Bar Windings Patents (Class 310/201)
  • Patent number: 10778049
    Abstract: A stator includes layers of coated conductor. The coating is insulative and provides electrical isolation of adjacent conductor layers. The multiple layers of coated conductor form a stator core, and the stator includes magnet assemblies that sandwich the stator core. The conductor layers stack in a direction orthogonal to a plane of the magnet assemblies. The conductor layers have a rectangular cross section.
    Type: Grant
    Filed: June 2, 2017
    Date of Patent: September 15, 2020
    Assignee: Sapphire Motors
    Inventor: Tracy McSheery
  • Patent number: 10658897
    Abstract: A stator for a rotary electric machine includes a stator core defining multiple slots, and a stator coil including multiple phase windings each of which is connected to a corresponding phase of a power source. Each phase winding includes multiple conductors that are inserted into the slots, connected to adjacent conductors in series, and spaced apart from the adjacent conductors by multiple slot pitches, unit patterns each of which includes some of conductors, and a bridge conductor connecting the unit patterns to each other in series by connecting a pair of conductors arranged in an innermost layer of corresponding slots. Each first conductor of each phase winding is connected to a power line and arranged in an outermost layer of one of the multiple slots.
    Type: Grant
    Filed: August 18, 2017
    Date of Patent: May 19, 2020
    Assignee: LG Electronics Inc.
    Inventors: Hyounggun Lee, Minjung Kim, Yangsoo Lee
  • Patent number: 10615654
    Abstract: The disclosed stator or rotor has a distributed wave winding, in which the wires are associated in pairs lying with straight segments in the same slots. Head portions of two successive straight segments of each wire of a pair protrude from opposite ends of slots. For forming two wire groups, a plurality of coil windings are simultaneously created by winding up n parallel wires with intermediate spacing onto a striplike former that is rotatable about its longitudinal axis. From each of the parallel wires one straight segment and one end turn are doubled by being bent over with the wire length of a head portion, and then head portions are formed and the wires interlaced. Finally, the two wire groups are wound onto one another and thereby intertwined with one another, and then introduced as an entire intertwined wave winding strand into the stator or rotor slots.
    Type: Grant
    Filed: March 11, 2014
    Date of Patent: April 7, 2020
    Assignee: Elmotec Statomat Holding GmbH
    Inventors: Sadik Sadiku, Keith Witwer
  • Patent number: 10608492
    Abstract: A stator reducing a coil end height without interference between conductor segments and without damage to an insulating coating. Each conductor segment includes linear parts inserted in slots formed in a stator core and different in circumferential direction, inclined parts inclined and extending from respective end parts of the linear parts toward a center part so as to project toward the outside in an axis direction from an axis-direction end surface of the core, and a projecting curve part connecting apical ends of the inclined parts to each other and curves and projects toward the outside in the axis direction. Connection parts between the linear parts and the inclined parts and a curved part of the projecting curve part are all bent parts having the same bend radius of minimum R, which has a size equal to or more than a sheet width of a conductor strand.
    Type: Grant
    Filed: June 29, 2017
    Date of Patent: March 31, 2020
    Assignee: FUJI ELECTRIC CO., LTD.
    Inventors: Hideki Ohguchi, Hitoshi Nakazono, Hideki Nishikawa
  • Patent number: 10574106
    Abstract: A stator for a rotating electric machine includes an annular stator core and a stator coil. The stator core has a plurality of slots arranged in a circumferential direction thereof. The stator coil is formed of a plurality of electric conductor segments mounted on the stator core. Each of the electric conductor segments has a pair of in-slot portions and a turn portion. Each of the pair of in-slot portions is inserted in a corresponding one of the slots of the stator core. The turn portion is located on one axial side of the stator core and connects the pair of in-slot portions. Moreover, for each of the electric conductor segments, at least one of the pair of in-slot portions of the electric conductor segment includes a protruding part that protrudes in the circumferential direction of the stator core.
    Type: Grant
    Filed: August 24, 2017
    Date of Patent: February 25, 2020
    Assignee: DENSO CORPORATION
    Inventor: Toshihiro Takei
  • Patent number: 10574108
    Abstract: A winding arrangement method for a radial gap-type motor in which a three phase winding wound in a distributed winding form is inserted in slots of a stator includes: a coil forming step that, for each phase, forms a coil wound for each one pole pair; a coil group forming step that, for each phase, forms a first coil group by connecting odd-number-th coils along a direction of rotation via crossover wires, and forms a second coil group by connecting even-number-th coils along the direction of rotation via crossover wires; and a parallel-connecting step that, for each phase, connects the first coil group and the second coil group at one end, to form a current input side lead wire at the connection point, and connects the first coil group and the second coil group at the other end, to form a neutral point at the connection point.
