System and method for an electric machine

Abstract

The present disclosure provides a system for an electric machine (10, 12) that can include a clamp (162) including a clamp base (168) defining a first clamp tooth (172, 172a). A fastening void (178, 178a) is defined by the first clamp tooth. The fastening void can extend into the clamp base. A stator winding (22) defines an opening (206) therethrough. A coil carrier (164) defines a carrier body (190) and is configured to operably couple the stator winding to the clamp base.

Description

Technical Field

[0001] This disclosure relates generally to electric motors, and more specifically to systems and methods for assembling electric motors. In particular, the inventions claimed herein relate to the subject matter set forth in the claims. Background Technology

[0002] The stator core of an electric motor includes conductive elements such as stator winding coils, which are electrically connected together via conductors that can extend outside the stator core. During the installation of the winding coils within the motor, each coil, which can be electrically connected to one or more additional coils, is placed in a defined position within the stator core. Therefore, systems for distributing conductive elements within the stator core are desirable in this technology. Summary of the Invention

[0003] The invention claimed herein relates to the subject matter defined in the appended claims. Aspects and advantages of the invention claimed herein, as well as other subject matter, are set forth in part in the following description, or may be apparent from the description or learned by practice of the art.

[0004] In some aspects, the subject matter of this invention relates to a system for an electric motor. The system includes a clamp comprising a clamp base defining first clamp teeth. A first fastening gap is defined by the first clamp teeth. The first fastening gap extends into the clamp base. A first stator winding defines a first opening therethrough. A coil carrier defines a carrier body. A first fastener includes a first segment and a second segment, the first segment being selectively held by the carrier body and positioned through the first opening defined by the first stator winding, the second segment being configured to be positioned within the first fastening gap.

[0005] Typically, the fastening clearance defined by the clamp teeth can be specifically considered as being defined within the clamp teeth, or more specifically, extending through the corresponding clamp teeth and into the clamp base. This fastening clearance can extend from the apex of the corresponding clamp tooth in a radially outward direction.

[0006] In some aspects, the subject matter of this invention relates to a method for assembling an electric motor. The method includes positioning a first fastener operably coupled to a first coil carrier through a first opening defined by a first stator winding. The method further includes selectively coupling the first fastener to a first fastener gap defined by a clamp. The method further includes positioning a second fastener operably coupled to a second coil carrier through a second opening defined by a second stator winding. Additionally, the method includes selectively coupling the second fastener to a second fastener gap defined by the clamp. The method includes positioning a bracket at a defined position on the clamp and connecting the first stator winding and the second stator winding to form a phase loop via a busbar, wherein a portion of the busbar extends through the bracket. The method further includes brazing a first connection point between the first stator winding and the busbar and brazing a second connection point between the second stator winding and the busbar.

[0007] In some aspects, the subject matter of this invention relates to a system for an electric motor. The system includes a clamp having a clamp base defining clamp teeth. A fastening gap is defined by the clamp teeth. The fastening gap extends into the clamp base. A stator winding defines an opening therethrough. A coil carrier defines a carrier body. The coil carrier is configured to operatively engage the stator winding to the clamp base. The system further includes an anchor and a support operatively engaged with the anchor and the coil carrier. The support is configured to maintain a defined distance between the anchor and the coil carrier.

[0008] These and other features, aspects, and advantages of the present invention will become more readily understood with reference to the following description and the appended claims. The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the invention. Attached Figure Description

[0009] The description, with reference to the accompanying drawings, sets forth a full and implementable disclosure of the present technology (including its best embodiments) for those skilled in the art, wherein:

[0010] Figure 1A A perspective view of an electric motor according to various aspects of the subject matter of the present invention is shown;

[0011] Figure 1B It is along Figure 1A A cross-sectional view of the motor taken by line IA-IA;

[0012] Figure 2 It is along Figure 1A A sectional view of the motor taken from line II-II;

[0013] Figure 3This is a side perspective view of the wedge-shaped portion at the axial end of the stator core of an electric motor according to various aspects of the subject matter of the present invention;

[0014] Figure 4 This is a top perspective view of the wedge-shaped portion at the axial end of the stator core of an electric motor according to various aspects of the subject matter of the present invention.

[0015] Figure 5 This is a top perspective view of the wedge-shaped portion of the axial end of the stator core of an electric motor, which includes multiple stator windings and multiple end winding portions, according to various aspects of the subject matter of the present invention.

[0016] Figure 6 This is a top perspective view of the wedge-shaped portion of the axial end of the stator core of an electric motor including multiple busbars, according to various aspects of the subject matter of the present invention.

[0017] Figure 7 This is a top perspective view of the wedge-shaped portion of the axial end of the stator core of an electric motor including multiple brackets, according to various aspects of the subject matter of the present invention.

