End winding support bracket

Abstract

Disclosed herein is a bracket connectable to a stator core of an electric machine. The carrier includes a comb portion having a plurality of teeth arranged in at least one row such that a notch is defined between each pair of adjacent teeth. Each notch is sized to receive a portion of the bus bar therein. The bracket further includes: a protrusion sized and shaped to be received within a mounting recess defined in the stator core; and an arm extending between the comb portion and the protrusion such that the comb portion is offset relative to the protrusion.

Description

Technical Field

[0001] The field of the present disclosure relates generally to electric machines, and more particularly to support structures used with electric machines. Background Art

[0002] The stator core of an electric machine includes conductive elements such as stator winding coils that are electrically coupled together via conductors extending outside the stator core. For example, the end winding leads may be electrically connected to a busbar that spans multiple end windings across the perimeter of the electric machine. During operation, the electric machine may be subject to various loads, including both electromagnetic forces generated within the electric machine and external forces applied to the electric machine during its operation. Therefore, the conductive elements outside the stator core must be mechanically supported and constructed to withstand any vibration loading, shock loading, thermal growth or other loads that may be applied to the electric machine.

[0003] In many applications of known electric machines, particularly in aerospace applications, it is necessary to minimize the physical size and weight of the electric machine. Therefore, there is a need for a support structure for use with an electric machine, wherein the structure will support conductive elements external to the stator core without significantly increasing the overall size and weight of the electric machine. Summary of the invention

[0004] Disclosed herein is an electric machine comprising a rotor and a stator magnetically coupled to the rotor. The stator comprises a stator core and a plurality of stator windings coupled to a radial inner surface of the stator core, the stator core having an outer surface and a plurality of circumferentially spaced mounting recesses defined therein. Each stator winding comprises an end winding portion extending outwardly from an axial end of the stator core and at least one lead extending from the end winding portion. The electric machine also comprises at least one busbar electrically coupled to at least two of the leads, and a bracket. The bracket comprises a comb-shaped portion having a plurality of teeth arranged in at least one row so that a notch is defined between each pair of adjacent teeth. The size of each notch is set and oriented to receive a portion of the busbar therein. The bracket also comprises: a protrusion, the size and shape of the protrusion being set to be received in a corresponding one of the plurality of mounting recesses; and an arm extending between the comb-shaped portion and the protrusion so that the comb-shaped portion is offset relative to the protrusion.

[0005] Also disclosed herein is a bracket that can be connected to a stator core of an electric machine. The bracket includes a comb-like portion having a plurality of teeth arranged in at least one row such that a notch is defined between each pair of adjacent teeth. Each notch is sized and oriented to receive a portion of a busbar therein. The bracket also includes a protrusion sized and shaped to be received within a mounting recess defined in the stator core; and an arm extending between the comb-like portion and the protrusion such that the comb-like portion is offset relative to the protrusion.

[0006] A method of assembling an electric machine is also disclosed herein, the electric machine comprising a rotor, a stator, a busbar, and a bracket. The bracket comprises a comb-shaped portion having a plurality of teeth arranged in at least one row so that a notch is defined between each pair of adjacent teeth. The method comprises: positioning a protrusion of the bracket within a mounting recess defined in an outer surface of a stator core of the stator; inserting a portion of the busbar into one of the plurality of notches; coupling a stator winding to a radial inner surface of the stator core; and coupling the busbar to a lead extending from an end winding portion of the stator winding.

[0007] There are various improvements to the features mentioned in the above aspects of the present disclosure. Additional features may also be incorporated into the above aspects of the present disclosure. These improvements and additional features may exist alone or in any combination. For example, the various features discussed below with respect to any of the illustrated embodiments of the present disclosure may be incorporated into any of the above aspects of the present disclosure alone or in any combination. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is an exploded perspective view of an exemplary motor;

[0009] Figure 2 It was taken along line 2-2 Figure 1 a cross-sectional view of the exemplary electric machine shown;

[0010] Figure 3 is a perspective view of an exemplary wedge-shaped portion of an axial end of a stator core of an electric machine.

[0011] Figure 4 yes Figure 3 Another perspective view of an exemplary wedge-shaped portion of an axial end of a stator core of an electric machine is shown.

[0012] Figure 5 yes Figure 4 Another perspective view of an exemplary wedge-shaped portion is shown, further illustrating multiple end winding sections.

[0013] Figure 6 yes Figure 5Another perspective view of an exemplary wedge-shaped portion is shown, further illustrating a plurality of busbars.

[0014] Figure 7 yes Figure 6 Another perspective view of the exemplary wedge-shaped portion is shown, further illustrating the plurality of brackets.

[0015] Figure 8 yes Figure 7 A perspective view of one of the plurality of brackets shown.

[0016] Fig. 9 yes Figure 7 Another perspective view of one of the plurality of brackets shown.

[0017] Fig.10 yes Figure 7 Another perspective view of one of the plurality of brackets shown.

[0018] Fig.11 is a perspective view of an alternative embodiment of a bracket.

[0019] Fig.12 yes Fig.11 A cross-sectional view of the bracket shown.

[0020] Fig.13 yes Figure 7 Another perspective view of the exemplary wedge-shaped portion is shown, further illustrating the outer retaining ring.

[0021] Fig.14 It was taken along line 14-14 Figure 1 A partial cross-sectional view of the electric machine is shown.

[0022] Corresponding reference characters indicate corresponding parts throughout the several views. DETAILED DESCRIPTION

[0023] The following detailed description illustrates exemplary end winding support brackets and methods of their use with electric machines by way of example and not limitation. The description should enable one of ordinary skill in the art to make and use the brackets, and the description describes several exemplary embodiments of the brackets. The exemplary brackets are described herein in conjunction with the assembly of electric machines. However, it is contemplated that the brackets have general application to a wide range of systems in a variety of fields other than electric machines.

[0024] Figure 11 is a perspective view of an exemplary electric machine 300. In an exemplary embodiment, the electric machine 300 includes a stator 112 and a rotor 114, which are magnetically coupled and coaxially aligned around a central longitudinal axis 16 of the electric machine 300. The electric machine 300 can be an electric motor, wherein the rotor 114 rotates relative to the stator 112 to convert electrical energy into mechanical energy. In other embodiments, the electric machine 300 can be a generator, wherein the relative rotation between the rotor 114 and the stator 112 converts mechanical energy into electrical energy. In further embodiments, the electric machine 300 can be any other type of rotating electric machine, such as, but not limited to, a synchronous electric machine, a multi-phase electric machine, an electric machine with concentrated windings, an electric machine with distributed windings, a reluctance electric machine, an induction electric machine, a winding-excited electric machine, a salient pole electric machine, an interior permanent magnet (IPM) electric machine, an electric machine with permanent magnets arranged differently from an IPM electric machine (e.g., a surface PM electric machine, etc.), and / or any other suitable electric machine.

