment structure to form an annular stator and to establish a magnetic circuit between adjacent stator segments.

Abstract: A stator for an electric machine includes stator teeth with powder coat insulation covering a portion of each tooth. An end cap with a routing element is positioned on one side of the stator. Wire extends around and contacts the powder coat insulation on the stator teeth and is routed via the routing element.

Abstract: A method of connecting phases of a segmented stator electric machine includes providing a stator core. An end cap assembly is attached to the stator core. Winding wire is wound around the end cap assembly and the stator core to form a stator segment assembly. A plurality of the stator segment assemblies are assembled into a stator including first, second and third phases. A phase wire stitching machine is used to connect opposite ends of the winding wire of each of the stator segment assemblies to form the first, second and third phases of the stator. The phase wires can be attached to the stator segment assemblies using terminals, IDCs, hook terminals, and/or directly to the winding wire.

Abstract: An interconnecting ring and wire guide for an electric machine includes an annular radial ring having a radially inner edge and a radially outer edge. An axial ring projects axially from the radially inner edge of the annular radial ring. A guide positioner positions the annular radial ring and the axial ring relative to the electric machine. Wire dividers are located on a radially outer surface of the radial ring. The wire dividers include a plurality of circumferential projections that are formed on the radially outer surface of the radial ring. A plurality of wire guides are located adjacent to a radially outer edge of the annular radial ring. Indicia on an outer surface of the annular radial ring identifies at least one of a mounting position for the interconnecting ring and wire guide and a wiring schematic for phases wiring of the electric machine.

Abstract: A stator assembly that may be rounded into an annular form is disclosed that includes a plurality of stator segments where each stator segment defines a yoke portion and a stator tooth and a containment structure configured to position the stator segments relative to one another such that the stator segments do not physically touch one another and such that no magnetic circuit between adjacent stator segments is formed. Also disclosed is a method for forming a segmented stator, involving the steps of positioning a plurality of stator segment in a containment structure such that no magnetic circuit between adjacent stator segments is formed, forming a winding coil about at least some of the stator segments; and deforming the containment structure to form an annular stator and to establish a magnetic circuit between adjacent stator segments.

Abstract: A method of connecting phases of a segmented stator electric machine includes providing a stator core. An end cap assembly is attached to the stator core. Winding wire is wound around the end cap assembly and the stator core to form a stator segment assembly. A plurality of the stator segment assemblies are assembled into a stator including first, second and third phases. A phase wire stitching machine is used to connect opposite ends of the winding wire of each of the stator segment assemblies to form the first, second and third phases of the stator. The phase wires can be attached to the stator segment assemblies using terminals, IDCs, hook terminals, and/or directly to the winding wire.

Abstract: An interconnecting ring and wire guide for an electric machine includes an annular radial ring having a radially inner edge and a radially outer edge. An axial ring projects axially from the radially inner edge of the annular radial ring. A guide positioner positions the annular radial ring and the axial ring relative to the electric machine. Wire dividers are located on a radially outer surface of the radial ring. The wire dividers include a plurality of circumferential projections that are formed on the radially outer surface of the radial ring. A plurality of wire guides are located adjacent to a radially outer edge of the annular radial ring. Indicia on an outer surface of the annular radial ring identifies at least one of a mounting position for the interconnecting ring and wire guide and a wiring schematic for phases wiring of the electric machine.

Abstract: A shroud is provided for a dynamoelectric device such as an electric motor comprising a rotor and a wire wound stator, where the shroud fully contains the end turns of the stator wire windings, provides terminal connections for winding leads, and includes a circuitry compartment to house a temperature and current protective device.