Electric machine system

Patent metadata

Field	Value
Publication number	US-2021226484-A1
Application number	US-202117222932-A
Country	US
Kind code	A1
Filing date	Apr 5, 2021
Priority date	Oct 29, 2015
Publication date	Jul 22, 2021
Grant date	—

Abstract

A system includes a stator core, which includes a plurality of teeth and a plurality of bridges. The plurality of teeth are disposed about an axis of the stator core, wherein each tooth of the plurality of teeth extends in a radial direction from a proximal end to a distal end. Each bridge of the plurality of bridges is disposed between two adjacent teeth and connects the proximal ends of the two teeth. The plurality of teeth and the plurality of bridges define a plurality slots, each having a proximal end and a distal end, wherein the proximal end of each slot is closed and the distal end of each slot is open.

First claim

What is claimed is:

1 . A method of manufacturing an electric machine stator comprising the steps of:
providing a stator core, the stator core comprising a plurality of teeth disposed about an axis of the stator core, each tooth of the plurality of teeth extending in a radial direction from a proximal end to a distal end, and a plurality of bridges, wherein each bridge of the plurality of bridges is disposed between two adjacent teeth and connects the proximal ends of the two teeth, wherein the plurality of teeth and the plurality of bridges define a plurality slots; inserting a first winding into a first slot of the plurality of slots; and coupling a first magnetic keystone to the stator core to block removal of the first winding.

2 . The method of claim 1 , further comprising the steps of:
inserting a plurality of successive windings into respective slots of the plurality of slots; and coupling respective magnetic keystones to the stator core to block removal of the plurality of windings.

3 . The method of claim 1 , further comprising the step of installing the stator core into a stator housing.

4 . The method of claim 1 , wherein the step of inserting the first winding into the first slot of the plurality of slots further comprises radially inserting the first winding into the first slot of the plurality of slots.

5 . A method for manufacturing an electric motor, the method comprising the steps of:
providing a stator core that includes a plurality of open slots, wherein the stator core has a plurality of teeth disposed about an axis of the stator core, each tooth of the plurality of teeth extending in a radial direction from a proximal end to a distal end, and a plurality of bridges, wherein each bridge of the plurality of bridges is disposed between two adjacent teeth of the plurality of teeth to connect the proximal ends of the two adjacent teeth to form a corresponding one of the plurality of open slots; providing a plurality of windings; radially inserting each of the plurality of windings into a corresponding one of the plurality of open slots; and inserting a magnetic keystone over each of the plurality of windings to enclose each of the plurality of windings in a corresponding one of the plurality of open slots.

6 . The method of claim 5 , wherein the step of providing a plurality of windings comprises providing a plurality of pre-formed unitary windings.

7 . The method of claim 5 , wherein the step of providing a plurality of windings comprises providing a plurality of windings wherein each of the plurality of windings comprises a collection of individual magnetic coils.

8 . The method of claim 5 , wherein the step of providing a plurality of windings further comprises connecting two or more of the plurality of windings to form connected groups of windings.

9 . The method of claim 8 , wherein the step of radially inserting each of the plurality of windings into a corresponding one of the plurality of open slots comprises inserting a connected group of windings into a corresponding set of the plurality of the open slots.

10 . The method of claim 8 , wherein the step of connecting two or more of the plurality of windings to form connected groups of windings comprises the step of joining each of the plurality of windings on one end to place the connected groups of windings in a series configuration.

11 . The method of claim 8 , wherein the step of connecting two or more of the plurality of windings to form connected groups of windings comprises the step of joining each of the plurality of windings on one both ends to place the connected groups of windings in a parallel configuration.

12 . The method of claim 5 , wherein the step of inserting a magnetic keystone over each of the plurality of windings further comprises snapping the magnetic keystone into place within the teeth.

13 . A method for manufacturing an electric motor, the method comprising the steps of:
providing a stator core that includes a plurality of open slots formed between two adjacent teeth that extend radially outward from a common bridge; temporarily mounting the stator on a rotatable shaft; providing a plurality of windings; radially inserting one of the plurality of windings into a corresponding one of the plurality of open slots; inserting a magnetic keystone over the winding to enclose the winding; rotating the stator core on the rotatable shaft to reveal one of the remaining open slots; repeating the steps of radially inserting and enclosing one of the plurality of windings into a corresponding one of the plurality of open slots; and removing the stator core from the rotatable shaft when each one of the plurality of open slots contains a corresponding winding enclosed by a magnetic keystone.

14 . The method of claim 13 , further comprising the step placing a cover over the stator core before the step of radially inserting the first of the plurality of windings into a corresponding one of the plurality of open slots.

15 . The method of claim 13 , further comprising the step of applying one or more clamps around the stator core before the stator core is removed from the rotatable shaft.

16 . The method of claim 15 , further comprising the steps of:
inserting the stator core into a motor housing; and removing the one or more clamps from the stator core.

17 . The method of claim 13 , wherein the step of providing a plurality of windings comprises providing a plurality of pre-formed unitary windings.

18 . The method of claim 13 , wherein the step of providing a plurality of windings comprises providing a plurality of windings wherein each of the plurality of windings comprises a collection of individual magnetic coils.

19 . The method of claim 13 , wherein the step of providing a plurality of windings further comprises connecting two or more of the plurality of windings to form connected groups of windings.

20 . The method of claim 19 , wherein the step of radially inserting each of the plurality of windings into a corresponding one of the plurality of open slots comprises inserting a connected group of windings into a corresponding set of the plurality of the open slots.

Assignees

• Baker Hughes Oilfield Operations Llc

Inventors

• Torrey David Allan
• Van Dam Jeremy Daniel
• Yin Weijun
• Reddy Patel Bhageerath
• Hughes Michael Franklin
• Zierer Joseph John

Classifications

• H02K15/066

  inserted perpendicularly to the axis of the slots or inter-polar channels · CPC title

• H02K1/148

  Sectional cores (H02K1/141 takes precedence) · CPC title

• H02K15/085

  by laying conductors into slotted stators · CPC title

• H02K3/48

  in slots · CPC title

• H02K15/02

  of stator or rotor bodies · CPC title