[0025] The stator 112 includes a stator core 18 extending between axial ends 111 and including a central opening 20 extending along the central longitudinal axis 16. The rotor 114 extends a distance along the central longitudinal axis 16 and includes a shaft 22 and a rotor core 24 mounted to the shaft 22. The shaft 22 rotates about the central longitudinal axis 16 relative to the stator core 18. The rotor core 24 is rotatably coupled to the shaft 22 so that the rotor core 24 rotates with the shaft 22 about the central longitudinal axis 16.

[0026] In an exemplary embodiment, the rotor 114 extends within the central opening 20 of the stator core 18 and is rotatable within the central opening 20 relative to the stator core 18. That is, the stator core 18 of the electric machine 300 is sized to extend around the rotor 114 so that the rotor 114 can rotate within the stator 112. In other embodiments, the rotor 114 can be sized to extend around the stator 112 and rotate around the stator 112.

[0027] Figure 2 yes Figure 1 The exemplary motor 300 shown is along ( Figure 1 In particular, Figure 2 The cross-sectional view of FIG. 1 shows both the stator 112 and the rotor 114 of the motor 300. In the exemplary embodiment, the stator core 18 includes a stator base 28, a plurality of circumferentially spaced stator teeth 30, and a plurality of circumferentially spaced spacers 33, wherein each stator tooth 30 and spacer 33 extends radially inward from the stator base 28. Figure 3 and Figure 4, each stator tooth 30 extends from a first end 31 adjacent to the stator base 28 to a second free end 32. The second end 32 of each stator tooth 30 may partially define the central opening 20 of the stator core 18. In some embodiments, the second ends 32 of each stator tooth 30 are connected together. Each stator tooth 30 may also define at least one wedge-shaped retaining groove 37 near its second end 32. Each wedge-shaped retaining groove 37 extends along the axial length of each stator tooth 30 between the axial ends 111 of the stator core 18. A plurality of wedge-shaped members 39 are each shaped and sized to be received in and retained by a corresponding pair of wedge-shaped retaining grooves 37 defined between an adjacent pair of stator teeth 30. Each wedge-shaped member 39 secures the stator conductor 40 within a corresponding raceway 38. The raceway 38 will be discussed in more detail below.

[0028] Each divider 33 extends from a first end 34 adjacent to the stator base 28 to a second free end 35. The stator teeth 30 and dividers 33 are circumferentially spaced in an alternating pattern around the stator base 28 such that a divider 33 is positioned between each pair of circumferentially adjacent stator teeth 30, and such that a stator tooth 30 is positioned between each pair of circumferentially adjacent dividers 33. The stator core 18 may include any number of stator teeth 30 and dividers 33 that enables the electric machine 300 to operate as described herein.

[0029] The inner surface of the stator base 28 between each adjacent stator tooth 30 and the spacer 33 forms a radial inner surface 36 of the stator core 18 (at Figure 3 38 is partially defined by the radial inner surface 36, each pair of circumferentially adjacent dividers 33, and the corresponding stator teeth 30 disposed therebetween. Each raceway 38 is shaped and sized to receive a stator conductor 40 therein. Each stator conductor 40 extends longitudinally through the stator core 18 and is coupled to the radial inner surface 36 thereof. The stator core 18 may include the same number of stator conductors 40 as raceways 38, or alternatively, the stator core 18 may include fewer stator conductors 40 than raceways 38, such that at least one raceway 38 does not receive a stator conductor 40 therein. The rotor 114 includes a shaft 22 ( Figure 1 ) and the rotor core 24.

[0030] The rotor core 24 is rotatable relative to the stator 112 about the central longitudinal axis 16. In the exemplary embodiment, the rotor core 24 includes a rotor base 44, a plurality of magnetic segments 46 extending radially outward from the rotor base 44, and a plurality of non-magnetic segments 48 extending radially outward from the rotor base 44. In other embodiments, the segments 46 and 48 extend radially inward from the rotor base 44.

[0031] The magnetic segments 46 and the non-magnetic segments 48 surround the rotor periphery C of the rotor core 24. rThe magnetic segments 46 and the non-magnetic segments 48 are arranged in an alternating pattern of circumferential spacing. In other words, the magnetic segments 46 are radially spaced about the central longitudinal axis 16 so that the magnetic segments 46 are circumferentially spaced a distance therefrom so that the non-magnetic segments 48 extend between circumferentially adjacent magnetic segments 46 spaced about the rotor periphery Cr of the rotor core 24. In the exemplary embodiment, the rotor 114 is a toothed rotor in which the magnetic segments 46 define rotor teeth 45 of the rotor core 24.

[0032] The rotor base 44 includes a radially inner rotor surface 50 that defines a central opening 52 in the rotor core 24. The outer periphery of the rotor core 24 is defined by the end surfaces 47 and 49 of the magnetic segment 46 and the non-magnetic segment 48, respectively. An air gap G is defined between the outer periphery of the rotor core 24 and the second end 32 of each stator tooth 30 of the stator core 18. The rotor base 44 may include one or more mortises (not shown) each sized and oriented to receive a corresponding tenon (not shown) extending from the shaft 22 therein for mounting the rotor core 24 to the shaft 22. Other arrangements for mounting the rotor core 24 to the shaft 22 may be provided in addition to or in lieu of the mortises and tenons.

[0033] The rotor core 24 may be formed by one or more stacks of multiple laminates, or alternatively, may be formed as a single piece of material. The rotor base 44 of the rotor core 24 may be made of non-magnetic material and may be formed integrally with the magnetic segment 46. Alternatively or in addition, the rotor base 44 may be formed integrally with the non-magnetic segment 48. For example, when the rotor core 24 is formed by a stack of laminates, the rotor base 44 of each laminate or layer within the stack may be formed integrally with the magnetic segment 46 and / or the non-magnetic segment 48 of the laminate. In addition, and for example, in an embodiment in which the rotor core 24 is formed as a single piece of material, the rotor base 44 is a single piece of material that is integrally formed of magnetic material and includes all magnetic segments 46 and non-magnetic segments 48 of the rotor core 24. In an exemplary embodiment, the magnetic segment cooperates with the rotor base 44 to form the rotor 114 as a toothed rotor. In other words, in such an embodiment, the rotor base 44 carries magnetic flux. Whether constructed from a stack of laminates or from a single piece of material, the toothed rotor structure of rotor 114 distinguishes rotor 114 from a "segmented" rotor, which includes a rotor core having magnetic segments that are magnetically isolated or segmented from a rotor base and from each other. In an exemplary embodiment, stator 112 and / or rotor 114 may include permanent magnets. In some alternative embodiments, rotor 114 is a segmented rotor.