    Type: Grant
    Filed: February 15, 2016
    Date of Patent: February 25, 2020
    Assignee: FANUC CORPORATION
    Inventors: Gang Ren, Hidetoshi Uematsu
  • Patent number: 10491069
    Abstract: An electric machine employs laminated sheets windings (LSWs) and permanent magnets which rotate about the LSWs. A ‘radial’ embodiment employs magnets which are magnetized radially and LSWs laid parallel to the rotation axis. An ‘axial’ embodiment uses axially magnetized magnets with LSWs laid radially in the plane of the motor. The magnets may be arranged as Halbach arrays. Magnets and LSWs are arranged concentrically with an air gap therebetween; the motor may employ “Large Air Gap Electric Ring” (LAGER) technology. The laminated sheets form a continuous stack of series-connected concentric metal layers; dielectric layers insulate each metal layer from its adjacent layers. Cuts arranged periodically around each LSW run parallel to the rotation axis and extend through all of the metal layers, with adjacent cuts originating on opposite sides of the LSW such that they form a serpentine path for current to flow as it flows around the winding.
    Type: Grant
    Filed: September 15, 2015
    Date of Patent: November 26, 2019
    Assignee: GreenTech Motors Corporation
    Inventors: Jean-Marc Gery, Dan Jones
  • Patent number: 10454332
    Abstract: An active part of an electric machine includes a plurality of coils, each having a sub-conductor. The coils are formed by windings of the sub-conductors thereof. The windings of a coil each have a predetermined winding length. In addition, the active part has a carrier part, in the grooves of which, the coils are arranged. The coils have a winding head region which projects from an end surface of the carrier part. The coils are also arranged in the form of a tiered winding. At least one of the coils has a V-shaped cross-section in the winding head region, as a result of an arrangement of its sub-conductor.
    Type: Grant
    Filed: October 2, 2015
    Date of Patent: October 22, 2019
    Assignee: SIEMENS AKTIENGESELLSCHAFT
    Inventors: Zolt Bogdan, Janos Iles, Andreas Lindmeier, Norbert Schönbauer, Mirjana Vukovic, Robin Brenner, Dominik Ratzisberger, Claus Teringl
  • Patent number: 10404112
    Abstract: An electric motor includes a yoke having six magnetic poles; a rotary shaft which is provided inside the yoke in a freely rotatable manner; an armature core (6) which has teeth (36) attached to the rotary shaft, radially extending in a radial direction and set in an arrangement of an even number, and an even number of slots (37) formed between the teeth; an armature coil (7) which is wound around the teeth in a single wave winding; and a commutator (13) which is provided in the rotary shaft to be adjacent to the armature core (6) and has a plurality of circumferentially disposed segments (41) to which the armature coil (7) is connected.
    Type: Grant
    Filed: August 8, 2018
    Date of Patent: September 3, 2019
    Assignee: Mitsuba Corporation
    Inventors: Yoshichika Kawashima, Teppei Tokizaki, Natsumi Tamura
  • Patent number: 10389198
    Abstract: A stator for an electric rotary machine including a stator core and a coil, wherein the coil has plural slot coils, each slot coil being inserted into the slot, and plural connection coils, each connection coil connecting the slot coils in a position lying further axially outwards than an axial end face of the stator core, and is constituted in such a way that the slot coil and the connection coil are joined at an abutment portion; the slot coil and the connection coil are formed by plate conductors, the plate conductor having a plate surface that is planar and that intersects a thickness direction thereof; and the plate surface of the slot coil is brought into surface contact with the plate surface of the connection coil in the abutment portion.
    Type: Grant
    Filed: March 31, 2014
    Date of Patent: August 20, 2019
    Assignee: HONDA MOTOR CO., LTD.
    Inventor: Tomotaka Iki
  • Patent number: 10369628
    Abstract: Certain embodiments of the invention may include systems and methods for providing stator bar shape tooling. According to an example embodiment of the invention, a method is provided for shaping an element. The method can include providing at least one constraining surface, wherein the at least one constraining surface is fabricated at least in part by selective laser sintering, and deforming an element with the at least one constraining surface to define at least an external shape of a formed element.
    Type: Grant
    Filed: November 18, 2016
    Date of Patent: August 6, 2019
    Assignee: General Electric Company
    Inventors: Caleb James Munholand, Mark Stephen Clough, Mark Kent Shoemaker, David John Wardell
  • Patent number: 10333364
    Abstract: An electrical machine includes a winding core with a plurality of end slots. A winding is seated in the end slots with end windings where the winding crosses from end slot to end slot. A slot insulator is seated in two of the end slots. The slot insulator includes a first slot liner seated in a first one of the two end slots with a winding slot defined therethrough in an axial direction. A second slot liner is seated in a second one of the two end slots with a winding slot defined therethrough in the axial direction, wherein the second slot liner is spaced apart in a lateral direction relative to the axial direction from the first slot liner by a gap. The slot insulator includes a span portion bridging across the gap to connect the first and second slot liners.
