Motor and method for manufacturing the same

Abstract

The present invention relates to an electrode and a method for manufacturing the same. The electric machine may include a substantially annular stator stack having a plurality of laminations, the laminations including mounting ears. A portion of the laminations may be oriented such that the mounting ears are angularly offset from each other. The stator may be secured to the housing at two mounting ear locations, thereby increasing structural rigidity and improving performance.

Description

Background Art

[0001] Rotating electric machines are found in many industrial and product applications. Significant torsional reaction forces may be transmitted to the motor stator, requiring the stator to be adequately fixed or mechanically grounded to prevent unwanted displacements as well as harmful noise, vibration and harsh environments in certain applications. Summary of the invention

[0002] In an exemplary embodiment, an electric machine may include a substantially annular stator stack including a plurality of laminations, each lamination having a circumferential outer protrusion defining a hole. The laminations may be stacked adjacent to one another, wherein a majority of adjacent laminations have corresponding holes that are substantially aligned with one another to define a stator stack having a stator mounting boss, and a first smaller portion of adjacent laminations have corresponding holes that are substantially aligned with one another to define a first bracket stack having a first bracket mounting tab. The first bracket stack may be stacked at one end of the stator stack, and the stator mounting boss and the bracket mounting tab are angularly displaced from one another. The first bracket stack may include a total thickness between about 1.0 mm and about 4.0 mm and 3 to 20 laminations.

[0003] All of the laminations may be substantially identical except for one or more of the features described herein.

[0004] In addition to one or more features described herein, the laminations may be between about 0.2 mm and about 0.4 mm.

[0005] In addition to one or more features described herein, a majority of adjacent laminations may be welded to a first smaller portion of an adjacent lamination.

[0006] In addition to one or more features described herein, the electric machine may include a machine housing, a first threaded fastener passing through the stator mounting boss to secure a majority of adjacent laminations to the machine housing, and a second threaded fastener passing through the first bracket mounting tab to secure a first smaller portion of adjacent laminations to the machine housing.

[0007] In addition to one or more features described herein, the electric machine may include a second smaller portion of adjacent laminations stacked intermediately within the stator stack and having apertures substantially aligned with one another to define a second stack having a second bracket mounting tab, the stator mounting boss and the second bracket mounting tab being angularly offset from one another, with the first and second bracket mounting tabs being located on opposite sides of the angled stator mounting boss.

[0008] In another exemplary embodiment, an electric machine may include a machine housing and a substantially annular first stator stack, the first stator stack including a first plurality of first laminations, each first lamination including a circumferentially outer first mounting ear defining a first hole, the first laminations being stacked adjacent to each other, the first holes being substantially aligned with each other to define a stator mounting boss. The electric machine may also include a substantially annular second stator stack, the second stator stack including a second plurality of second laminations, each second lamination having a circumferentially outer second mounting ear defining a second hole, the second laminations being stacked adjacent to each other, and the second holes being substantially aligned with each other to define a first bracket mounting tab. The second stator stack may include a total thickness between about 1.0 mm and about 4.0 mm and 3 to 20 laminations. The stacked second stator stack may be adjacent to the first stator stack, wherein the stator mounting boss and the bracket mounting tab are angularly separated. The electric machine may include: a first fastener passing through the stator mounting boss to fasten the first stator stack to the machine housing; and a second fastener passing through the first bracket mounting tab to fasten the second stator stack to the machine housing.

[0009] The first and second laminates may be substantially identical except for one or more of the features described herein.

[0010] In addition to one or more features described herein, the second mounting ear of the second lamination may define a third hole, the second laminations may be stacked adjacent to each other, the third holes are substantially aligned with each other, and the second stator stack may be stacked adjacent to the first stator stack, wherein the third hole is substantially aligned with the first hole.

[0011] In addition to one or more features described herein, the electric machine may also include a third substantially annular stator stack having a third plurality of second laminations stacked adjacent to one another and the second holes substantially aligned with one another to define a second bracket mounting tab. The third stator stack may be stacked adjacent to the second stator stack opposite the first stator stack, the third holes of the third stator stack being substantially aligned with the first holes defining the first stack mounting boss, the second holes of the second and second stator stacks being located on angled opposite sides of the stator mounting boss.

