Reliance Electric Technologies, LLC

Grayson W Lambert, Jr

Sidney Bell

Jerry L Martin

Barron D Grant

Thomas S Evon

Thomas S Cufr

A technique is provided for manufacturing a stator of an electrical machine, such as a motor. The stator is formed by using thin end plates or laminations that are attached to each other by rods around a group of laminations. The end plates maintain pressure on the laminations. Within the laminations, slots extend thru the length of the stator. A slot liner is placed within each slot as an insulating layer between coils and the laminations. Furthermore, an insulating end piece or lamination is positioned within each end plate and adjacent to the laminations to provide support to the slot liners that extend beyond the laminations. The insulating end lamination supports the slot liners during the winding processes to prevent the slot liners from damage. In addition to providing support, the insulating end lamination is able to provide extra insulation between the coils, laminations, and the end plate. Moreover, by having thin end plates, the motor may be wound by automated processes to reduce the cost of manufacture.

Electric apparatus having a stator with insulated end laminations within the central opening of end plates

A technique for forming stator coils for an electric motor is disclosed. The technique includes forming D-shaped or generally trapezoidal coils having a closed loop defining a long side and a short side joined by end portions. The coils are installed in a stator core having a plurality of slots formed around its inner periphery. The long sides of the coils are disposed in a predetermined position within these slots, such as in a lower position, while the short sides are disposed in opposite positions, such as in upper positions. The long sides extend beyond the short sides at end regions of the stator core. The end portions of each coil wrap around the ends of the stator core and incline from the long side of the respective coil to the short side thereof. Crossing points are established between the long side of each coil and end portions of adjacent coils. The crossing points are located in predetermined positions and the coils may be taped to insulate the long sides from the end portions at the locations of the crossing points. The physical spacing of the end portions owing to the trapezoidal shape of the coils reduces potential difference gradients between the coils, reducing the risk of corona breakdown in inverter drive applications and the like.

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Gainesville, GA, United States of America

Grayson W Lambert, Jr