[0034] The rotor core 24 may include any number of magnetic segments 46 and / or non-magnetic segments 48. In addition, the rotor core 24 may include any number of rotor teeth 45. In one embodiment, the rotor core 24 includes the same number of rotor teeth 45 as the stator core 18 includes stator teeth 30. Alternatively, the stator core 18 may include more or less stator teeth 30 than the number of rotor teeth 45 included in the rotor core 24. In an exemplary embodiment, the rotor core 24 includes fourteen rotor teeth 45, and the motor 300 includes more stator teeth 30 than the rotor teeth 45.

[0035] Figures 3 to 7 and Fig.13 Each exemplary wedge-shaped portion 90 is illustrated at an axial end 111 of the stator core 18. The illustrated wedge-shaped portions 90 may represent any circumferential portion of the stator core 18 at either axial end 111 thereof, and it should be understood that each wedge-shaped portion 90 included in each axial end 111 of the stator core 18 may include the same circumferential portion as the stator core 18. Figures 3 to 7 and Fig.13 The same features and components as those shown in, or may include the same features and components as those shown in Figures 3 to 7 and Fig.13 Features and components that are different from those shown in .

[0036] In the exemplary embodiment, the stator core 18 includes a radially outer surface 1 ( Figure 4 ) and a flange 103 that defines the stator core 18 and extends radially outward from the radial outer surface 101. In an exemplary embodiment, the flange 103 defines at least one mounting hole 104 therein, the shape and size of the mounting hole being set to receive a fastener (not shown) therethrough. The stator core 18 also includes an outer surface 105 extending substantially perpendicularly from the radial inner surface 36 of the stator core 18. In addition, the stator core 18 includes a plurality of recessed surfaces 107 and a plurality of recessed sidewalls 108, each of which extends generally axially. Each recessed sidewall 108 extends from the outer surface 105 to a corresponding recessed surface 107. Each recessed surface 107 and the corresponding recessed sidewall 108 define a mounting recess 109 extending from the outer surface 105 into the stator core 18. The plurality of mounting recesses 109 are circumferentially spaced around each axial end 111 of the stator core 18. In an exemplary embodiment, each mounting recess 109 is dovetail-shaped. In alternative embodiments, each mounting recess 109 may have any other suitable shape that enables motor 300 to function as described herein.

[0037] The exterior surface also includes a plurality of first apertures 102 defined therein. In an exemplary embodiment, the first apertures 102 and mounting recesses 109 are circumferentially spaced about the exterior surface 105 of the stator core 18 such that a first aperture 102 is defined between each pair of adjacent mounting recesses 109, and such that a mounting recess 109 is defined between each pair of circumferentially adjacent first apertures 102. In alternative embodiments, depending on the design of the stator core 18, at least some of the circumferentially spaced pairs of mounting recesses 109 do not include a first aperture 102 defined therebetween.

[0038] Figure 5 is a perspective view of a portion of the stator core 18 and includes a plurality of rollers 38 ( Figure 2 38). In the exemplary embodiment, the stator conductors 40 are stator windings 40 formed by winding a plurality of wires (not shown) around one of the stator teeth 30 and between adjacent separators 33 in a raceway configuration. That is, the wires enable the stator windings 40 to extend longitudinally through the stator core 18 in a direction substantially parallel to the central longitudinal axis 16. In addition, at each axial end 111 of the stator core 18, the wires are wrapped around both sides (not shown) of the stator tooth 30 and around the ends (not shown) of the stator tooth 30. The plurality of wedges 39 secure each respective stator winding 40 within the respective raceway 38.

[0039] In some embodiments, the stator windings 40 may include one or more direct current (DC) windings and / or one or more alternating current (AC) windings. In other embodiments, the stator windings 40 may include copper windings, litz wire windings, fractional slot concentrated windings (not shown), and / or any other suitable type of stator windings. Each stator winding 40 may be or may represent any number of phases, such as but not limited to single phase or three phases. In other embodiments, the stator conductors may be rigid conductors having similar shapes.

[0040] The portion of each stator winding 40 that surrounds the end of the stator tooth 30 forms an end winding portion 60 that extends outward from the axial end 111 of the stator core 18. The ends (not shown) of the multiple wires that form each stator winding 40 extend axially outward from the end winding portion 60 to form leads 64. The multiple wires in each lead 64 can be brazed together to form a solid single lead, or they can be loosely bundled together. In some embodiments, each lead 64 is flexible and can be bent and / or manipulated into a variety of configurations or orientations. In other embodiments, the leads 64 are rigid and fixed in a single configuration.

[0041] Figure 5The exemplary wedge-shaped portion 90 shown includes four end winding portions 60 having first, second, third and fourth leads 64a-64d. Each lead 64a-d includes a radial portion 65a-d and an axial portion 66a-d, wherein the radial portion 65a-d extends radially inward toward the central longitudinal axis 16 and the axial portion 66a-d extends axially away from the stator core 18, such that each portion 66a-d is substantially parallel to the central longitudinal axis 16. In the exemplary embodiment, the first and third leads 64a and 64c are formed identically, and the second and fourth leads 64b and 64d are formed identically but have different dimensions than 64a and 64c. That is, the radial portions 65a and 65c of the respective first and third leads 64a and 64c each have a first radial length L r1 , and the radial portions 65b and 65d of the respective second and fourth leads 64b and 64d each have a radial length L greater than the first radial length L r1 The second long radial length L r2 Similarly, the axial portions 66a and 66c of the respective first and third leads 64a and 64c have a first axial length L a1 , and the axial portions 66b and 66d of the respective second and fourth leads 64b and 64d have a length greater than the first axial length L a1 Long second axial length L a2 In other embodiments, all of the leads 64a-64d may have substantially the same dimensions.

[0042] In some embodiments, the stator core 18 also includes a plurality of slot liners (not shown) that are sized and oriented to be received within corresponding raceways 38. The slot liners may be constructed of a non-conductive material to electrically insulate the stator windings 40 from the stator core 18. Each slot liner is positioned between the radial inner surface 36 of the stator core 18 and the stator windings 40 and extends longitudinally between the axial ends of the stator core 18.

[0043] Reference Figure 6, the motor 300 also includes at least one busbar 70 electrically coupled to at least two leads 64. In the exemplary embodiment, three busbars 70a-c are shown, but the motor 300 may include any suitable number of busbars 70 that enable the motor 300 to operate as described herein. Each busbar 70 may include an arcuate circumferential portion 72 and at least two axial protrusions 74. Each circumferential portion 72 has a depth d1 and a width w1, and extends a first arcuate length AL1 that enables the busbar 70 to extend between a pair of circumferentially adjacent axial protrusions 74. In other embodiments, the circumferential portion 72 may extend circumferentially beyond one or both of the axial protrusions 74. In addition, the circumferential portion 72 may extend substantially linearly between the at least two axial protrusions 74, or alternatively, the circumferential portion 72 may be formed with a radius of curvature R1, as shown in the exemplary embodiment. In other embodiments, the circumferential portion 72 may form a complete annular ring, so that the first arcuate length AL1 is a complete perimeter defined by the circumferential portion 72. In other embodiments, the circumferential portion 72 may be semicircular.

