Electric machine, tuned winding geometry and technology and related methods

Abstract

An example method of producing an electric machine is described herein. The method can include providing the electric machine. The electric machine can include a rotor and a stator, where the stator includes a magnetic core and a stator winding. Additionally, the magnetic core can include a plurality of teeth defining a plurality of slots between adjacent teeth. The stator winding can also include a first portion arranged inside a slot and a second portion arranged outside the slot. The method can further include optimizing, using a computing device, a geometry of the first portion of the stator winding, where the first portion of the stator winding in the provided electric machine has the optimized geometry.

What is claimed: 
     
         1 . An electric machine, comprising:
 a rotor; and   a stator comprising:   a magnetic core that comprises a plurality of teeth defining a plurality of slots between adjacent teeth; and   a stator winding that comprises a plurality of first portions arranged inside the plurality of slots and a plurality of second portions arranged outside of the plurality of slots between the adjacent teeth,   wherein each first portion of the plurality of first portions has a first length and a first cross-sectional area optimized for a frequency of an alternating current power supply that reduces resistive power loss in the stator winding when energized by the alternating current power supply; and   wherein each second portion of the plurality of second portions has a second length and cross-sectional area, different than the first cross-sectional area, optimized for magnetic flux in the stator.   
     
     
         2 . The electric machine of  claim 1 , wherein each of the first portions comprise a bar that extend past a first face of the magnetic core and past a second face of the magnetic core, opposite to the first face, wherein each slot of the plurality of slots extends from the first face to the second face. 
     
     
         3 . The electric machine of  claim 1 , wherein each second portion of the plurality of second portions comprise a first frontal part connected to a first first portion of the plurality of first portions disposed in a first slot of the plurality of slots and a second frontal part connected to a second first portion of the plurality of first portions disposed in a second slot of the plurality of slots, wherein the first frontal part is connected to the second frontal part at a given angle. 
     
     
         4 . The electric machine of  claim 1 , wherein each second portion defines a v-shape pointed inward to an axis of rotation of the magnetic core. 
     
     
         5 . The electric machine of  claim 1 , wherein the plurality of first portions include a plurality of layers in each slot, each layer of the plurality of layers having a different size such that inner layers of the plurality of layers are thicker compared to outer layers of the plurality of layers. 
     
     
         6 . The electric machine of  claim 1 , wherein a first layer thickness of each first portion of the plurality of first portions is greater than a second layer thickness of each second portion of the plurality of second portions. 
     
     
         7 . The electric machine of  claim 1 , further comprising:
 a motor structure; and   a nonmagnetic support, wherein the nonmagnetic support connects the motor structure to the magnetic core, and wherein the non-magnetic support is mounted to the magnetic core with an insulated coupler.   
     
     
         8 . An electric machine, comprising:
 a rotor; and   a stator comprising:
 a magnetic core that comprises a plurality of teeth defining a plurality of slots between adjacent teeth; and 
 a stator winding that comprises a plurality of first portions arranged inside the plurality of slots and a plurality of second portions arranged outside of the plurality of slots between the adjacent teeth, 
 wherein each first portion of the plurality of first portions comprises a bar that has a first thickness and a first cross-sectional area; and 
 wherein each second portion of the plurality of second portions comprises a first frontal part connected to a first bar of the plurality of first portions and to a second frontal part, wherein each frontal part has a second thickness that is less than the first thickness and a second cross-sectional area that is greater than the first cross-sectional area. 
   
     
     
         9 . The electric machine of  claim 8 , wherein the first thickness and first cross-sectional area, and a length the bar is optimized based on a frequency of an alternating current power source used to energize the stator winding. 
     
     
         10 . The electric machine of  claim 8 , wherein the second thickness and the second cross-sectional area are optimized based on magnetic flux fields produced when the stator winding is energized. 
     
     
         11 . The electric machine of  claim 8 , wherein the first bar includes a third frontal part defined on an opposite end from which the first bar is connected to the first frontal part, wherein the third frontal part extends from the first bar in a different direction than the first frontal part extends from the first bar. 
     
     
         12 . The electric machine of  claim 8 , wherein the a length of the first bar from the a end to a second end is configured to position the first frontal part and the second frontal part outside of a slot defined between adjacent teeth of a stator core in which the first bar is disposed. 
     
     
         13 . The electric machine of  claim 8 , wherein the first frontal part is connected to the second frontal part by one of:
 welding;   brazing;   soldering;   casting; and   riveting.   
     
     
         14 . A stator winding bobbin included in a plurality of bobbins that form a stator winding, the stator winding bobbin comprising:
 a first bar and a second bar, each having a first thickness and a first cross-sectional area, wherein the first bar includes a first end and a second end and the second bar includes a third end aligned with the first end and a fourth end aligned with the second end; and   a first frontal part, a second frontal part, a third frontal part, and a fourth frontal part, each having a second thickness that is less than the first thickness and a second cross-sectional area that is greater than the first cross-sectional area;   wherein:   the first frontal part includes a first side connected at a first angle to the first end of the first bar;
 the second frontal part includes a second side connected at a second angle to the second end of the first bar; 
   the third frontal part includes a third side connected to the third end of the second bar at a third angle;   the fourth frontal part includes a fourth side connected at a fourth angle to the fourth end of the second bar; and   the third frontal part is connected to the first frontal part at a fifth angle via shoes defined on sides opposite to the first side and the third side.   
     
     
         15 . The stator winding bobbin of  claim 14 , wherein a length of the first bar from the first end to the second end is tuned to a frequency of an alternating current power source to minimize losses through the stator winding when energized by the alternating current power source. 
     
     
         16 . The stator winding bobbin of  claim 14 , wherein the a length of the first bar from the first end to the second end is configured to position the first frontal part and the second frontal part outside of a slot defined between adjacent teeth of a stator core in which the first bar is disposed. 
     
     
         17 . The stator winding bobbin of  claim 14 , wherein the second thickness is less than a penetration depth of a current carried by the stator winding bobbin. 
     
     
         18 . The stator winding bobbin of  claim 14 , wherein the second cross-sectional area is between 4 and 6 times greater than the first cross-sectional area. 
     
     
         19 . The stator winding bobbin of  claim 14 , wherein:
 the first bar, first frontal part, and second frontal part are constructed from a first stamping from a metal sheet;   the second bar, third frontal part, and fourth frontal part are constructed from a second stamping from the metal sheet; and   the shoes are connected by at least one of:
 welding; 
 brazing 
 soldering; 
 casting; and 
 riveting. 
   
     
     
         20 . The stator winding bobbin of  claim 14 , wherein:
 the first angle, the second angle, the third angle, and the fourth angle have equal magnitude;   the first angle and the fourth angle are equal; and   the second angle and the third angle are equal.