Emerson Electric Company

Nidec Motor Corporation

Jason J Jurkowski

Paul G Michaels

Mark E Carrier

Weirong Wang

John Scott Rose

J Scott Rose

Donald R Shaw

William Wang

Chetan O Modi

Brian P Fogarty

An example end cap of a stator segment is provided for use in locating wires in a segmented stator assembly in desired positions. The end cap generally includes a body and an inboard wall. An identifier is defined by the inboard wall of the end cap for use in determining wire sizes to be used with the end cap. Terminal pockets are provided in the body for receiving the wires and making desired electrical connections, and steps located in the terminal pockets help secure the connectors in the terminal pockets. Plateaus, and troughs defined in the plateaus, are located outside the terminal pockets for use in trimming wires received in the terminal pockets as desired. And, retaining structures are located around the end cap to help with locating the wires in the desired positions.

End caps for stator segments of segmented stator assemblies

Segmented stator assemblies having a plurality of stator segments and a plurality of end caps are disclosed. According to one example embodiment, a segmented stator assembly includes a plurality of stator segments and a plurality of end caps. Each stator segment has a yoke portion and a tooth portion extending from the yoke portion. Each end cap is positioned over one of the stator segments. Each end cap includes a body portion positioned at least partially over the yoke portion of its associated stator segment. At least one of the body portions includes at least a first post that cooperates with a post of an adjacent end cap to define a first wire management tie-down. The stator assembly further includes a stator wire coupled to the first wire management tie-down. Stator assemblies and end caps having other wire management and routing features are also disclosed.

Segmented stator assemblies having end caps

An electromagnetic machine has a rotor and a stator core. The stator core has a plurality of radially-extending teeth and a plurality of bridges having opposite ends secured to corresponding teeth. Stator windings are positioned at least partially in slots between the teeth. Each of the bridges is in a compressed configuration and includes a midsection radially offset from the ends. In a method of making an electromagnetic machine, stator windings are wound around the teeth of the stator core while the stator core is in an expanded configuration in which each of the slots is relatively wider and the configuration of the stator core is changed after winding, for example by compressing or otherwise deforming the bridges, to a compressed configuration in which each of the slots is relatively narrower. The bridges hold the teeth in the expanded configuration facilitating high slot fill without using a segmented stator.

Full round stator assembly and electromagnetic machine having high slot fill

Lead end cap for a stator segment of a segmented stator assembly

A stator for an electromagnetic machine includes a plurality of discrete and individually wound stator segments having end caps positioned on the segments. The end caps have legs for positioning the end cap on the segments with an interference fit. The end caps have angled surfaces to facilitate winding of wire on the segments. The end caps have male and female couplings that mate together to couple adjacent segments together. The end caps have fingers and slots for aligning the segments on substantially the same plane. The end caps have wire isolation features, including hooks, shelves and ledges, for separating the interconnect wires routed on the stator to electrically interconnect the segments. The segments include scalloped contours on their outer edges for draining oil, and the end caps have passages for draining oil.

End cap for segmented stator

A method of stitching a plurality of interconnect wires on a stator of an electromagnetic machine is disclosed. The stator includes a plurality of discrete and individually wound stator segments having end caps positioned on the segments. The end caps have wire isolation features, including hooks, shelves and ledges, for separating the interconnect wires routed on the stator to electrically interconnect the segments. The method includes routing the interconnect wires between portions of the stator such that portions of the interconnect wires overlap and separating the overlapping portions in an axial direction with the wire isolation elements.

Methods of stitching interconnecting wires on a stator to reduce phase-on-phase conditions

Lead end cap for segmented stator

Base end cap for a segmented stator

End cap for interconnecting winding coils of a segmented stator to reduce phase-on-phase conditions and associated methods

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St. Peters, MO, United States of America

Jason J Jurkowski