[0044] Each axial protrusion 74 extends from a first end 75 connected to the circumferential portion 72 to a second free end 76. More specifically, in the exemplary embodiment, each axial protrusion 74 extends radially inward from the first end 75 to the second end 76. In other embodiments, the axial protrusions 74 may extend in any other suitable direction that enables the motor 300 to operate as described herein. In the exemplary embodiment, the portion of the axial protrusion 74 adjacent to the first end 75 is substantially flush with the circumferential portion 72, and the portion of the axial protrusion 74 adjacent to the second end 76 is substantially perpendicular to the circumferential portion 72. In other embodiments, the first end 75 and the second end 76 may both be substantially flush with the circumferential portion 72, or the ends 75 and 76 may both extend substantially perpendicular to the circumferential portion 72.

[0045] In an exemplary embodiment, each axial protrusion 74 is coupled to an axial portion 66 of one of the plurality of leads 64 such that each busbar 70 is electrically coupled to at least two leads 64. In other embodiments, the busbars 70 and leads 64 may be coupled together in any other suitable manner, for example, by coupling the axial protrusions 74 to radial portions 65 of the leads 64. In still other embodiments, the busbars 70 may not include any axial protrusions 74, and the circumferential portions 72 are directly coupled to at least two leads 64. The busbars 70 may be brazed to each lead 64 or may be coupled in any other suitable manner. In an exemplary embodiment, a single busbar 70 is coupled to each lead 64. In other embodiments, more than one busbar 70 may be coupled to each lead 64.

[0046] Reference Figure 7 The motor 300 also includes a mounting recess 109 ( Figure 4 ) in one of the at least one bracket 100, which provides mechanical support for the at least one busbar 70. In an exemplary embodiment, the first bracket 100a is received in the first mounting recess 109a, and the second bracket 100b is received in the second mounting recess 109b. Figures 8 to 10 , each bracket 100 includes a comb portion 120, a protrusion 140, and an arm 160 extending between the comb portion 120 and the protrusion 140 so that the comb portion 120 is offset relative to the protrusion 140. The comb portion 120 includes a plurality of teeth 124 arranged in at least one row. In an exemplary embodiment, each bracket 100 includes a first upper row 121 of teeth 124 and a second lower row 122 of teeth 124, the second lower row extending substantially parallel to the first row 121. In other embodiments, the comb portion 120 may include any other suitable number of rows, such as, but not limited to, only one row of teeth 124 or more than three rows of teeth 124.

[0047] Each row 121 and 122 of teeth 124 extends from a first end 127 to a second end 129 of the comb portion 120 by a length L. c In an exemplary embodiment, each row 121 and 122 is arranged along a length L c The rows 121 and 122 extend generally axially and are substantially parallel to the central longitudinal axis 16. In addition, each row 121 and 122 includes an upper surface 110 and a lower surface 130 substantially parallel to the upper surface 110. In addition, in the exemplary embodiment, the upper surface 110 and the lower surface 130 each have a width w of the comb portion 120. c Approximately the same width w c In other embodiments, the upper surface 110 and the lower surface 130 may have different widths w. c，u and w c，l (not shown) such that the comb portion 120 does not have a constant width. The comb portion 120 also includes an end surface 134 that is opposite the protrusion 140 and extends substantially perpendicular to the upper surface 110 and the lower surface 130 of the comb portion 120. A first outer aperture 136 is defined on the end surface 134 of each bracket 100, as described in more detail below.

[0048] Each of the plurality of teeth 124 extends downwardly substantially vertically from the lower surface 130 of each row 121 and 122. A notch 125 is defined between each pair of adjacent teeth 124. Each row 121 and 122 of the comb portion 120 includes at least two teeth 124 defining a notch 125 therebetween. Each notch 125 is sized and shaped to receive a portion of the busbar 70 therein. More specifically, in the exemplary embodiment, each notch 125 is sized and shaped to receive a portion of the circumferential portion 72 of the busbar 70 therein. Thus, each notch 125 has a width w that is wider than a depth d1 of the circumferential portion 72 of the busbar 70. i Each tooth has a width w t , the width is determined at least in part by the voltage rating of the electric machine 10 in order to provide the required electrical clearance and creepage distances between the busbars 70 disposed in adjacent recesses 125 .

[0049] Furthermore, in an exemplary embodiment, not every notch 125 of the bracket 100 receives a portion of the busbar 70. More specifically, in an exemplary embodiment, at least some of the notches 125 may remain empty and not receive a portion of the busbar 70. For example, referring to Figure 7 , the first bracket 100a receives a portion of the first busbar 70a in the notch 125 defined in the upper row 121a thereof, and a portion of the second busbar 70b is received in the notch 125 defined in the lower row 122b thereof. Similarly, the second bracket 100b receives a portion of the third busbar 70c in the notch 125 defined in the upper row 121b thereof. In the exemplary embodiment, no other notch 125 receives a portion of the busbar 70.

[0050] Each row 121 and 122 of the bracket 100 can accommodate c In an exemplary embodiment, the upper row 121a of the first bracket 100a and the upper row 121b of the second bracket 100b are circumferentially aligned along a first radius R1 (not shown) so that the portions of the first busbar 70a and the third busbar 70c received by the notches 125 in the upper rows 121a and 121b are formed with the same radius of curvature R1. In some embodiments, the same busbar 70 may extend through the notches 125 formed in the upper rows 121a and 121b of both the first bracket 100a and the second bracket 100b. Different notches 125 formed in the same row 121 or 122 of the bracket may accommodate busbars 70 having the same radius of curvature.

[0051] Similarly, the lower rows 122a and 122b of the first bracket 100a and the second bracket 100b are circumferentially aligned at the second radius R2, and the second busbar 70b is received in the notch 125 formed in the lower row 122a and is thus formed with the same second radius of curvature R2. In some embodiments, the same busbar 70 may extend through the notches 125 formed in the lower rows 122a and 122b of both the first bracket 100a and the second bracket 100b. In an exemplary embodiment, the second radius of curvature R2 is different from and less than the first radius of curvature R1. In an exemplary embodiment, no other notch 125 receives a portion of the busbar 70.

[0052] Each bracket 100 also includes a protrusion 140 formed with an inner face 142, an outer face 144, a top face 145, and a plurality of side faces 146. In an exemplary embodiment, the inner face 142 is substantially parallel to the outer face 144, and the top face 145 is substantially perpendicular to both the inner face 142 and the outer face 144. In alternative embodiments, the inner face 142, the outer face 144, and the top face 145 may be formed with any other suitable orientation relative to each other. Each protrusion 140 is shaped and sized to be received in a corresponding mounting recess 109 in the stator core 18. For example, if the mounting recess 109 is a dovetail recess, the protrusion 140 is formed as a dovetail protrusion. That is, the protrusion 140 is formed with a shape substantially the same as the shape of the mounting recess 109 into which it is to be inserted. In alternative embodiments, any other suitable mechanical coupling feature may be used to couple the bracket 100 to the stator core 18.