[0012] In addition to one or more features described herein, the electric machine may also include a substantially annular third stator stack having a third plurality of second laminations stacked adjacent to one another, and the second holes are substantially aligned with one another to define a second bracket mounting tab. The third stator stack may be stacked intermediately within the first stator stack, the third holes of the third stator stack are substantially aligned with the first holes defining the first stack mounting boss, and the second holes of the second stator stack and the third stator stack are located on angled opposite sides of the stator mounting boss.

[0013] In addition to one or more features described herein, the electric machine may also include a substantially annular third stator stack having a third plurality of second laminations stacked adjacent to one another, and the second holes being substantially aligned with one another to define a second bracket mounting tab. The third stator stack may be stacked adjacent to the second stator stack opposite the first stator stack, with the second holes of the second stator stack and the third stator stack being located on angled opposite sides of the stator mounting boss.

[0014] In addition to one or more features described herein, all laminations may be between about 0.2 mm and about 0.4 mm.

[0015] In addition to one or more features described herein, the first stator stack may be welded to the second stator stack.

[0016] In another exemplary embodiment, a method for constructing an electric machine may include: stamping a plurality of laminations, each lamination including a circumferential outer protrusion defining a mounting hole; stacking a first portion of the plurality of laminations such that the corresponding mounting holes are substantially aligned with each other to define a stator mounting boss; and stacking a second portion of the plurality of laminations such that the corresponding mounting holes are substantially aligned with each other to define a bracket mounting tab. The second portion of the laminations may include a total thickness between about 1.0 mm and about 4.0 mm and 3 to 20 laminations. The second portion may be stacked on top of the first portion to define a stator stack, wherein the stator mounting boss and the bracket mounting tab are angularly displaced from each other. The bottom end of the stator stack may be positioned to a locating surface of a machine housing, and the stator stack is secured to the machine housing via the stator mounting boss by a fastener, and the stator stack is secured to the machine housing via the bracket mounting tab by a fastener.

[0017] In addition to one or more features described herein, the method may include welding a first portion of the stacked laminations to a second portion of the stacked laminations.

[0018] In addition to one or more features described herein, stamping the plurality of laminations may include stamping the first portion and the second portion of the same lamination.

[0019] In addition to one or more features described herein, stamping a plurality of laminations may include stamping a first lamination having a mounting ear with a single hole for a first portion of the lamination; and stamping a second lamination having a mounting ear with a pair of holes for a second portion of the lamination, wherein stamping the first and second laminations is accomplished by progressive station tooling.

[0020] In addition to one or more features described herein, stamping a plurality of laminations may include stamping a first lamination having a mounting ear with a single hole for a first portion of the lamination and stamping a second lamination having a mounting ear with a pair of holes for a second portion of the lamination, wherein stamping the first and second laminations is accomplished by a selectively actuated stamping tool.

[0021] The above features and advantages and other features and advantages of the present disclosure will be apparent from the following detailed description when considered in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Other features, advantages and details appear, by way of example only, from the following detailed description, which refers to the accompanying drawings, in which:

[0023] Figure 1 An embodiment of a stacked laminated stator of an electric machine according to the present disclosure is shown.

[0024] Figure 2 A plan view of an embodiment of a stator lamination according to the present disclosure is shown.

[0025] Figure 3 A partial view of an embodiment of a stacked laminated stator of an electric machine according to the present disclosure is shown.

[0026] Figure 4 An embodiment of a stacked laminated stator of an electric machine according to the present disclosure is shown.

[0027] Figure 5 A plan view of an embodiment of a stator lamination according to the present disclosure is shown.

[0028] Figure 6 An embodiment of a stacked laminated stator of an electric machine according to the present disclosure is shown.

[0029] Figures 7A-7C A partial plan view showing an alternative embodiment of a stator lamination and manufacturing steps according to the present disclosure is shown.

[0030] Figure 8 An embodiment of a stacked laminated stator secured to a machine housing of an electric machine is shown in accordance with the present disclosure.

[0031] Fig. 9 An embodiment of a stacked laminated stator secured to a machine housing of an electric machine is shown in accordance with the present disclosure.

[0032] Figures 10A-10C A process of assembling a stator to a machine housing according to the present disclosure is shown. DETAILED DESCRIPTION

[0033] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. Throughout the drawings, corresponding reference numerals indicate identical or corresponding parts and features.

