Yasa Limited

Andrew Court

Charles Edmund King

Jon Barker

Timothy Woolmer

Jonathan James Biddulph

Christopher Thomas McCaw

Mark Stephen Ewart East

Tim Woolmer

Timothy James Thursby Woolmer

Mark East

Sophie Ann Parker

A double-rotor single stator axial flux machine, which is supplied having no bearings between the rotors and stator internal of the machine, is mounted to an external structure such as an interface of an engine of a vehicle or a portion of the transmission of a vehicle. The machine is mounted to the structure via the shaft of the machine (on which are seated bearings located in the structure) and the stator housing. The bearings of the structure, which are external to the machine, permit the rotors to rotate relative to the stator when the machine is installed on the structure.

Axial flux machine

We describe a method of manufacturing a stator of an axial flux permanent magnet machine, the machine having a stator comprising a stator housing defining a chamber comprising a set of coils wound on respective stator bars and disposed circumferentially at intervals about an axis of the machine, and a rotor bearing a set of permanent magnets and mounted for rotation about said axis, and wherein said rotor and stator are spaced apart along said axis to define a gap therebetween in which magnetic flux in the machine is generally in an axial direction, the method comprising: providing first and second radial walls for said stator housing; providing inner and outer side walls for said stator housing; assembling said first and second radial walls and said inner and outer side walls around said set of coils to form a stator assembly, wherein said assembling further comprises: providing one or more collapsible elements between said side walls and one or both of said first and second radial walls; and attaching said side walls to said first and second radial walls, wherein said attaching comprises controlling one or both of a spacing and a degree of parallelism of said first and second radial walls by controlling the collapse of said one or more collapsible elements.

Axial flux machine manufacture

We describe a method of manufacturing a housing for the stator of an axial flux permanent magnet machine, the machine having a stator comprising a set of coils wound on respective stator bars and disposed circumferentially at intervals about an axis of the machine, and a rotor bearing a set of permanent magnets and mounted for rotation about said axis, and wherein said rotor and stator are spaced apart along said axis to define a gap therebetween in which magnetic flux in the machine is generally in an axial direction, the method comprising: fabricating a radial wall for said stator housing to be located in said gap between said rotor and said stator by: placing a resin membrane into a mold of an injection molding machine; injection molding a set of reinforcing features onto said membrane using a thermoplastic polymer bondable when molten with said resin; and manufacturing said housing using said radial wall.

Stator-plate overmoulding

There is provided an axial flux motor comprising one or more rotating disks () and a stator () comprising a cavity () formed between walls () and containing therein more than one electro-magnetic coil assembly (). Each electro-magnetic coil assembly () comprises more than one pole piece (), each having an axially extending shank portion () and first and second radially extending end shoes () and one or more associated coils (), each of the one or more associated coils () being wound around a shank portion (), wherein said outer surface () of said end shoes are preferably joined to one or other of said walls (). One or both of said first or second shoes further comprise a heat exchange surface () facing a coil () wound around the shank () such as to define first cooling channels () between one or both of said heat exchange surface () and said coil (), and a second flow channel () defined by the spacing of said coil () and adjacent coils ().

Pole shoe cooling gap for axial motor

Growing community of inventors

Bicester, United Kingdom

Andrew Court