[0053] Reference Figure 7 In an exemplary embodiment, each protrusion 140 is received in the mounting recess 109 such that the inner face 142 engages the recessed surface 107 of the stator core 18 and such that each of the top face 145 and the side face 146 engages one of the plurality of recess side walls 108 defined within the stator core 18. In an exemplary embodiment, when the protrusion 140 is inserted into the mounting recess 109, the outer face 144 is substantially parallel to the outer surface 105 of the stator core 18. In other embodiments, when the protrusion 140 is installed in the mounting recess 109, the outer face 144 of the protrusion 140 may be oriented obliquely relative to the outer surface 105 of the stator core 18. In an exemplary embodiment, the depth d of the protrusion 140 is t Greater than the depth d of the corresponding mounting recess 109 mr , such that the outer face 144 of the protrusion 140 extends axially beyond the outer surface 105 of the stator core 18. In other embodiments, the depth d of the protrusion 140 is t It may be smaller than the depth d of the corresponding mounting recess 109 mr, so that the outer face 144 of the protrusion 140 remains in the mounting recess 109. In still other embodiments, the outer face 144 of the protrusion 140 may be substantially flush with the outer surface 105.

[0054] Each bracket 100 also includes an arm 160 extending between the protrusion 140 and the comb portion 120. In the exemplary embodiment, each arm 160 has a length L a , which is measured from a first end 161 adjacent to the interior face 142 of the protrusion 140 to a second end 162 adjacent to the first row 121 of teeth 124 in the comb portion 120. Figure 7 As shown, the arm 160 is a The arm 160 extends generally axially in a direction substantially parallel to the central longitudinal axis 16. The arm 160 includes an upper surface 164, a lower surface 166 substantially parallel to the upper surface 164, and a pair of opposing side surfaces 168 extending between the upper surface 164 and the lower surface 166. The arm 160 also includes an inner surface 169 that is substantially flush with the inner face 142 of the protrusion 140.

[0055] Each protrusion 140 extends substantially perpendicularly from an upper surface 164 of the arm 160 adjacent the first end 161 such that the inner face 142 and the outer face 144 of the protrusion 140 are substantially perpendicular to the upper surface 164 and the lower surface 166 of the arm 160. Figure 8 and Fig.10 In the exemplary embodiment shown, the width w of the arm 160 adjacent the second end 162 is a The width w of the comb-shaped portion 120 is c is substantially the same, and the shape of the inner surface 169 is the same as one of the partitions 33 ( Figure 3 In other embodiments, arm 160 may be formed with any suitable width or shape that enables bracket 100 to work as described herein. Fig. 9 , a radial offset r is defined between the top surface 145 of the protrusion 140 and the upper surface 164 of the arm 160 off , so that the comb portion 120 is radially offset relative to the protrusion 140. Figure 7 , the protrusion 140 of each bracket 100 is received in one of the mounting recesses 109 so that the comb portion 120 of the bracket 100 extends longitudinally and is radially offset relative to the protrusion 140 by the radial offset r off .

[0056] The bracket 100 also includes an instrument wiring groove 116 defined along the upper surface 110 of the upper row 121 of teeth 124. In an exemplary embodiment, the instrument wiring groove 116 extends along the entire length L of the comb portion 120.c and along the length L of the arm 160 a In some alternative embodiments, the instrument wiring groove 116 may not extend into the arm 160, and / or may extend only along the length L of the comb portion 120. c The instrument wiring groove 116 is shaped and sized to receive one or more sensors (not shown) therein so that the sensors extend generally axially through the motor 300. Such sensors may be, for example, but not limited to, thermocouples or other temperature sensors. In an exemplary embodiment, the bracket 100 also includes at least one instrument rotation groove 118 defined in the upper surface 110 of the upper row 121 of teeth 124. Each instrument rotation groove 118 extends along a width w of the upper surface 110. c The bracket 100 includes six instrument rotation grooves 118, but the bracket 100 may include any other suitable number of instrument rotation grooves 118. Each instrument rotation groove 118 is shaped and sized to at least partially receive one of the one or more sensors received in the instrument wiring groove 116 so that the sensor can be rewired from the axial direction to the circumferential direction. The exemplary embodiment shows two different sized grooves, but other embodiments may include only grooves of the same size, or multiple different sized grooves.

[0057] The bracket 100 also includes at least one restraining aperture 172 defined therein that extends across the width w of the comb portion 120. c Each of the restraining apertures 172 is shaped and sized to receive a restraining band therein. In the exemplary embodiment, each row 122 of the comb portion 120 includes four restraining apertures 172, but each row 122 may include any other suitable number of restraining apertures 172, such as, but not limited to, more than four restraining apertures 172 or less than four restraining apertures 172.

[0058] In an exemplary embodiment, each bracket 100 is constructed of a non-conductive, insulating material, such as, but not limited to, Or polyetheretherketone (PEEK). In other embodiments, the bracket 100 can be constructed of any other suitable lightweight, high-strength, electrically insulating polymer or composite material. Each bracket 100 can be manufactured by injection molding, machining, casting, additive manufacturing or any other suitable process.

[0059] An alternative embodiment of the bracket 200 is Figure 11 to Figure 12The bracket 200 includes a comb portion 220, a protrusion 240, and an arm 260 extending between the comb portion 220 and the protrusion 240. The bracket 200 also includes an instrument wiring channel 212 extending along the axial length of the bracket 200. The shape and size of the instrument wiring channel 212 are set to receive the sensor lead 216 therethrough to allow the stator lead 216 to pass through the motor 300 from the stator core 18 in the axial direction.

[0060] In an exemplary embodiment, and with reference to Fig.13 , the electric machine 300 also includes an inner retaining ring 180 coupled to the outer surface 105 of the stator core 18. The inner retaining ring 180 includes a plurality of circumferentially spaced second apertures 182 defined therein. The second apertures 182 are arranged so that when the inner retaining ring 180 is coupled to the stator core 18, each second aperture 182 can be axially aligned with the first aperture 102 of the stator core 18. The shape and size of the first aperture 102 and the second aperture 182 are set to receive fasteners 184 therethrough to secure the inner retaining ring 180 to the outer surface 105 of the stator core 18. In some embodiments, the portion of the inner retaining ring 180 that defines each second aperture 182 can be chamfered or countersunk so that when fully installed in the stator core 18, the head of each fastener is substantially flush with the inner retaining ring 180.