    Type: Grant
    Filed: July 6, 2015
    Date of Patent: June 25, 2019
    Assignee: Hamilton Sundstrand Corporation
    Inventors: Debabrata Pal, Craig R. Legros
  • Patent number: 10312762
    Abstract: Provided are a coil having excellent insulation properties, a rotating electrical machine equipped with the same, and a method for manufacturing the same. The coil (60) has a covered portion where a conductive body (602) is covered with an insulating film (612) and a stripped portion where the insulating film is stripped off, and the stripped portion is electrophoretically coated with a resin material (601). The coil (60) may have a configuration wherein segment conductors (28) each having a covered portion and stripped portion are included, connection parts are formed by the stripped portions of two different segment conductors (28) being connected at coil ends (62), and the thickness of the resin material (601) is no more than the thickness of the insulating film (612) at the boundary portion (630) between the covered portion and the stripped portion.
    Type: Grant
    Filed: December 13, 2013
    Date of Patent: June 4, 2019
    Assignee: Hitachi Automotive Systems, Ltd.
    Inventors: Kenichi Nakayama, Tomohiro Fukuda, Akira Toba, Shinji Yamazaki, Takashi Genmoto, Naoki Nishikawa, Hisaya Shimizu
  • Patent number: 10305335
    Abstract: To improve the insulating reliability of a stator for a rotating electrical machine and the rotating electrical machine, the stator is provided with a winding having a molten metal junction, and covering material which covers the winding. The covering material has a bending part which bends to be partially in contact with the winding.
    Type: Grant
    Filed: July 14, 2016
    Date of Patent: May 28, 2019
    Assignee: Hitachi Automotive Systems, Ltd.
    Inventor: Kenichi Nakayama
  • Patent number: 10263486
    Abstract: A plurality of coil groups are each configured by connecting a tip portion of a first conductor terminal and a tip portion of a second conductor terminal that is subject to connection therewith using a connecting conductor, and the connecting conductors include: a pair of connecting portions that are respectively disposed so as to contact the tip portion of the first conductor terminal and the tip portion of the second conductor terminal that is subject to connection therewith in a circumferential direction of the tip portions so as to be parallel to the tip portions, and that are joined together with the tip portions; and a linking portion that links the pair of connecting portions.
    Type: Grant
    Filed: September 22, 2014
    Date of Patent: April 16, 2019
    Assignee: Mitsubishi Electric Corporation
    Inventors: Masashi Nakamura, Akihiro Yamamura, Shinkichi Sawa, Masaya Inoue
  • Patent number: 10236735
    Abstract: An electric conductor is provided for forming a coil upon being bent. The electric conductor includes a pair of electric conductor wires and an insulating coat. The electric conductor wires each have a substantially rectangular cross section and are arranged in alignment with each other in an alignment direction. The alignment direction is perpendicular to corresponding sides of the substantially rectangular cross sections of the electric conductor wires; the corresponding sides have the same length. The insulating coat is formed on outer peripheral surfaces of the electric conductor wires. The insulating coat has a thick portion formed at a boundary between the electric conductor wires. The thick portion is thicker than and protrudes outward from other portions of the insulating coat which adjoin the thick portion in a circumferential direction of the electric conductor.
    Type: Grant
    Filed: October 11, 2016
    Date of Patent: March 19, 2019
    Assignee: DENSO CORPORATION
    Inventors: Yuichi Kudose, Takefumi Kaji
  • Patent number: 10164490
    Abstract: In a rotary electric machine according to the present invention, an armature winding includes a plurality of distributed winding bodies that are each produced by winding a single conductor wire that is insulated, that is jointless and continuous, and that has a constant cross-sectional area perpendicular to a longitudinal direction, the conductor wires include first through third coil end portions that link first through fourth rectilinear portions and first through fourth rectilinear portions, and are formed such that radial widths w? of the first through fourth rectilinear portions are wider than radial widths w of the first through third coil end portions.
    Type: Grant
    Filed: June 27, 2014
    Date of Patent: December 25, 2018
    Assignee: MITSUBISHI ELECTRIC CORPORATION
    Inventors: Hironori Tsuiki, Tatsuro Hino, Atsushi Sakaue, Akira Hashimoto, Kazunori Muto, Masashi Nakamura, Shinkichi Sawa, Hiroyuki Akita
  • Patent number: 10050480
    Abstract: An electrical axial flux machine including a rotor shaft is provided. The rotor shaft is rotatable about an axis of rotation. Two rotors are arranged on the rotor shaft. The two rotors are spaced apart when viewed in a direction of the axis of rotation. The axial flux machine further includes a stator arranged between the two rotors when viewed in the direction of the axis of rotation. The stator includes stator teeth. Each of the stator tooth extends in the direction of the axis of rotation between two end regions. The stator teeth are arranged and distributed uniformly around the axis of rotation at a radial spacing from the axis of rotation and include a stator winding system. At least one ring structure is provided connecting the two end regions of the stator teeth. A housing further surrounds the stator radially on the outside.
    Type: Grant
    Filed: April 3, 2014
    Date of Patent: August 14, 2018
    Assignee: Siemens Aktiengesellschaft
    Inventors: Marco Köhler, Korbinian Petermaier, Marco Schramm
  • Patent number: 10020702
    Abstract: A stator having slots separated by stator teeth, into which shaped bars, formed from a plurality of individual wires, are deployed, wherein in each case sidewalls of a stator tooth bounding adjacent slots in a region of the shaped bars run essentially parallel to one another.
