System for an electrical motor with a segmented rotor and a segmented stator

Patent metadata

Field	Value
Publication number	US-12374951-B2
Application number	US-202418949800-A
Country	US
Kind code	B2
Filing date	Nov 15, 2024
Priority date	Aug 26, 2019
Publication date	Jul 29, 2025
Grant date	Jul 29, 2025

Abstract

A system includes: a segmented stator assembly; a set of windings; and a rotor. The segmented stator assembly includes a set of pole pieces arranged radially about an axis. Each pole piece defines: a rim extending about a periphery of the pole piece; a recess arranged on a first side of the pole piece; and a shoulder arranged on a second side, opposite the first side, of the pole piece. Each pair of adjacent pole pieces, in the segmented stator assembly, defines a pair of linearly-offset and angularly-offset rims that cooperate to define a tapered annular interstice in a radial array of tapered annular interstices. Each winding is arranged about a tapered annular interstice in the radial array of tapered annular interstices. The rotor: encompasses the segmented stator assembly; and includes magnetic elements configured to magnetically couple to the set of windings to rotate the rotor about the axis.

First claim

We claim:

1. A system comprising:
a segmented stator assembly comprising a set of pole pieces arranged radially about a motor axis:
each pole piece in the set of pole pieces defining:
a rim extending about a periphery of the pole piece;
a recess arranged on a first side of the pole piece; and
a shoulder arranged on a second side, opposite the first side, of the pole piece; and

each pair of adjacent pole pieces, in the segmented stator assembly, defining a pair of linearly-offset and angularly-offset rims that cooperate to define a tapered annular interstice in a radial array of tapered annular interstices;

a set of windings, each winding in the set of windings arranged about a tapered annular interstice in the radial array of tapered annular interstices; and
a rotor:
encompassing the segmented stator assembly; and
comprising a set of magnetic elements configured to magnetically couple to the set of windings to rotate the rotor about the motor axis.

2. The system of claim 1 :
wherein each pair of adjacent pole pieces, in the segmented stator assembly, further defines a shoulder interposed between a pair of linearly-offset and angularly-offset rims that cooperate to define a splayed H-bridge structure in a radial array of splayed H-bridge structures; and
wherein each winding in the set of windings is wound about a shoulder of a splayed H-bridge structure, in the radial array of H-bridge structures, to locate the winding within a tapered annular interstice in the radial array of tapered annular interstices.

3. The system of claim 1 , wherein each pair of adjacent pole pieces, in the segmented stator assembly, comprises:
a first pole piece defining:
a first rim extending about a periphery of the first pole piece; and
a first tapered mating recess arranged on a first side of the first pole piece; and

a second pole piece defining:
a second rim extending about a periphery of the second pole piece; and
a second rectilinear shoulder:
arranged on a second side of the second pole piece, the second side facing the first side of the first pole piece; and
configured to insert within the first tapered mating recess to:

locate the second rim linearly-offset and angularly-offset from the first rim; and
form a tapered annular interstice, in the radial array of tapered annular interstices, between the second rim and the first rim.

4. The system of claim 1 , wherein each pair of adjacent pole pieces, in the segmented stator assembly, comprises:
a first pole piece defining:
a first rim extending about a periphery of the first pole piece; and
a first rectilinear mating recess arranged on a first side of the pole piece; and

a second pole piece defining:
a second rim extending about a periphery of the second pole piece; and
a second tapered shoulder:
arranged on a second side of the second pole piece, the second side facing the first side of the first pole piece; and
configured to insert within the first rectilinear mating recess to:
locate the second rim linearly-offset and angularly-offset from the first rim; and
form a tapered annular interstice, in the radial array of tapered annular interstices, between the second rim and the first rim.

5. The system of claim 1 :
wherein each pole piece in the set of pole pieces further defines a retention feature arranged on the rim extending about the periphery of the pole piece; and
further comprising a retention ring:
arranged coaxial with the motor axis;
nested within an inner radial of the segmented stator assembly; and
defining a set of grooves:
arranged about a periphery of the retention ring; and
configured to mate with retention features of the set of pole pieces to retain the set of pole pieces radially about the motor axis.

6. The system of claim 5 :
wherein the retention ring further defines a bore coaxial with the motor axis; and
further comprising a shaft:
extending through a journal of the retention ring;
coupled to the rotor; and
configured to rotate about the motor axis during magnetic coupling between the set of magnetic elements and the set of windings.

7. The system of claim 1 :
wherein the set of pole pieces define a set of linearly-offset and angularly-offset grooves that cooperate to define a radial channel about an outer radial of the segmented stator assembly; and
further comprising a retention filament:
wound about the radial channel; and
configured to compress the set of pole pieces to maintain the set of pole pieces radially about the motor axis.

8. The system of claim 1 , further comprising a filament:
wound about an outer radial side of the segmented stator assembly to compress the set of pole pieces about the motor axis;
extending across a height of the segmented stator assembly; and
comprising a coating configured to electrically insulate the set of windings from the set of magnetic elements during rotation of the rotor about the segmented stator assembly.

9. The system of claim 1 :
wherein the rotor further comprises:
an inner rotor core:
nested within an inner radial of the segmented stator assembly;
defining a set of inner radial slots arranged about the inner rotor core; and
comprising a subset of inner radial magnetic elements, in the set of magnetic elements, adjacent the set of inner radial slots; and

a first outer plate:
arranged across a first axial side of the segmented stator assembly;
defining a first set of axial slots arranged about the first outer plate; and
comprising a first subset of axial magnetic elements, in the set of magnetic elements, adjacent the first set of axial slots; and

further comprising a shaft:
coupled to the inner rotor core;
coaxial with the motor axis; and
configured to rotate about the motor axis during magnetic coupling between the set of magnetic elements and the set of windings.

10. The system of claim 9 , wherein the rotor further comprises:
an outer rotor wall:
encompassing an outer radial of the segmented stator assembly;
defining a set of outer radial slots arranged about the outer rotor wall; and
comprising a subset of outer radial magnetic elements, in the set of magnetic elements, adjacent the set of outer radial slots; and

a second outer plate:
arranged across a second axial side, opposite the first axial side, of the segmented stator assembly;
defining a second set of axial slots arranged about the second outer plate;
comprising a second subset of axial magnetic elements, in the set of magnetic elements, adjacent the second set of axial slots; and
cooperating with the outer rotor wall, the first outer plate, and the inner rotor core to encompass the set of magnetic elements radially about the segmented stator assembly.

Assignees

• Linear Labs Inc

Inventors

• Hunstable Fred Eugene
• Aguirre Cessar
• Hatch Erik

Classifications

• H02K3/04

  Windings characterised by the conductor shape, form or construction, e.g. with bar conductors · CPC title

• H02K21/14

  with magnets rotating within the armatures · CPC title

• H02K1/30

  using intermediate parts, e.g. spiders · CPC title

• H02K1/278

  Surface mounted magnets; Inset magnets · CPC title

• H02K5/225

  Terminal boxes or connection arrangements (specially adapted for submersible motors H02K5/132) · CPC title