[0061] Further references Fig.13 , the motor 300 also includes an outer retaining ring 190. In an exemplary embodiment, the outer retaining ring 190 is coupled to the first end surface 134a of the first bracket 100a and the second end surface 134b of the second bracket 100b and extends arcuately therebetween. The outer retaining ring 190 defines a plurality of outer retaining apertures 192 spaced circumferentially therearound. The outer retaining apertures 192 are arranged so that the first outer aperture 136a defined on the first bracket 100a and the second outer aperture 136b defined on the second bracket 100b are each aligned with one of the plurality of outer retaining apertures 192. The shapes and sizes of the outer apertures 136a and 136b and the outer retaining apertures 192 are set to receive fasteners 194 therethrough to secure the outer retaining ring 190 to the first bracket 100a and the second bracket 100b.

[0062] Fig.14 1 is a partial cross-sectional view of an electric machine in which at least one bracket 100 is mounted. An annular opening region 320 extends axially through the electric machine 300 and is partially defined by the radial offset r between the protrusion 140 and the comb portion 120. off The opening area 320 is defined by the radial offset r between the protrusion 140 and the comb portion 120. off That is, the opening area 320 represents the radial offset r that would otherwise not be included in the bracket 100. off. The radial space that would otherwise be occupied by the comb-shaped portions 120 of the plurality of brackets 100 is moved radially inward into the space already occupied by the plurality of busbars 70 so that the radial space where the busbars 70 and the end windings 64 are located can be most efficiently utilized. In an exemplary embodiment, the open area 320 is used to accommodate an impingement cooling manifold plenum 310 for use in cooling the end winding portions 60. In an alternative embodiment, no additional components are placed in the open area 320, and the motor 300 can be constructed with a smaller housing 340 to reduce the overall size and weight of the motor 300.

[0063] In an alternative embodiment of the electric machine 10, the outer surface 105 of the stator core 18 is substantially coaxially aligned with the radial inner surface 36 of the stator core 18. Each protrusion 140 of each bracket 100 is received in a corresponding mounting recess 109 such that the comb portion 120 of the bracket 100 extends radially outward from the stator core 18 and is longitudinally offset relative to the protrusion 140. The longitudinal offset between the protrusion 140 and the comb portion 120 helps to reduce the axial space required for the busbar 70 and the bracket 100, thereby creating space for other components, or allowing the axial extent of the electric machine 10 to be reduced.

[0064] An exemplary method of assembling the electric machine 300 described herein includes positioning a protrusion 140 extending from the bracket 100 within a mounting recess 109 defined in the outer surface 105 of the stator core 18. A portion of the busbar 70 is then inserted into one of the plurality of notches 125 of the comb portion 120 of the bracket 100 that is offset relative to the protrusion 140. The stator winding 40 is coupled to the radial inner surface 36 of the stator core 18, and the busbar 70 is coupled to the leads 64 extending from the end winding portions 60 of the stator winding 40.

[0065] In embodiments where the outer surface 105 of the stator core 18 is oriented substantially perpendicular to the radial inner surface 36 of the stator core 18, positioning the protrusion 140 of the bracket 100 within the mounting recess 109 includes positioning the protrusion 140 in the mounting recess 109 such that the comb portion 120 of the bracket 100 extends longitudinally and is radially offset relative to the protrusion 140. In some embodiments where the outer surface 405 of the stator core 18 is oriented substantially coaxially with the radial inner surface 36 of the stator core 18, as shown and described with reference to FIG. 15 , positioning the protrusion 140 of the bracket 100 within the mounting recess 409 includes positioning the protrusion 140 in the mounting recess 409 such that the comb portion 120 of the bracket 100 extends radially and is longitudinally offset relative to the protrusion 140.

[0066] In an embodiment in which the busbar 70 includes a first busbar 70a having a first radius of curvature R1 and a second busbar 70b having a second radius of curvature R2 different from the first radius of curvature R1, and the plurality of teeth 124 of the comb portion 120 are arranged into at least a first upper row 121a and a second lower row 121a substantially parallel to the first row 122a, the method further includes inserting a portion of the second busbar 70b into the recess 125 of the second row 122a of the comb portion 120.

[0067] In an embodiment where the outer surface 105 of the stator core 18 includes a plurality of first apertures 102 defined therein and the inner retaining ring 180 defines a plurality of second apertures 182, the method further includes coupling the inner retaining ring 180 to the outer surface 105 such that the first apertures 102 and the second apertures 182 are aligned to receive fasteners therethrough, and inserting the plurality of fasteners through the plurality of first apertures 102 and the second apertures 182 to secure the inner retaining ring 180 to the outer surface 105 of the stator core 18.

[0068] The bracket 100 further includes a plurality of grooves defined on the upper surface 110 and along the length L of the comb-shaped portion 120. c In embodiments of the extended instrument wiring recess 116 , the method further includes inserting a portion of a sensor (not shown) within the instrument wiring recess 116 .

[0069] Embodiments of the motor and bracket described herein provide several advantages over existing designs. The offset between the protrusion and the comb-shaped portion enables the bracket to be mounted within the same physical enclosure as the busbar, thereby creating radial or axial space to mount other components or reduce the radial or axial extent of the motor. In an exemplary embodiment, the radial space created by the radial offset of the bracket is occupied by an annular impingement cooling plenum that supplies cooling air through a plurality of small impingement slots to facilitate cooling of the end windings. If the bracket is constructed without a radial offset, and the comb-shaped portion instead extends substantially axially from the protrusion, the bracket will radially obstruct the annular plenum. In this case, the plenum must be constructed with different inner radii around its periphery in order to achieve the desired proximity to the end windings without obstructing the bracket. A component with such a complex geometry would be much more difficult and expensive to manufacture than an annular plenum enabled by a radially offset bracket.

[0070] In addition, the dovetail shape of the tabs prevents movement of the brackets in radial and circumferential directions; therefore, the brackets can be installed one by one without the need for attachment hardware until assembly is complete. The inner retaining ring completely secures the tabs in the mounting recesses without passing any fasteners through the tabs themselves, thereby improving their mechanical integrity. The fastener holes defined in the tabs would need to be countersunk in order to prevent the heads of the fasteners from interfering with other machine components, further compromising the mechanical integrity of the tabs. Passing the fasteners only through the inner retaining ring and the stator core also advantageously separates the conductive ground plane of the metal hardware from the non-conductive brackets.

[0071] Additionally, the same bracket design can be used in motors having different configurations, including those having end winding leads and busbars with different orientations. Figures 3 to 7 and Figure 13 to Figure 14 In the exemplary embodiment of FIG. 15 , the end windings extend substantially radially from the stator core, and the brackets provide an axial offset to reduce the radial space occupied by the busbars and the brackets. In the exemplary embodiment of FIG. 15 , the end windings extend substantially radially from the stator core, and the brackets provide an axial offset to reduce the axial space occupied by the busbars and the brackets.

[0072] Finally, constructing the bracket from a non-conductive material reduces the electrical clearance required between the busbars, thereby allowing them to be mounted closer together and overall reducing the size requirements of the motor.