[0034] Figure 1 An embodiment of a stacked laminated stator 100 of an electric machine according to the present disclosure is shown. Figure 2 Shows the corresponding Figure 1 A plan view of an embodiment of a stator lamination 200 of an embodiment of an embodiment of the present invention. The lamination 200 is substantially annular, having an inner radius (r) and an outer radius (R). The lamination 200 may include a plurality of spaced teeth 201 extending radially inward from a radially outer back iron 203, thereby defining a slot 202 therebetween. The outer radius (R) generally defines the outer periphery of the lamination 200 and the constructed stator 100. According to known structures and magnetic properties, the stator can preferably be constructed of low carbon, high silicon steel. The lamination 200 can preferably be produced by a stamping machine operating on a rolled steel sheet blank. The lamination 200 may include a plurality of circumferential external protrusions or mounting ears 205, which are preferably symmetrically distributed around the periphery at equal angular intervals. However, alternative or asymmetrical distributions around the periphery of the lamination and the stator are conceivable. Each mounting ear 205 has a hole or orifice 207 formed therein. As used herein, the hole may include a slot that is discontinuous to form a closed hole. As used herein, "substantially annular" means mostly but not entirely annular, wherein the laminations are primarily defined between an inner radius (r) and an outer radius (R), but may include protrusions (e.g., mounting ears 205) and material voids (e.g., slots 202 between teeth 201) beyond the outer radius (R). The thickness of the laminations 200 may vary depending on the application; however, in any given stator configuration, the lamination thickness is preferably the same. In one embodiment, a nominal lamination 200 thickness between about 0.2 mm and 0.4 mm may be preferred.

[0035] A plurality of laminations 200 may be stacked to manufacture the stator 100. According to one embodiment, the stator stack 101 may include a first plurality of laminations 200. The support stack 103 may include a second plurality of laminations 200. The stator stack 101 may include a major portion or a majority of the total laminations 200 used in the stator 100. The support stack 103 may include a smaller portion or a minority of the total laminations 200 used in the stator 100. The stator stack 101 may include a number of smaller sub-stacks 105 that allow rotational redirection of these sub-stacks to mitigate the effects of material thickness variations and tolerance stacking. The redirection of the sub-stacks may advantageously uniformize the anisotropic magnetic properties in the rolled steel used in the lamination production. The support stack 103 may be any suitable thickness for the support construction, which will advantageously provide sufficient support deflection as further described herein. The stiffness of the support stack 103 may be adjusted by increasing or decreasing the number of laminations 200. In one embodiment, the support stack 103 can be between about 1.0 mm and 4.0 mm, or between about 3 and 20 laminations 200, with a lamination thickness between about 0.2 mm and 0.4 mm. Whether or not explicitly stated, it is assumed that all numerical values ​​herein are modified by the term "about". For the purposes of this disclosure, ranges can be expressed as from "about" one particular value to "about" another particular value. The term "about" generally refers to a range of values ​​that a person skilled in the art would consider to be equivalent to the listed values, have the same function or result, or be reasonably within the manufacturing tolerance of the listed values.

[0036] The laminations 200 of the stator stack 101 can be stacked adjacent to each other, and the mounting ear holes 207 are substantially aligned with each other to define the stator mounting bosses 107. Similarly, the laminations 200 of the bracket stack 103 can be stacked adjacent to each other, and the mounting ear holes 207 are substantially aligned with each other to define the bracket mounting tabs 109. The stator stack 101 and the bracket stack 103 can be stacked adjacent to each other. The thinner bracket stack 103 can beneficially provide the flexure or deformation ability of the mounting tabs 109 without deforming the stator back iron. Each of the stator stack 101 and the bracket stack 103 can be welded to secure all corresponding laminations 200 in each stack, and can be welded to secure the stator stack 101 to the bracket stack 103.

[0037] Figure 3 FIG. 2 shows a partial view of an embodiment of a stacked lamination stator 300 of an electric machine according to the present disclosure. The stator 300 may utilize the previously described Figure 2 The stator stack 200 shown is constructed as a stack.