    Type: Grant
    Filed: June 21, 2013
    Date of Patent: July 10, 2018
    Inventors: Arno Mathoy, Martin Stoeck
  • Patent number: 9915554
    Abstract: The width of a terminal block is decreased by decreasing a space between an external connecting terminal at each end of the external connecting terminals and an end portion of the terminal block, whereas a space between a winding terminal at each end of the winding terminals of terminals and an end portion of the terminal block is sufficiently obtained. A terminal 7 is provided with an external connecting terminal 71 and a winding terminal 72, and the terminal 7 has a shape such that a center line Lp in the width direction of the winding terminal 72 is shifted from a center line Le in the width direction of the external connecting terminal 71. A plurality of the terminals 7 are arranged on a terminal block 11 so that pitches between the winding terminals 72 are unequal.
    Type: Grant
    Filed: June 4, 2015
    Date of Patent: March 13, 2018
    Assignee: MINEBEA CO., LTD.
    Inventor: Haruki Otobe
  • Patent number: 9887596
    Abstract: In a rotating electric machine, a stator includes a stator core having slots formed therein and a stator coil comprised of phase windings each of which includes in-slot portions and turn portions. The turn portions of the phase windings together constitute a coil end part of the stator coil. Further, a cooling mechanism is provided to drop liquid coolant onto the coil end part. Moreover, the turn portions of the phase windings include long-pitch turn portions and short-pitch turn portions. In the coil end part, there are axially-overlapping pairs of the long-pitch and short-pitch turn portions over an entire circumferential range of the stator coil. For each axially-overlapping pair of the long-pitch and short-pitch turn portions, the short-pitch turn portion is located axially inside the long-pitch turn portion and faces the long-pitch turn portion through a void space formed therebetween over entire lengths of the long-pitch and short-pitch turn portions.
    Type: Grant
    Filed: February 19, 2016
    Date of Patent: February 6, 2018
    Assignee: DENSO CORPORATION
    Inventor: Akito Tamura
  • Patent number: 9831735
    Abstract: A stator includes a hollow cylindrical stator core and a stator coil formed of a plurality of electric conductor segments. Each of the electric conductor segments includes, at least, an in-slot portion received in a corresponding slot of the stator core and a protruding portion that protrudes from the in-slot portion outside of the corresponding slot. Each of the electric conductor segments also has an insulating coat covering its outer surface. For each intersecting pair of the protruding portions of the electric conductor segments, at least one of the two protruding portions of the intersecting pair has an indentation formed in a side face thereof radially facing the other protruding portion at the intersection of the two protruding portions. Further, a thickness of the insulating coats at the indentations is substantially equal to a thickness of the insulating coats at the in-slot portions of the electric conductor segments.
    Type: Grant
    Filed: July 24, 2013
    Date of Patent: November 28, 2017
    Assignee: DENSO CORPORATION
    Inventors: Atsuo Ishizuka, Tetsuya Gorohata
  • Patent number: 9772203
    Abstract: A stator structure and a VR type resolver, in which the winding of the resolver can be prevented from corroding without increasing the production cost, are provided. The stator structure has stator protruding portions and coils wound around the stator protruding portions, the coils consisting of exciting coils, sine phase detection coils, and cosine phase detection coils, and at least the coils wound at the outermost side are formed by wires in which conductive portions are made of aluminum.
    Type: Grant
    Filed: July 2, 2014
    Date of Patent: September 26, 2017
    Assignee: MINEBEA CO., LTD.
    Inventor: Haruki Otobe
  • Patent number: 9748803
    Abstract: An electric machine comprise a first carrier having an array of electromagnetic elements and a second carrier having electromagnetic elements defining magnetic poles, the second carrier being arranged to move relative to the first carrier. An airgap is provided between the first carrier and the second carrier. The electromagnetic elements of the first carrier include posts, with slots between the posts, one or more electric conductors in each slot, the posts of the first carrier having a post height in mm. The first carrier and the second carrier together define a size of the electric machine. The magnetic poles having a pole pitch in mm. The size of the motor, pole pitch and post height are selected to fall within a region in a space defined by size, pole pitch and post height that provides a benefit in terms of force or torque per weight per excitation level.
    Type: Grant
    Filed: August 11, 2016
    Date of Patent: August 29, 2017
    Assignee: Genesis Robotics LLC
    Inventor: James Brent Klassen
  • Patent number: 9742226
    Abstract: An electric machine comprise a first carrier having an array of electromagnetic elements and a second carrier having electromagnetic elements defining magnetic poles, the second carrier being arranged to move relative to the first carrier. An airgap is provided between the first carrier and the second carrier. The electromagnetic elements of the first carrier include posts, with slots between the posts, one or more electric conductors in each slot, the posts of the first carrier having a post height in mm. The first carrier and the second carrier together define a size of the electric machine. The magnetic poles having a pole pitch in mm. The size of the motor, pole pitch and post height are selected to fall within a region in a space defined by size, pole pitch and post height that provides a benefit in terms of force or torque per weight per excitation level.