[0073] As used herein, the terms "about," "substantially," "substantially," and "approximately," when used in conjunction with ranges of size, concentration, temperature, or other physical or chemical property or characteristic, are intended to encompass variations that may exist in the upper and / or lower limits of the range of the property or characteristic, including variations resulting, for example, from rounding, measurement methodology, or other statistical variations.

[0074] When introducing elements of the present disclosure or embodiments thereof, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," "containing," and "having" are intended to be inclusive and mean that there may be additional elements besides the listed elements. The use of terms indicating a particular orientation (e.g., "top," "bottom," "side," etc.) is for ease of description and does not require any particular orientation of the items being described.

[0075] As various changes could be made in the above constructions and methods without departing from the scope of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not limiting.

[0076] Further aspects of the invention are provided by the subject matter of the following clauses:

[0077] 1. An electric machine, comprising: a rotor; a stator magnetically coupled to the rotor, the stator comprising: a stator core, the stator core comprising an outer surface and a plurality of circumferentially spaced mounting recesses defined in the outer surface; a plurality of stator windings coupled to the radially inner surface of the stator core, each stator winding comprising: an end winding portion extending outwardly from an axial end of the stator core; and at least one lead extending from the end winding portion; at least one bus bar electrically coupled to at least two of the leads; and a bracket, the bracket comprising: a comb portion, the comb portion comprising a plurality of teeth arranged in at least one row so that a recess is defined between each pair of adjacent teeth, each of the recesses being sized to receive a portion of the bus bar therein; a protrusion, the protrusion being sized and shaped to be received within a respective one of the plurality of mounting recesses; and an arm extending between the comb portion and the protrusion so that the comb portion is offset relative to the protrusion.

[0078] 2. An electric machine according to claim 1, wherein the outer surface of the stator core extends substantially perpendicular to the radial inner surface, and wherein the bracket protrusion is received in one of the mounting recesses defined on the outer surface of the stator core so that the comb portion is radially offset relative to the protrusion.

[0079] 3. An electric machine according to any of the preceding clauses, wherein the stator core outer surface is substantially coaxially aligned with the radial inner surface, and wherein the bracket protrusion is received in one of the mounting recesses so that the comb-like portion of the bracket extends radially and is longitudinally offset relative to the protrusion.

[0080] 4. The electric machine according to any one of the preceding clauses, wherein the at least one busbar comprises a first busbar having a first radius of curvature and a second busbar formed with a second radius of curvature different from the first radius of curvature of the first busbar.

[0081] 5. An electric machine according to any of the preceding clauses, wherein the protrusion is dovetail-shaped, and wherein each of the plurality of mounting recesses is dovetail-shaped.

[0082] 6. An electric machine according to any of the preceding clauses, wherein the outer surface of the stator core also includes a plurality of first apertures defined therein, wherein the electric machine also includes an inner retaining ring defining a plurality of second apertures, and wherein the inner retaining ring is connected to the outer surface so that the first apertures are substantially aligned with the second apertures.

[0083] 7. An electric machine according to any of the preceding clauses, wherein the bracket comprises a first bracket disposed in a first mounting recess of the plurality of mounting recesses, wherein the first bracket defines a first outer aperture on a first end surface opposite the protrusion, and

[0084] The motor further comprises: a second bracket disposed in a second mounting recess among the plurality of mounting recesses, the second bracket defining a second outer opening on a second end surface opposite to the second bracket; and an outer retaining ring defining a plurality of outer retaining openings, the outer retaining ring extending arcuately between the first end surface and the second end surface.

[0085] 8. A bracket capable of being connected to a stator core of an electric motor, the bracket comprising: a comb portion, the comb portion comprising a plurality of teeth arranged in at least one row so that a recess is defined between each pair of adjacent teeth, each of the recesses being sized to receive a portion of an electrical bus therein; a protrusion, the protrusion being sized and shaped to be received within a mounting recess defined in the stator core; and an arm extending between the comb portion and the protrusion so that the comb portion is offset relative to the protrusion.

[0086] 9. A bracket according to clause 8, wherein the bracket is constructed of a non-conductive material.

[0087] 10. A bracket according to any of the preceding clauses, wherein the at least one busbar includes a first busbar and a second busbar, the first busbar having a first radius of curvature, wherein the plurality of teeth of the comb portion are arranged into at least a first row and a second row substantially parallel to the first row, each notch in the second row being sized to receive a portion of the second busbar therein, the second busbar being formed with a second radius of curvature different from the first radius of curvature of the first busbar.

[0088] 11. A bracket according to any of the preceding clauses, wherein the bracket includes an instrument wiring groove defined on an upper surface thereof and extending along the length of the comb portion.

[0089] 12. A bracket according to any of the preceding clauses, wherein the bracket further comprises at least one instrument rotation groove defined on the upper surface of the bracket, the instrument rotation groove extending along the width of the comb portion and at least partially intersecting with the instrument wiring groove.

[0090] 13. A bracket according to any of the preceding clauses, wherein the protrusion is dovetail-shaped.

[0091] 14. A bracket according to any of the preceding clauses, wherein the bracket further defines at least one constraining aperture extending through the comb portion, each constraining aperture being sized and shaped to receive a strap therethrough.

[0092] 15. A method for assembling an electric machine including a rotor, a stator, a busbar and a bracket, the method comprising: positioning a protrusion of the bracket in a mounting recess defined in an outer surface of a stator core of the stator, wherein the bracket includes a comb-like portion, the comb-like portion being offset relative to the protrusion and having a plurality of teeth arranged in at least one row so that a notch is defined between each pair of adjacent teeth; inserting a portion of the busbar into one of the plurality of notches; connecting a stator winding to the radial inner surface of the stator core; and connecting the busbar to a lead extending from an end winding portion of the stator winding.

[0093] 16. A method according to clause 15, wherein the outer surface of the stator core is oriented substantially perpendicular to the radial inner surface of the stator core, wherein positioning the protrusion of the bracket within the mounting recess includes positioning the protrusion in the mounting recess so that the comb-shaped portion of the bracket is radially offset relative to the protrusion.

[0094] 17. A method according to any of the preceding clauses, wherein the outer surface of the stator core is oriented substantially coaxially with the radial inner surface of the stator core, and wherein positioning the protrusion of the bracket within the mounting recess includes positioning the protrusion in the mounting recess so that the comb-like portion of the bracket is longitudinally offset relative to the protrusion.

[0095] 18. A method according to any of the preceding clauses, wherein the busbar comprises a first busbar and a second busbar, the first busbar having a first radius of curvature, wherein the plurality of teeth of the comb-shaped portion are arranged into at least a first row and a second row substantially parallel to the first row, wherein the method further comprises inserting a portion of the second busbar into a recess of the second row of the comb-shaped portion, the second busbar being formed with a second radius of curvature different from the first radius of curvature of the first busbar.