[0038] A plurality of laminations 200 may be stacked to make a stator 300. According to one embodiment, a stator stack 301 may include a first plurality of laminations 200. A support stack 303 may include a second plurality of laminations 200. A support stack 304 may include a third plurality of laminations 200. The stator stack 301 may include a major portion or majority of the total laminations 200 used in the stator 300. The support stacks 303, 304 may include a minor portion or minority of the total laminations used in the stator 300. The stator stack 301 may be stacked in a manner similar to that described with respect to FIG. Figure 1 The same approach described includes many smaller sub-stacks. The stent stacks 303, 304 can be any suitable thickness for stent construction, which will advantageously provide sufficient stent flexure, as further described herein. In one embodiment, the stent stack 103 can be between about 1.0 mm and 4.0 mm, or between about 3 to 20 laminations 200 having a thickness between about 0.2 mm and 0.4 mm.

[0039] The laminations 200 of the stator stack 301 can be stacked adjacent to each other with the mounting ear holes 207 substantially aligned with each other to define stator mounting bosses 307. The laminations 200 of the bracket stack 303 can be stacked adjacent to each other with the mounting ear holes 207 substantially aligned with each other to define bracket mounting tabs 309. Similarly, the laminations 200 of the bracket stack 304 can be stacked adjacent to each other with the mounting ear holes 207 substantially aligned with each other to define bracket mounting tabs 311. As shown, the stator stack 301 and the bracket stacks 303, 304 can be stacked adjacent to each other with the stator stack 301 below the bracket stacks 303, 304. The thinner bracket stacks 303, 304 can beneficially provide the ability for the mounting tabs 309 to flex or deform without significantly deforming the stator back iron. Each of the stator stack 301, the bracket stack 303, and the bracket stack 304 can be welded to secure all of the respective laminations 200 in each stack, and can be welded to secure together the stator stack 301, the bracket stack 303, and the bracket stack 304. The bracket mounting tabs 309, 311 can be angularly separated on angled opposite sides of the stator mounting boss 307.

[0040] Figure 4 An embodiment of a stacked laminated stator 600 of an electric machine according to the present disclosure is shown. Figure 2 and Figure 5 The corresponding Figure 4200 and 700 of an embodiment of the stator laminations 200 and 700. The laminations 200 and 700 are substantially annular, having respective inner radius (r) and outer radius (R). The laminations 200 and 700 include a plurality of teeth 201 and 701, respectively, extending radially inward from radially outer back irons 203 and 703, respectively. The outer radius (R) generally defines the outer periphery of the laminations 200 and 700 and the constructed stator 600. According to known structure and magnetic properties, the stator is preferably made of low carbon high silicon steel. The laminations 200 and 700 can preferably be produced by a stamping machine operating on rolled steel plate stock. The lamination 200 may include a plurality of circumferential external protrusions or mounting ears 205, which are preferably symmetrically distributed around the periphery at equal angular intervals. However, alternative or asymmetrical distributions around the periphery of the laminations and stator can be conceived. Each mounting ear 205 has a hole or hole 207 formed therein. The lamination 700 may include a plurality of peripheral external protrusions or mounting ears 705, which are preferably symmetrically distributed around the periphery at equal angular intervals. However, alternative or asymmetrical distributions around the periphery of the lamination and stator are contemplated. Each mounting ear 705 has a pair of holes or orifices 707, 708 formed therein. As used herein, the hole may include a slot that is discontinuous to form a closed hole. Each mounting ear 705 may include a side lobe 712 extending generally tangentially from the hole 708. The side lobe 712 defines the hole 708 and may include an undercut 710 to partially separate the side lobe 712 from the back iron 703, thereby allowing flexure without deforming the back iron 703. The thickness of the lamination 700 may vary depending on the application; for example, in any given support structure, the lamination thickness is preferably the same. In one embodiment, a nominal lamination 700 thickness between about 0.2 mm and 0.4 mm may be preferred.

[0041] Multiple laminations 200 and 700 may be stacked to make the stator 600. According to one embodiment, the stator stack 601 may include a first plurality of laminations 200. The bracket stack 603 may include a second plurality of laminations 700. The stator stack 601 may include a major portion or a majority of the total laminations used in the stator 600. The bracket stack 603 may include a smaller portion or a minority of the total laminations used in the stator 600. The stator lamination 601 may include a number of smaller sub-stacks 605 that allow rotational redirection of these sub-stacks to mitigate the effects of material thickness variations and tolerance stacking. The redirection of the sub-stacks may advantageously uniformize the anisotropic magnetic properties in the rolled steel used in the lamination production. The bracket stack 603 may be any suitable thickness for the bracket construction, which will advantageously provide sufficient bracket flexure, as will be further described herein. The stiffness of the bracket stack 603 may be adjusted by increasing or decreasing the number of laminations 700. In one embodiment, the bracket stack 603 can be between about 1.0 mm and 4.0 mm, or between about 3 and 20 mm of the laminate 200, with the thickness of the laminate being between about 200 mm and about 300 mm.