[0018] Figure 8 This is in accordance with various aspects of the subject matter of the present invention. Figure 7 A perspective view of one of the multiple brackets shown;

[0019] Figure 9 This is in accordance with various aspects of the subject matter of the present invention. Figure 7 Another perspective view of one of the multiple brackets shown;

[0020] Figure 10 This is in accordance with various aspects of the subject matter of the present invention. Figure 7 Another perspective view of one of the multiple brackets shown;

[0021] Figure 11 This is a perspective view of a system configured to facilitate the formation of a sub-assembly of an electric motor prior to installation within a stator core, according to various aspects of the subject matter of the invention, the system including a portion of a clamp.

[0022] Figure 12 This is an alternative perspective view of a system configured to facilitate the formation of a sub-assembly of an electric motor prior to installation within the stator core, according to various aspects of the subject matter of the invention.

[0023] Figure 13 This is a perspective view of a system constructed to facilitate the formation of a sub-assembly of an electric motor prior to installation within the stator core, according to various aspects of the subject matter of the invention.

[0024] Figure 14 This is a perspective view of a stator according to various aspects of the subject matter of the invention, wherein a portion of a stator winding is mounted in the stator;

[0025] Figure 15 This is a perspective view of a stator according to various aspects of the subject matter of the invention, wherein stator windings are mounted in the stator; and

[0026] Figure 16 A flowchart is shown of a method for assembling an electric motor according to various aspects of the subject matter of the present invention.

[0027] Reference characters are used repeatedly in this specification and drawings to indicate the same or similar features or elements of the technology. Detailed Implementation

[0028] Reference will now be made in detail to embodiments of this disclosure, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation and not by way of limitation of this disclosure. Indeed, it will be apparent to those skilled in the art that various modifications and variations may be made to the invention claimed herein without departing from the scope of the invention claimed herein. For example, features partially illustrated or described may be used in combination with another embodiment to produce further embodiments. Therefore, this disclosure is intended to cover such modifications and variations that fall within the scope of the appended claims.

[0029] The techniques of this application will be described in conjunction with the examples shown. The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, unless otherwise specifically stated, all embodiments described herein should be considered exemplary.

[0030] The detailed description uses numerical and letter names to refer to features in the drawings. Similar or analogous names in the drawings and description have been used to refer to similar or analogous parts of the invention. As used herein, relational terms such as first and second, top and bottom, etc., are used only to distinguish one entity or action from another entity or action, and do not necessarily require or imply any actual such relationship or order between such entities or actions. The terms “comprising,” “including,” or any other variation thereof are intended to cover non-exclusive inclusion, such that a process, method, article of manufacture, or apparatus that comprises a list of elements includes not only those elements but may also include other elements not expressly listed or inherent to such process, method, article of manufacture, or apparatus. An element preceded by “comprising…one” does not exclude the presence of additional identical elements in the process, method, article of manufacture, or apparatus that includes that element, unless further limited.

[0031] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of individual components. Unless otherwise stated herein, the terms “connected,” “fixed,” “attached to,” etc., refer to direct connection, fixation, or attachment, as well as indirect connection, fixation, or attachment via one or more intermediate components or features. The terms “upstream” and “downstream” refer to the relative directions of current flow. For example, “upstream” refers to the direction in which current flows out, and “downstream” refers to the direction in which current flows in. The term “selectively” refers to the ability of a component to operate in various states (e.g., on and off) based on manual and / or automatic control of that component.

[0032] Unless otherwise stated herein, the terms “connection,” “fixed,” “attached to,” etc., refer to direct connection, fixation, or attachment, as well as indirect connection, fixation, or attachment via one or more intermediate components or features. As used herein, the terms “comprising,” “including,” “having,” or any other variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, article of manufacture, or apparatus that includes a list of features is not necessarily limited to those features, but may include other features not expressly listed or inherent to such process, method, article of manufacture, or apparatus.

[0033] Furthermore, any arrangement of components that perform the same function is effectively “associated” to achieve that function. Therefore, any two components combined herein to achieve a specific function can be considered “associated” with each other to achieve the desired function, regardless of the architecture or intermediate components used. Similarly, any two such associated components can also be considered “operably connected” or “operably linked” to each other to achieve the desired functionality, and any two components that can be suchly associated can also be considered “operably linked” to each other to achieve the desired functionality. Some examples of operably linked components include, but are not limited to: physically pairable, physically interactive components; wirelessly interactive, wirelessly interactive components; logically interactive and / or logically interactive components.

[0034] Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” include plural references.

[0035] Furthermore, the term "axial" refers to movement or positioning parallel to an axis (e.g., the axis of an electric motor such as a generator or motor). The term "radial" refers to movement or positioning perpendicular to an axis (e.g., the axis of a conductive winding or the axis of a motor). In such cases, if the first component resides closer to the axis than the second component, this document will state that the first component is "radially inward" or "inner" of the second component. On the other hand, if the first component resides further away from the axis than the second component, this document may state that the first component is "radially outward" or "outer" of the second component. Finally, the term "circumferential" refers to movement or positioning around or through an axis, such as the circumferential inner surface of the stator body of a generator or motor. As mentioned above, it should be understood that such terms can be applied relative to the axis of the motor.