    Type: Grant
    Filed: August 11, 2016
    Date of Patent: August 22, 2017
    Assignee: Genesis Robotics LLP
    Inventor: James Brent Klassen
  • Patent number: 9627946
    Abstract: A lead wire connection structure includes a rectifier that is arranged at the outside or the inside in an axis direction of the brackets so as to rectify AC voltage, which is generated on the stator, to DC voltage; in which, when a number of conductors of a connecting portion, at which lead conductors of the stator winding and the rectifier are connected, is “N” (N is integer and greater than or equal to 2) per one position, conductors, of which number is less than or equal to “N?1” per one position, are connected at the connecting portion, and conductors excepted from the conductors, of which number is less than or equal to “N?1”, are welded onto the remaining conductors at a position being nearer the stator winding side than the connecting portion.
    Type: Grant
    Filed: October 12, 2011
    Date of Patent: April 18, 2017
    Assignee: Mitsubishi Electric Corporation
    Inventors: Yoshiro Imazawa, Kazunori Tanaka, Ryoichi Sasahara
  • Patent number: 9570965
    Abstract: A rotor coil for a revolving armature includes a strand coil that includes a part arranged in a core slot of the rotor and is composed of a plurality of element wires; and a solid coil welded to an end of the strand coil wherein the end of the strand coil and an end of the solid coil are welded by friction stir welding. A manufacturing method of a rotor coil includes the step of performing friction stir welding wherein the friction stir welding is performed for the butt joint with the end of the strand coil arranged in an advancing side defined by a rotation direction of a tool and with the solid coil arranged in a retreating side.
    Type: Grant
    Filed: February 12, 2013
    Date of Patent: February 14, 2017
    Assignee: MITSUBISHI HITACHI POWER SYSTEMS, LTD.
    Inventors: Ryosuke Umezu, Yasuaki Kageyama, Juichi Enyama, Seunghwan Park, Satoshi Hirano
  • Patent number: 9525316
    Abstract: A method and system is provided to join the wire ends of a stator by placing a crimpable element on a wire end pair such that the wire ends of the wire end pair are surrounded by the crimpable element, and deforming the crimpable element using a crimping tool to form a crimped joint. The crimped joint is configured to provide an electrical connection between the wire ends of the wire end pair. The wire ends may be retained in substantial contact with each other by the crimpable element. The wire end portion of the stator may be immersed in a molten solder bath to form a solder joint joining the wire end pair comprising a crimped joint. The stator may be configured as a bar pin stator including a plurality of bar pins defining the wire ends.
    Type: Grant
    Filed: November 22, 2013
    Date of Patent: December 20, 2016
    Assignee: GM Global Technology Operations LLC
    Inventor: Richard M. Kleber
  • Patent number: 9509188
    Abstract: A stator of a rotary electric machine includes a stator core that includes a plurality of slots; and a plurality of conductor segment coils that each have a U-shape. A sectional area of the U-shaped portion of the conductor segment coil that protrudes out from one side in the axial direction of the stator core is larger than a sectional area of a tip end portion of the conductor segment coil that protrudes out from the other side in the axial direction of the stator core; and the sectional area of the tip end portion of the conductor segment coil that protrudes out from the other side in the axial direction of the stator core is larger than a sectional area of an in-slot portion of the conductor segment coil.
    Type: Grant
    Filed: October 3, 2013
    Date of Patent: November 29, 2016
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Hiroki Kato
  • Patent number: 9496773
    Abstract: A rotating electrical machine includes a stator and a rotor. The stator winding includes a plurality of conductor segments inserted through the slots from one end surface of the stator core with end portions of the conductor segments projecting out beyond another end surface of the stator core. The conductor segments include an undeformed portion, a plastically deformed portion formed at the end portions thereof and a tapered portion. The plastically deformed portion has a dimension of the plastically deformed portion along a circumferential direction that is greater than a dimension of the undeformed portion along the circumferential direction and so that a dimension of the plastically deformed portion along a radial direction is smaller than a dimension of the undeformed portion along the radial direction. The conductor segments are welded together at tops of the plastically deformed portions thereof.
    Type: Grant
    Filed: December 13, 2012
    Date of Patent: November 15, 2016
    Assignee: Hitachi Automotive Systems, Ltd.
    Inventors: Takashi Ishigami, Yutaka Matsunobu, Yoshimi Mori
  • Patent number: 9337696
    Abstract: A rotary electric machine includes: a rotating shaft having an axis extending in an axial direction; a rotor fixed to the rotating shaft; a stator provided with a plurality of stator coils; a wire connection part provided at one side of the stator coils in the axial direction, the wire connection part connecting end portions of the stator coils in a specified wire connection pattern; and a resin molded part arranged to cover the wire connection part and the stator coils. The wire connection part includes a plurality of conductive members connected to the end portions of the stator coils and an insulating member arranged to at least partially cover surfaces of the conductive members. The insulating member has projection portions protruding toward the resin molded part existing at the one side of the stator coils in the axial direction.