[0042] The laminations 200 of the stator stack 601 can be stacked adjacent to each other, and the mounting ear holes 207 are substantially aligned with each other to define the stator mounting boss 607. Similarly, the laminations 700 of the bracket stack 603 can be stacked adjacent to each other, and the mounting ear holes 707, 708 are substantially aligned with each other to define the bracket mounting tab 609. The stator stack 601 and the bracket stack 603 can be stacked adjacent to each other, wherein the hole 707 is substantially aligned with the stator mounting boss 607 and the hole 708 is generally tangentially overhanging from the stator mounting boss. The thinner bracket stack 603 can beneficially provide the flexure or deformation ability of the mounting tab 609 in the overhang area 611 without deforming the stator back iron. Each of the stator stack 601 and the bracket stack 603 can be welded to secure all of the respective laminations 200 and 700 in each stack, and can be welded to secure the stator stack 601 to the bracket stack 603.

[0043] Figure 6 An embodiment of a stacked laminated stator 800 of an electric machine according to the present disclosure is shown. Figure 2 and Figure 5 The stator laminations 200 and 700 are shown to construct a stator 800 .

[0044] Basically, as this article is relative to Figure 2 , Figure 4 and Figure 5As described, a plurality of laminations 200 and 700 may be stacked to make a stator 800. According to one embodiment, a stator stack 801 may include a first plurality of laminations 200. A bracket stack 803 may include a second plurality of laminations 700. A bracket stack 804 may include a third plurality of laminations 700. A fourth stator stack 802 may include a fourth plurality of laminations 200. Stator stacks 801, 802 may include a major portion or majority of the total laminations used in stator 800. Bracket stacks 803, 804 may include a minor portion or minority of the total laminations used in stator 800. Stator stacks 801, 802 may be stacked in a manner similar to that described with respect to Figure 4 The same manner as described includes a number of smaller sub-stacks 805. The laminations 200 of the stator stacks 801, 802 can be stacked adjacent to each other, wherein the mounting ear holes 207 are substantially aligned with each other to define stator mounting bosses 807. The bracket stacks 803, 804 can include corresponding mounting tabs 809, which include overhang areas 811. The bracket stacks 803, 804 can be any suitable thickness for bracket construction, which will advantageously provide sufficient bracket flexure, as further described herein. In one embodiment, the second and third stator stacks 803, 804 can be between about 1.0 mm and 4.0 mm, or between about 3 and 20 laminations 700, with the thickness of the laminations being between about 0.2 mm and 0.4 mm.

[0045] Figure 6 The stator 800 and Figure 6 The stator 600 of FIG. 803 differs in that the bracket stack 804 is located in the middle of the bracket stacks 801, 802. In addition, the bracket stack 804 is characterized in that its corresponding overhang area 811 is arranged on the opposite side of the stator mounting boss 807 at an angle from the corresponding overhang area 811 of the bracket stack 803. It should be understood that the bracket stacks 803, 804 can be identical except that their respective orientations within the stator stacks 801, 802 are different.

[0046] Stator stacks 200 and 700 can be manufactured on the same stamping machine or equivalent tool using a progressive die. Figures 7A-7C The first stroke or set of strokes at the first station or set of stations can punch out the larger protrusion or mounting ear 905 (including the overhang portion 903), the undercut and the two holes of the lamination 900 ( Fig. 7A ). The workpiece may be completed at this point with respect to mounting ears 905, leaving behind the dual hole mounting ears of stack 700. The workpiece may be advanced to a second station or set of stations to punch out overhang 903 (dashed lines, FIG. 7 ), leaving behind stack 200 ( Figure 7C ) of a single hole mounting ear 905. Similarly, a single stroke may produce a single hole or double hole mounting ear in the punch press, thereby being able to selectively actuate the punching tool corresponding to the overhang portion 903.