[0096] 19. A method according to any of the preceding clauses, wherein the outer surface of the stator core includes a plurality of first apertures defined in the outer surface of the stator core, the method further comprising: connecting an inner retaining ring to the outer surface, the inner retaining ring defining a plurality of second apertures such that the first apertures and the second apertures are aligned to receive fasteners therethrough; and inserting a plurality of fasteners through the plurality of first apertures and the plurality of second apertures to secure the inner retaining ring to the outer surface of the stator core.

[0097] 20. A method according to any of the preceding clauses, wherein the bracket further comprises an instrument wiring groove defined on an upper surface thereof, the instrument wiring groove extending along the length of the comb portion, the method further comprising inserting a portion of the sensor into the instrument wiring groove.

Claims

1. A motor, comprising: Rotor; a stator magnetically coupled to the rotor, the stator comprising: a stator core comprising an exterior surface and a plurality of circumferentially spaced apart mounting recesses defined in the exterior surface; A plurality of stator windings coupled to a radially inner surface of the stator core, each stator winding comprising: end winding portions extending outwardly from axial ends of the stator core; and at least one lead extending from said end winding portion; at least one bus bar electrically coupled to at least two of the leads; and A bracket, the bracket comprising: a comb portion comprising a plurality of teeth arranged in at least one row such that a notch is defined between each pair of adjacent teeth, each of the notches being sized to receive a portion of the busbar therein; a protrusion sized and shaped to be received within a corresponding one of the plurality of mounting recesses; and An arm extends between the comb portion and the projection such that the comb portion is offset relative to the projection.

2. The electric machine of claim 1 , wherein the stator core outer surface extends substantially perpendicular to the radial inner surface, and wherein the bracket protrusion is received in one of the mounting recesses defined on the stator core outer surface such that the comb portion is radially offset relative to the protrusion.

3. The electric machine of claim 1 , wherein the stator core outer surface is substantially coaxially aligned with the radial inner surface, and wherein the bracket protrusion is received in one of the mounting recesses such that the comb portion is longitudinally offset relative to the protrusion. 4 . The motor of claim 1 , wherein the at least one busbar comprises a first busbar having a first curvature radius and a second busbar formed with a second curvature radius different from the first curvature radius of the first busbar. 5 . The electric machine of claim 1 , wherein the protrusion is dovetail-shaped, and wherein each of the plurality of mounting recesses is dovetail-shaped.

6. The electric machine of claim 1 , wherein the stator core outer surface further comprises a plurality of first apertures defined therein, wherein the electric machine further comprises an inner retaining ring defining a plurality of second apertures, and wherein the inner retaining ring is coupled to the outer surface such that the first apertures are substantially aligned with the second apertures.

7. The motor of claim 1 , wherein the bracket comprises a first bracket disposed in a first mounting recess of the plurality of mounting recesses, wherein the first bracket defines a first outer aperture on a first end surface opposite the protrusion, and wherein the motor further comprises: a second bracket disposed in a second mounting recess of the plurality of mounting recesses, the second bracket defining a second outer aperture on a second end surface opposite the second bracket; and An outer retaining ring defining a plurality of outer retaining apertures extends arcuately between the first end surface and the second end surface.

8. A bracket connectable to a stator core of an electric machine, the bracket comprising: a comb portion comprising a plurality of teeth arranged in at least one row such that a notch is defined between each pair of adjacent teeth, each of the notches being sized to receive a portion of the electrical busbar therein; a protrusion sized and shaped to be received within a mounting recess defined in the stator core; and An arm extends between the comb portion and the projection such that the comb portion is offset relative to the projection.

9. The bracket of claim 8, wherein the bracket is constructed of a non-conductive material.

10. The bracket of claim 8, wherein the at least one busbar comprises a first busbar and a second busbar, the first busbar having a first radius of curvature, wherein the plurality of teeth of the comb portion are arranged in at least a first row and a second row substantially parallel to the first row, each notch of the second row being sized to receive a portion of the second busbar therein, the second busbar being formed with a second radius of curvature different from the first radius of curvature of the first busbar.

11. The bracket of claim 8, further comprising an instrument wiring groove defined on an upper surface thereof and extending along a length of the comb portion.

12. The bracket of claim 11, further comprising at least one instrument rotation groove defined on the upper surface of the bracket, the instrument rotation groove extending along the width of the comb portion and at least partially intersecting the instrument wiring groove.

13. The bracket of claim 8, wherein the protrusion is dovetail-shaped.

14. The bracket of claim 8, wherein the bracket further defines at least one restraining aperture extending through the comb portion, each restraining aperture being sized and shaped to receive a strap therethrough.

15. A method of assembling an electric machine comprising a rotor, a stator, a busbar and a bracket, the method comprising: positioning a protrusion of the bracket within a mounting recess defined in an exterior surface of a stator core of the stator, wherein the bracket includes a comb-like portion offset relative to the protrusion and having a plurality of teeth arranged in at least one row such that a notch is defined between each pair of adjacent teeth; inserting a portion of the busbar into one of the plurality of recesses; coupling a stator winding to a radially inner surface of the stator core; as well as The busbars are coupled to leads extending from end winding portions of the stator windings.

16. The method of claim 15, wherein the outer surface of the stator core is oriented substantially perpendicular to the radial inner surface of the stator core, wherein positioning the protrusion of the bracket within the mounting recess includes positioning the protrusion in the mounting recess such that the comb portion of the bracket is radially offset relative to the protrusion.

17. The method of claim 15, wherein the outer surface of the stator core is oriented substantially coaxially with the radial inner surface of the stator core, wherein positioning the protrusion of the bracket within the mounting recess includes positioning the protrusion in the mounting recess such that the comb portion of the bracket is longitudinally offset relative to the protrusion.

18. The method of claim 15, wherein the busbar comprises a first busbar and a second busbar, the first busbar having a first radius of curvature, wherein the plurality of teeth of the comb portion are arranged in at least a first row and a second row substantially parallel to the first row, wherein the method further comprises inserting a portion of the second busbar into a notch in the second row of the comb portion, the second busbar being formed with a second radius of curvature different from the first radius of curvature of the first busbar.

19. The method of claim 15, wherein the stator core exterior surface includes a plurality of first apertures defined therein, the method further comprising: coupling an inner retaining ring to the exterior surface, the inner retaining ring defining a plurality of second apertures such that the first apertures and the second apertures are aligned to receive a fastener therethrough; as well as A plurality of fasteners are inserted through the plurality of first apertures and the plurality of second apertures to secure the inner retaining ring to the stator core exterior surface.

20. The method of claim 15, wherein the bracket further comprises an instrument wiring groove defined on an upper surface thereof, the instrument wiring groove extending along a length of the comb portion, the method further comprising inserting a portion of a sensor into the instrument wiring groove.

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