    Type: Grant
    Filed: June 25, 2013
    Date of Patent: May 10, 2016
    Assignee: KABUSHIKI KAISHA YASKAWA DENKI
    Inventors: Kenji Funakoshi, Hideyuki Onda, Kanta Yamaguchi
  • Patent number: 9214847
    Abstract: Provided is a motor comprising: a stator equipped with a coil basket, which is a distributed winding coil that uses flat wire, and a stator core; and a rotor with a central shaft. The motor is characterized in that: the coil end at one end of the coil basket has bent sections that are bent on the rotor side in relation to wire sections inside slots of the stator core; and a lower-side concentric section and horizontal sections, which comprise the coil end at the other end, are positioned further toward the shaft center side of the rotor than the inner peripheral surface of the teeth; and the coil end at one end and the coil end at the other end comprise five flat wires that are lap wound in a flatwise direction.
    Type: Grant
    Filed: July 20, 2010
    Date of Patent: December 15, 2015
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kitamura Manabu, Atsushi Watanabe, Takashi Yamada, Shingo Hashimoto, Yoshiyuki Kawasaki, Kiyotaka Koga
  • Patent number: 9041262
    Abstract: A stator coil includes first to fourth in-slot portions and first and second turn portions. Both the first and third in-slot portions are received in one slot of a stator core, while both the second and fourth in-slot portions are received in another slot. The first and second turn portions both protrude from an axial end face of the stator core and respectively connect the pair of the first and second in-slot portions and the pair of the third and fourth in-slot portions. The second turn portion is located inside the first turn portion. When viewed along an axial direction of the stator core, the first and second turn portions extend so as to cross each other with a reference line C interposed therebetween; the reference line C is defined to extend along a circumferential direction of the stator core through an intersection between the first and second turn portions.
    Type: Grant
    Filed: January 18, 2013
    Date of Patent: May 26, 2015
    Assignee: DENSO CORPORATION
    Inventors: Tomoyuki Okamura, Norio Kamegawa
  • Patent number: 9035523
    Abstract: The invention relates to a coil (1), in particular for an electric machine, in particular a transformator or an electromechanical converter, in particular an electric motor, for guiding an electric current for producing a magnetic field. Said coil consists of individual windings (2) that are essentially embodied as a flat body thus obtaining a tightly packed structure when the windings (2) are superimposed, and respectively, each winding (2) comprises at least one circulating conductor path with the exception of at least one electric interruption on one side. Said conductor path of a winding (2) comprises, on one point, an electroconductive connection with a conductor path of an adjacent winding (2). The windings (2) are incidentally, essentially electrically isolated to each other.
    Type: Grant
    Filed: May 5, 2009
    Date of Patent: May 19, 2015
    Assignee: Brose Fahrzeugteile GmbH & Co. KG, Würzburg
    Inventor: Marcus Podack
  • Patent number: 9030087
    Abstract: A system for completing an electrical circuit includes first and second base contacts electrically isolated from each other, each having a magnetic portion secured thereto, each magnetic portion having an opposite polarity, and each of said base contacts electrically connected to an electrical lead for transmitting an electrical signal through said base contacts. The system also includes first and second mating contacts electrically isolated from each other, each having a magnetic portion of opposite polarity secured thereto.
    Type: Grant
    Filed: September 9, 2013
    Date of Patent: May 12, 2015
    Inventor: Christopher Moore
  • Patent number: 9018818
    Abstract: An insulating cap is provided for an end winding of an electrical machine working at a high voltage, the end winding including a plurality of insulated winding bars protruding from respective winding slots and electrically conductively connected to one another in pairs at their ends so as to form a plurality of electrical connections. The cap includes an opening allowing the insulating cap to be pushed over a region of one of the electrical connections such that the insulating cap insulates an outside of the electrical connection. An interior includes a layer configured to gradually dissipate a high electrical field in the region of the electrical connection to an outside of the insulating cap, the outside of the insulating cap being at earth potential.
    Type: Grant
    Filed: April 27, 2012
    Date of Patent: April 28, 2015
    Assignee: Alstom Renewable Technologies
    Inventors: Markus Huwyler, Andreas Koepfler, Thomas Klamt
  • Patent number: 8987969
    Abstract: The invention has an object to provide a stator including coils that protrude less in the radial direction of the stator and can be made smaller in the radial direction of the stator, and a method of manufacturing the same.