[0047] Figure 8 Shows Figure 1 Embodiments of a stacked lamination stator 100 are provided, which is secured to a machine housing 1001. The machine housing 1001 may include mounting means for the stator 100, such as feet, posts, bosses, etc. The machine housing 1001 may include short posts 1010 for directly interfacing with the bottom of the stator mounting boss 107. The short posts 1010 may provide a close tolerance locating surface for the bottom of the stator 100. An alternative surface may provide a stator location for the housing 1001. The posts 1010 may include internal threads for receiving bolts 1012 through the stator mounting boss 107. In addition to alternatives to posts that provide a locating surface for the bottom of the stator, alternatives to posts may also provide internal threads for receiving bolts 1012. Bolts 1012 may be tightened to secure the stator to the machine housing, with the bottom of the stator positively located to the housing 1001 at the short posts 1010 or alternative locating surfaces. The major portion of the total laminations that make up the stator stack 101 provides the relative inflexibility of the stator mounting bosses 107 and the primary mechanical coupling of the stator 100 to the housing 1001. The machine housing 1001 may include long posts or risers 1016 or an alternative to secure the bracket mounting tabs 109 to the housing 1001. The long posts 1016 or an alternative surface for securing the bracket mounting tabs 109 to the housing 1001 may provide a non-interfering surface as opposed to the short posts or an alternative locating surface for the bottom of the stator. In other words, since the bottom of the stator 100 is positioned onto the short posts 1010 or an alternative locating surface and the stator 100 is secured to the housing 1001 by bolts 1012, the bracket mounting tabs 109 preferably do not contact the long posts 1016 or an alternative surface for securing the bracket mounting tabs 109 to the housing 1001. The initial degree of freedom from interference between the short posts or alternatives and the bracket mounting tabs 109 is referred to herein as Figures 10A-10CDetailed description is given. The support 1016 may include internal threads for receiving the bolt 1014 through the mounting tab 109. In addition to the alternative form of the support that provides an attachment surface for the mounting tab 109, the alternative form of the support may also provide internal threads for receiving the bolt 1014. The bolt 1014 may be tightened to attach the stator top to the machine housing at the mounting tab 109, thereby strengthening the stator against torsional displacement of the top overhanging end mainly due to reaction forces during machine operation. Advantageously, the small portion of the total laminations that make up the support stack 103 provides a relative flexibility of the mounting tab 109, thereby enabling the support stack 103 to be mechanically firmly coupled to the housing 1001 without causing undesirable deformation of the support stack 103. Advantageously, the relative flexibility of the mounting tab 109 enables the stator 100 to be effectively assembled to the positioning surface without interference even in the event that the mounting tab 109 actually interferes with the attachment surface. The design capability of the mounting tabs 109 to deform without causing undesirable deformation of the bracket stack 103 is advantageous. Therefore, it should be understood that the mounting tabs 109 enable the stator 100 to be attached to the housing in two planes, and the locating surface of the housing 1001 at the bottom of the stator 100 has a single plane critical tolerance.

