Magnetic core for an electric motor

Patent metadata

Field	Value
Publication number	US-2016352159-A1
Application number	US-201615167664-A
Country	US
Kind code	A1
Filing date	May 27, 2016
Priority date	May 27, 2015
Publication date	Dec 1, 2016
Grant date	—

Abstract

A magnetic core for an electric motor has a ring-shaped yoke, teeth extending outwardly from the yoke, and a tooth tip extending from a distal end of each tooth. The core is formed from curved or coils strip laminations having teeth arranged in tooth groups. Each group has four tooth types arranged sequentially. Each tooth has left and right half tooth tips. The length of the half tooth tips vary according to tooth type. When assembled, first type tooth overlap with third type teeth and second type teeth overlap with fourth type teeth, whereby the opening of the winding slot is narrowed compared to laminations having all identical teeth.

First claim

1 . A magnetic core for an electric motor, comprising:
a ring-shaped yoke; teeth extending outwardly from the yoke, and a tooth tip extending from a distal end of each tooth in a circumferential direction of the core, each tooth tip having a left half tooth tip and a right half tooth tip; wherein the magnetic core has a plurality of lamination layers, each lamination layer comprising: multiple teeth having a first type tooth, a second type tooth, a third type tooth and a fourth type tooth, the left half tooth tip of the first type tooth being a short tooth tip, the right half tooth tip of the first type tooth being a long tooth tip, the left and right half tooth tips of the second type tooth being both short tooth tips, the left half tooth tip of the third type tooth being a long tooth tip, the right half tooth tip of the third type tooth being a short tooth tip, the left and right half tooth tips of the fourth type tooth being both long tooth tips; and wherein, in an axial direction of the motor, the first type tooth of at least one lamination layer overlaps with the third type tooth of another lamination layer, the second type tooth of the at least one lamination layer overlaps with the fourth type tooth of the another lamination layer, the third type tooth of the at least one lamination layer overlaps with the first type tooth of the another lamination layer, and the fourth type tooth of the at least one lamination layer overlaps with the second type tooth of the another lamination layer.

2 . The magnetic core of claim 1 , wherein each lamination layer includes an even number of teeth; the magnetic core is formed by stacking multiple layers of first core laminations and multiple layers of second core laminations and, in the motor axial direction, the first type tooth, second type tooth, the third type tooth and fourth type tooth of the first core lamination overlap with the third type tooth, fourth type tooth, first type tooth, and second type tooth of the second core lamination, respectively.

3 . The magnetic core of claim 1 , wherein the first type tooth, second type tooth, the third type tooth and fourth type tooth form one tooth group, the magnetic core includes two types of lamination layers, a first type of core lamination is formed by cutting off a first half of a first tooth group from a core lamination having sequentially arranged k+1 tooth groups, and a second type of core lamination is formed by cutting off a second half of a last tooth group from a core lamination having sequentially arranged 1 tooth groups, where k is an integer greater than zero; the first type of core lamination and the second type of core lamination are alternately arranged.

4 . The magnetic core of claim 3 , wherein each tooth group satisfies one of the following conditions:
(a) each tooth group includes multiple first type teeth, one second type tooth, multiple third type teeth and one fourth type tooth that are sequentially arranged, wherein the number of the first type teeth is the same as the number of the third type teeth; (b) each tooth group includes one second type tooth, multiple third type teeth, one fourth type tooth, and multiple first type teeth that are sequentially arranged, wherein the number of the first type teeth is the same as the number of the third type teeth; (c) each tooth group includes multiple third type teeth, one fourth type tooth, multiple first type teeth, and one second type tooth that are sequentially arranged, wherein the number of the first type teeth is the same as the number of the third type teeth; (d) each tooth group includes one fourth type tooth, multiple first type teeth, one second type tooth, and multiple third type teeth that are sequentially arranged, wherein the number of the first type teeth is the same as the number of the third type teeth.

5 . The magnetic core of claim 1 , wherein each lamination layer has S teeth, wherein multiple first type teeth, one second type tooth, multiple third type teeth and one fourth type tooth are sequentially arranged to form one tooth group, the number of the third type teeth is the same as the number of the first type teeth in each tooth group, and each tooth group has T teeth, with S and T satisfying the following relation: S/T=N+½, where N is a positive integer and T is an even number.

6 . The magnetic core of claim 1 , wherein a sum of the length of the right half tooth tip of the first type tooth and the length of the left half tooth tip of the second type tooth, a sum of the length of the right half tooth tip of the second type tooth and the length of the left half tooth tip of the third type tooth, a sum of the length of the right half tooth tip of the third type tooth and the length of the left half tooth tip of the fourth type tooth tip, and a sum of the length of the right half tooth tip of the fourth type tooth and the length of the left half tooth tip of the first type tooth tip are substantially the same.

7 . The magnetic core of claim 1 , wherein the magnetic core is made by spirally rolling an elongated sheet material multiple turns, with each turn forming one lamination layer of the magnetic core.

8 . The magnetic core of claim 1 , wherein each lamination layer of the magnetic core is made by bending an individual sheet material.

9 . A method for making a magnetic core for an electric motor, comprising the following steps:
step S 1 : forming a plurality of elongated sheet materials by punching, with each sheet material including a connecting portion and a plurality of teeth extending from the connecting portion, each tooth including a tooth tip extending from a distal end of the tooth to two sides thereof, the tooth tip including a left half tooth tip and a right half tooth tip; each sheet material including a plurality of groups each having a first type tooth, a second type tooth, a third type tooth and a fourth type tooth that are sequentially arranged, the left half tooth tip of the first type tooth being a short tooth tip, the right half tooth tip of the first type tooth being a long tooth tip, the left and right half tooth tips of the second type tooth are both short tooth tips, the left half tooth tip of the third type tooth being a long tooth tip, the right half tooth tip of the third type tooth being a short tooth tip, the left and right half tooth tips of the fourth type tooth being both long tooth tips; step S 3 : bending each sheet material into a ring-shaped core lamination, with the connecting portions of all sheet materials making a ring-shaped yoke and the teeth of each sheet material extending outwardly from the yoke; and step S 4 : stacking multiple layers of ring-shaped core laminations, with the first type tooth of at least one lamination layer overlapping with the third type tooth of another lamination layer, the second type tooth of the at least one lamination layer overlapping with the fourth type tooth of the another lamination layer, the third type tooth of the at least one lamination layer overlapping with the first type tooth of the another lamination layer, and the fourth type tooth of the at least one lamination layer overlapping with the second type tooth of the another lamination layer.

10 . The method of claim 9 , wherein:
at step S 1 , each lamination layer after being punched has S teeth, wherein multiple first type teeth, one second type tooth, multiple third type teeth and one fourth type tooth that are sequentially arranged to form one tooth group, and each tooth group has T teeth, with S and T satisfying the following relation: S/T=N+½, where N is a positive integer and T is an even number; and at step S 3 , the first type tooth, second type tooth, third type tooth and fourth type tooth of a fi

Assignees

• Johnson Electric Sa

Inventors

• Li Yue
• Jiang Mao Xiong
• Zhao Jian
• Wang Yong
• Li Yong
• Liao yan fei
• Ye Ying Song
• Hua Hai Jun

Classifications

• H02K1/146 Primary

  consisting of a generally annular yoke with salient poles · CPC title

• H02K15/022

  with salient poles · CPC title

• Y02P80/30

  Reducing waste in manufacturing processes; Calculations of released waste quantities · CPC title

• H02K2213/03

  Machines characterised by numerical values, ranges, mathematical expressions or similar information · CPC title

• H02K15/026

  Wound cores · CPC title