    Type: Grant
    Filed: September 30, 2009
    Date of Patent: March 24, 2015
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventor: Hideki Kamatani
  • Patent number: 8981613
    Abstract: The electric rotating machine includes a stator winding constituted of conductor segments each having a pair of in-slot portions and a coil end section projecting from both axial ends of a stator core. The coil end section includes a joint-side end portion having a skew portion intersecting with another one of the conductor segments at an axial end of the stator core. The skew portion is formed with a joint end portion at an extremity thereof, the joint end portion being formed with a conductor exposed portion where an inner conductor is exposed and joined to a conductor exposed portion of another conductor segment. A joint area between the joint end portions and a vicinity thereof are covered by an insulating resin member. The insulating resin member is thicker at a portion covering the conductor exposed portions than at a portion covering other than the conductor exposed portions.
    Type: Grant
    Filed: August 17, 2012
    Date of Patent: March 17, 2015
    Assignee: Denso Corporation
    Inventors: Hiroyuki Ikuta, Masato Yamaji
  • Patent number: 8963382
    Abstract: A stator includes a ring-shaped stator core having a plurality of slots arranged in a circumferential direction and a stator coil wound around the slots. The stator coil disposed within the slots is fixed by an impregnating material applied from an inner peripheral side of the stator core. An innermost-diameter coil wire of the stator coil positioned on the innermost-diameter side within the slots is provided with a first angle section that is angled towards an outward core-diameter direction side from a center section in a core-axis direction towards one end side, and a second angle section that is angled towards the outward core-diameter direction side from the center section in the core-axis direction towards another end side. The center section in the core-axis direction of the innermost-diameter coil wire projects towards an inward core-diameter direction side.
    Type: Grant
    Filed: August 5, 2011
    Date of Patent: February 24, 2015
    Assignee: Denso Corporation
    Inventors: Shigenori Yoneda, Toshiaki Oohara
  • Patent number: 8957562
    Abstract: A stator includes a core having a plurality of slots and a plurality of U-shaped conductors, which are inserted in the corresponding slots. Each of the conductors has a pair of legs and a joint portion that connects the legs together. Each slot receives four legs and each of the legs in the slot is one leg of the corresponding one of the conductors. Two of the four conductors corresponding to the four legs inserted in each slot are overlapped with each other at the joint portions as viewed at least circumferentially.
    Type: Grant
    Filed: June 18, 2012
    Date of Patent: February 17, 2015
    Assignee: Asmo Co., Ltd.
    Inventors: Yoshimasa Kinpara, Noriyasu Nishio, Teruhisa Tateiwa, Takenobu Kawakami
  • Patent number: 8946963
    Abstract: A polyphase stator for an internally ventilated rotating electrical machine comprises a body (14) provided with slots and carrying a coil (12) having at least one winding per phase. A plurality of pairs of lateral branches are mounted in a slot of the body (14). A plurality of connecting heads (50 to 55) extend outside the body (14) so as to form a first lead-out (42) and interconnect each pair of lateral branches. A plurality of coupling feet (150 to 155) are offset circumferentially with respect to the plurality of connecting heads and extend outside the body (14) so as to form a second lead-out (43) and interconnect each pair of lateral branches. One of the pluralities has a generally pointed shape and has an axial length of between 15 and 20 mm. The stator is used with an alternator or alternator-stator for a motor vehicle. An internally ventilated electrical machine is equipped with the stator.
    Type: Grant
    Filed: July 4, 2008
    Date of Patent: February 3, 2015
    Assignee: Valeo Equipments Electriques Moteur
    Inventors: Xavier Dunesme, Jerome Fournier, Nicolas Langlard, Pierre Faverolle
  • Patent number: 8946964
    Abstract: The invention incorporates a modular winding system for an electrical machine that includes a plurality of readily assembled modular windings for engaging a plurality of stator teeth of the machine. Windings comprise a pair of opposed legs terminating in upper and lower flanges, and are readily secured together to make consistent electrical contact between adjacent windings.
    Type: Grant
    Filed: August 5, 2011
    Date of Patent: February 3, 2015
    Inventor: Christopher Moore
  • Publication number: 20150028701
    Abstract: A stator bar includes a substantially quadrangular conductive element made of a plurality of interwoven strands. The stator bar also includes an electric insulation applied around the conductive element and including a plurality of corners corresponding to corners of the conductive element. The electric insulation includes an inner insulation zone facing the conductive element, and an outer insulation zone surrounding the inner insulation zone. The radius of at least one of the corners is between 1.5-2.5 millimeters. Permittivity at the corners of the electric insulation decreases by 35-45% from the inner insulation zone facing the conductive element towards the outer insulation zone. The insulation includes at least one mica layer, where one of the at least one mica layer includes titanium dioxide (TiO2).
    Type: Application
    Filed: October 14, 2014
    Publication date: January 29, 2015
    Applicant: ALSTOM Technology Ltd
    Inventors: Thomas BAUMANN, Massimiliano Vezzoli, Dieter Stoll, Johann Haldemann
  • Publication number: 20150022038
    Abstract: The present technology contemplates a stator or rotor of an electric machine comprising a main cylindrical body with a circular array of slots; at least one bar winding comprising a first and second plurality of basic conductors and a second plurality of special conductors. The first and second circular array comprise a first and second arc of legs of the first and second set of said conductors which are inserted as well as legs of the conductors. The present technology also contemplates electric machines and electric or hybrid drive vehicles comprising such stators of rotors.