[0048] Fig. 9 Shows Figure 4Embodiments of stacked lamination stators 600 are provided, which are fixed to a machine housing 1101. The machine housing 1101 may include mounting means for the stator 600, such as feet, posts, bosses, etc. The machine housing 1101 may include short posts 1110 for directly docking with the bottom of the stator mounting boss 607. The short posts 1110 may provide a close tolerance locating surface for the bottom of the stator 600. An alternative surface may provide a stator location for the housing 1101. The posts 1110 may include internal threads for receiving bolts 1112 passing through the stator mounting boss 607. In addition to alternatives to posts that provide a locating surface for the bottom of the stator, alternatives to posts may also provide internal threads for receiving bolts 1112. Bolts 1112 may be tightened to secure the stator to the machine housing, while the bottom of the stator is positively located to the housing 1101 at the short posts 1110 or alternative locating surfaces. It should be appreciated that the majority of the total laminations that make up the stator stack 601 provide the relative inflexibility of the stator mounting bosses 607 and the primary mechanical coupling of the stator 600 to the housing 1101. The machine housing 1101 may include a long post or riser 1116 or an alternative surface for connecting the bottom of the overhanging region 611 of the mounting tab 609 to the housing 1101. Unlike the short post or alternative locating surface for the bottom of the stator, the long post 1116 or an alternative surface for securing the bottom of the overhanging region 611 of the mounting tab 609 to the housing 1101 may provide a non-interfering surface. In other words, because the bottom of the stator 600 is positioned onto the short post 1110 or an alternative locating surface, and the stator 600 is secured to the housing 1101 by bolts 1112, the overhanging region 611 of the mounting tab 609 preferably does not contact the long post 1116 or an alternative surface for securing the overhanging region 611 of the mounting tab 609 to the housing 1101. Reference Figures 10A-10CThe initial freedom from interference between the short support or alternative and the overhanging area 611 of the mounting tab 609 is described in more detail herein. The support 1116 may include internal threads for receiving bolts 1114 that pass through the overhanging area 611 of the mounting tab 609. In addition to the alternative of the support providing an attachment surface for the overhanging area 611 of the mounting tab 609, the alternative of the support may also provide internal threads. The bolts 1114 may be tightened to attach the top of the stator to the machine housing 1101 at the overhanging area 611 of the mounting tab 609, thereby strengthening the stator against torsional displacement of the top cantilever end (which is mainly caused by reaction forces during machine operation). Advantageously, the small portion of the total laminations that make up the bracket stack 603 provides relative flexibility of the overhanging area 611 of the mounting tab 609, enabling the bracket stack 603 to be securely mechanically coupled to the housing 1101 without causing undesirable deformation of the bracket. Advantageously, the relative flexibility of the overhanging region 611 of the mounting tab 609 allows the stator 600 to be effectively assembled to the locating surface without interference even in the event that the overhanging region 611 of the mounting tab 609 is physically disturbed. The design capability of the overhanging region 611 of the mounting tab 609 to deform without causing undesirable deformation of the bracket stack 603 is advantageous. Therefore, it should be understood that the overhanging region 611 of the mounting tab 609 enables the stator 600 to be attached to the housing in a two-plane manner, and the locating surface of the housing 1101 at the bottom of the stator 600 has a single-plane critical tolerance.

[0049] Figures 10A-10C The process of assembling the stator according to the present disclosure to the machine housing is shown. In order to properly understand certain advantageous aspects according to the present disclosure, the illustration is not drawn to scale and the size is exaggerated. Figures 10A-10C 1, like reference numerals refer to like features between the various views. Stator stack 1201 may include a first plurality of stacked laminations as described herein. Bracket stack 1203 is stacked adjacent to stator stack 1201, bracket stack 1203 including mounting tabs 1205 defining apertures 1207. A bottom portion (not shown) of stator stack 1201 is secured to a portion of the stator stack 1201 as described herein with respect to the stator stack 1201. Figures 8 to 9 The mounting tab 1205 may be provided with a locating surface (not shown). To ensure accurate positioning of the stator, it is desirable that other stator features, such as the bracket stack 1203, remain undisturbed by other features in the machine housing. Thus, the post 1209 or an alternative may provide a surface 1213 for securing the mounting tab 1205, the surface 1213 having a tolerance to provide, for example, a nominal 1.0 mm assembly gap or spacing 1211. The bolt may be inserted through the hole 1207 and received into the post 1209 as described herein. When the bolt engages and deforms the mounting tab ( Fig. 10B and 10C), the individual laminations used to construct the bracket stack 1203 and the mounting tabs 1205 are able to slide, thereby relieving bending stresses, thereby reducing any stress transfer to the bracket stack 1203. Advantageously, interference during the assembly of the mounting tabs 1205 with the pillars 1209 may also cause the mounting tabs to deflect relative to each other, which can also be accommodated in a similar manner, wherein the individual laminations used to construct the bracket stack 1203 and the mounting are able to slide, thereby relieving bending stresses, thereby reducing any stress transfer to the bracket stack 1203.

[0050] Unless explicitly described as “direct”, when the relationship between a first element and a second element is described in the above disclosure, the relationship may be a direct relationship in which no other intermediate elements exist between the first element and the second element, but an indirect relationship in which one or more intermediate elements exist between the first element and the second element (spatially or functionally).

[0051] It should be understood that one or more steps in the method may be performed in a different order (or simultaneously) without changing the principles of the present disclosure. In addition, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the present disclosure may be implemented in the features of any other embodiment and / or combined with the features of other embodiments, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the permutation of one or more embodiments with respect to each other is still within the scope of the present disclosure.