    Type: Application
    Filed: October 7, 2014
    Publication date: January 22, 2015
    Inventor: Sante Guercioni
  • Publication number: 20150022045
    Abstract: Reliability related to an insulating process of conductor connection terminals of an electrical rotating machine stator using segment conductors is improved. An electrical rotating machine is configured so that stator coils 13 are inserted into slots 111 of a stator core 11, the stator coil 13 is formed by electrically connecting a stator coil connection terminal 41 of a segment conductor, the stator core 11 and the stator coils 13 are fixed with resin, and insulating members 24 and 25 are arranged so as to weave between the stator coil connection terminals 41 adjacent to each other in a circumferential direction.
    Type: Application
    Filed: December 7, 2012
    Publication date: January 22, 2015
    Inventors: Shuya Hagiwara, Koji Obata
  • Publication number: 20150015110
    Abstract: An electric rotating machine is provided that can ensure insulation quality between a coil end and an inside wall of a housing or of a case. The electric rotating machine includes a stator including a stator core and a stator winding. The stator core has a plurality of slots rowed in a circumferential direction. The stator winding is formed of a conductor rectangular in a cross section and is inserted into the slots, the conductor being provided with an insulating coated layer. The stator winding has a first segment transition bent section provided on a radially outside of the stator and a second segment transition bent section provided on a radially inside of the stator. The first segment transition bent section has a layer-transition bent section angle greater than a layer-transition bent section angle of the second segment transition bent section.
    Type: Application
    Filed: January 15, 2013
    Publication date: January 15, 2015
    Inventors: Tomoaki Kaimori, Yoshimi Mori, Takahiro Ohmori, Kenichi Nakayama
  • Patent number: 8918986
    Abstract: A method (20) is described for making a stator (1) of an electric machine, the stator comprising a stator core (2), the stator core comprising a main body and a plurality of slots (8) which are axially extended inside the main body and are adapted to receive bar conductors. (5, 5?, 5?) of a bar stator winding. The method (20) comprises the steps of : inserting (23) at least one preshaped insulating sheet (10) inside at least one of said slots (8); hot shaping (26) said preshaped insulating sheet (10) inside the slot, along the entire axial extension of the slot (8) or along a substantial portion thereof, in order to confer form regularity and stability to said preshaped insulating sheet (10). Through the described process, it is possible to make stators with bar winding having a stator core with relatively high height and slot fill factor.
    Type: Grant
    Filed: March 3, 2010
    Date of Patent: December 30, 2014
    Assignee: Tecnomatic S.p.A.
    Inventor: Sante Guercioni
  • Patent number: 8907540
    Abstract: A stator assembly for an electric machine including a stator core supporting a plurality of electrical conductors. A plurality of elongated insulator spacers is interwoven between the conductors proximate connection ends thereof in axially spaced relation to the stator core.
    Type: Grant
    Filed: November 18, 2011
    Date of Patent: December 9, 2014
    Assignee: REMY Technologies, L.L.C.
    Inventors: Colin Hamer, Bradley D. Chamberlin, Cary Ramey
  • Publication number: 20140346915
    Abstract: A rotating electrical machine includes a stator and a rotor. The stator winding includes a plurality of conductor segments inserted through the slots from one end surface of the stator core with end portions of the conductor segments projecting out beyond another end surface of the stator core. The conductor segments include an undeformed portion, a plastically deformed portion formed at the end portions thereof and a tapered portion. The plastically deformed portion has a dimension of the plastically deformed portion along a circumferential direction that is greater than a dimension of the undeformed portion along the circumferential direction and so that a dimension of the plastically deformed portion along a radial direction is smaller than a dimension of the undeformed portion along the radial direction. The conductor segments are welded together at tops of the plastically deformed portions thereof.
    Type: Application
    Filed: December 13, 2012
    Publication date: November 27, 2014
    Inventors: Takashi Ishigami, Yutaka Matsunobu, Yoshimi Mori
  • Patent number: RE46265
    Abstract: Each pair of coils mutually connected in a stator winding is arranged in a fashion that a first coil of each pair of coils has an inner-circumferential-side coil terminal (212) led out from an inner-circumferential-side slot position in the direction of a coil end (220) of the stator winding, and that a second coil of each pair of coils has an outer-circumferential-side coil terminal (211) led out from an outer-circumferential-side slot position in the direction of the coil end (220) of the stator winding for connection to the inner-circumferential-side coil terminal (212), wherein there is provided a coil terminal connection structure in which the inner-circumferential-side coil terminal (212) is connected to the outer-circumferential-side coil terminal (211) across the coil end (220), and joint parts (211a, 212a) thereof are bent close to the coil end (220).
    Type: Grant
    Filed: October 4, 2013
    Date of Patent: January 3, 2017
    Assignee: Hitachi, Ltd.
    Inventors: Yuichiro Tanaka, Takashi Ishigami, Kenichi Nakayama, Yasuyuki Saito