[0052] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and elements thereof may be substituted with equivalents without departing from the scope of the invention. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the disclosure without departing from the substantive scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A motor, comprising: Machine housing; a first substantially annular stator stack comprising a first plurality of first laminations, each first lamination comprising a circumferentially outer first mounting ear defining a first aperture, the first laminations being stacked adjacent to one another, the first apertures being substantially aligned with one another to define a stator mounting boss; a second substantially annular stator stack comprising a second plurality of second laminations, each second lamination comprising a circumferentially outer second mounting ear defining a second aperture, the second laminations being stacked adjacent to one another, the second apertures being substantially aligned with one another to define a first bracket mounting tab, the second stator stack having a thickness less than a thickness of the first stator stack; a second stator stack stacked adjacent to the first stator stack, with the stator mounting bosses and the bracket mounting tabs angularly separated; a first fastener extending through the stator mounting boss to fasten the first stator stack to the machine housing; and A second fastener passes through the first bracket mounting tab to secure the second stator stack to the machine housing.

2. The motor according to claim 1, wherein: The first and second laminations are substantially identical.

3. The motor according to claim 1, wherein: The second mounting ears of the second laminations define third apertures, the second laminations are stacked adjacent to each other, the third apertures are substantially aligned with each other, the second stator stack is stacked adjacent to the first stator stack, the third apertures are substantially aligned with the first apertures.

4. The electric machine of claim 3 further comprising a substantially annular third stator stack comprising a third plurality of second laminations stacked adjacent to one another, the second holes being substantially aligned with one another to define a second bracket mounting tab, the third stator stack being stacked adjacent to the second stator stack opposite the first stator stack, the third holes of the third stator stack being substantially aligned with the first holes defining the first stack mounting bosses, the second holes of the second stator stack and the third stator stack being located on angled opposite sides of the stator mounting bosses.

5. The electric machine of claim 3 further comprising a substantially annular third stator stack comprising a third plurality of second laminations stacked adjacent to one another, the second holes being substantially aligned with one another to define a second bracket mounting tab, the third stator stack being stacked intermediately within the first stator stack, the third holes of the third stator stack being substantially aligned with the first holes defining the first stack mounting boss, and the second holes of the second stator stack and the third stator stack being located on angled opposite sides of the stator mounting boss.

6. The electric machine of claim 1 further comprising a substantially annular third stator stack comprising a third plurality of second laminations stacked adjacent to one another, the second apertures being substantially aligned with one another to define a second bracket mounting tab, the third stator stack being stacked adjacent to the second stator stack opposite the first stator stack, the second apertures of the second stator stack and the third stator stack being located on angled opposite sides of the stator mounting boss.

7. A method for constructing an electric machine, comprising: stamping a plurality of laminations, each lamination including a circumferential outer protrusion defining a mounting hole; stacking a first portion of the plurality of laminations such that the corresponding mounting holes are substantially aligned with one another to define a stator mounting boss; stacking a second portion of the plurality of laminations such that the corresponding mounting apertures are substantially aligned with one another to define a bracket mounting tab, the second portion of the laminations having a thickness less than a thickness of the first portion; stacking the second portion on top of the first portion to define a stator stack, wherein the stator mounting bosses and the bracket mounting tabs are angularly displaced from one another; Positioning the bottom end of the stator stack against the locating surface of the machine housing and securing the stator stack to the machine housing with fasteners extending through the stator mounting bosses; and The stator stack is secured to the machine housing by fasteners passing through the bracket mounting tabs. 8 . The method of claim 7 , wherein stamping a plurality of laminations comprises stamping the same laminations for the first portion and the second portion.

9. The method according to claim 7, wherein: Stamping a plurality of laminations includes: stamping a first lamination including a mounting ear having a single hole for a first portion of the lamination; and stamping a second lamination including a mounting ear having a pair of holes for a second portion of the lamination, wherein stamping the first lamination and the second lamination is accomplished by a progressive station tool.

10. The method according to claim 7, wherein: Stamping a plurality of laminations comprises: stamping a first lamination including a mounting ear having a single hole for a first portion of the lamination; and stamping a second lamination including a mounting ear having a pair of holes for a second portion of the lamination, wherein stamping the first lamination and the second lamination is accomplished by a selectively actuated stamping tool.

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