[0036] Terms with approximate meanings (such as “about,” “approximately,” “generally,” and “substantially”) are not limited to specified precise values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value, or the precision of the method or machine used to construct or manufacture the component and / or system. For example, approximate language may refer to tolerances of 1%, 2%, 4%, 5%, 10%, 15%, or 20% of the end values ​​of an individual value, a range of values, and / or a range of defined values. When used in the context of angles or directions, such terms include those greater than or less than ten degrees of said angle or direction. For example, “generally vertical” includes directions within a vertical range of ten degrees along any direction (e.g., clockwise or counterclockwise).

[0037] Throughout this specification and claims, unless the context or language otherwise indicates, scope limitations are combined and interchanged, such scopes are identified and include all subscopes contained herein. For example, all scopes disclosed herein include end values, and end values ​​can be combined independently of each other.

[0038] As used herein, when used in a list of two or more items, the term "and / or" means that any one of the listed items may be used alone, or any combination of two or more of the listed items may be used. For example, if a composition or component is described as containing parts A, B, and / or C, the composition or component may contain only A; only B; only C; a combination of A and B; a combination of A and C; a combination of B and C; or a combination of A, B, and C.

[0039] Generally, the subject matter of this invention relates to a system that can be implemented to facilitate the formation of sub-assemblies of a motor prior to installation within the stator core. For example, the system may include clamps, one or more coil carriers, and / or anchors to attach these components to each other prior to the installation of one or more stator windings, one or more brackets, and / or one or more busbars into the stator core. In various examples, each of the stator windings, brackets, and / or busbars implemented within the motor may be pre-assembled within the system prior to installation within the stator core. Additionally or alternatively, a portion of the stator windings, brackets, and / or busbars implemented within the motor may be pre-assembled within the system prior to installation within the stator core. The systems disclosed herein can allow for more compact motors with reduced housing size and weight, and / or reduced spacing between active electrical components based on electrical clearances (voltage levels) rather than mechanical considerations and in-situ space requirements of manufacturing processes (e.g., induction brazing).

[0040] Now for reference Figure 1A and Figure 1B The diagram illustrates an electric motor 10 according to various aspects of the subject matter of the invention. For illustrative purposes only, the motor 10 may be configured as an electric motor / generator 12 comprising a stator 14 and a rotor 16, wherein the relative rotation between the rotor 16 and the stator 14 converts electrical energy into mechanical energy, or vice versa. In further embodiments, the motor 10 may be any other type of rotating electric motor, such as, but not limited to, a synchronous motor, a multiphase motor, a motor with concentrated windings, a motor with distributed windings, a reluctance motor, an induction motor, a wound-excited motor, a salient-pole motor, an internal permanent magnet (IPM) motor, a motor having permanent magnets arranged differently from those of an IPM motor (e.g., a surface PM motor, etc.), and / or any other suitable motor.

[0041] The stator 14 may also include a stator frame 18 and a stator core 20, the stator core including one or more stator windings 22. The rotor 16 of the motor 10 may include a shaft 24 and a rotor core 26 mounted to the shaft 24. The stator 14 is disposed around the rotor 16. The shaft 24 may be driven to rotate about a longitudinal axis 28 by, for example, a gas turbine, steam turbine, wind turbine, water turbine, internal combustion engine, or any other suitable device configured to provide a rotational output. The rotor 16 is disposed within the stator 14, which is configured to provide a static magnetic field. As described above, rotation of the rotor 16 within the stator 14 can generate current in the stator windings 22, thereby producing an electrical output from the motor / generator 12. Additionally or alternatively, an electrical input to the motor / generator 12 can cause rotation of the rotor 16 within the stator 14, thereby producing a mechanical output from the motor / generator 12.

[0042] In the illustrated example, the rotor 16 extends within the central opening 30 of the stator core 20 and is rotatable relative to the stator core 20 within the central opening 30. That is, the dimensions of the stator core 20 of the motor 10 are set to extend around the rotor 16, such that the rotor 16 is rotatable within the stator 14. In another example, the dimensions of the rotor 16 may be set to extend around the stator 14 and rotate around the stator 14.

[0043] Now for reference Figures 2 to 4 The stator core 20 includes a stator base 32, a plurality of circumferentially spaced stator teeth 34, and a plurality of circumferentially spaced spacers 36. In the illustrated example, each stator tooth 34 and spacer 36 extends radially inward from the stator base 32. For example, each stator tooth 34 extends from a first end 38 adjacent to the stator base 32 to a second free end 40. The second end 40 of each stator tooth 34 may partially define a central opening 30 of the stator core 20. In some examples, the second ends 40 of each stator tooth 34 are joined together. Each stator tooth 34 may also define at least one wedge-shaped retaining groove 42 near its second end 40. Each wedge-shaped retaining groove 42 may extend along the axial length of each stator tooth 34 between the axial ends 44 of the stator core 20. The respective shapes and dimensions of the plurality of wedges 46 are configured to be received in and held by a corresponding pair of wedge-shaped retaining grooves 42 defined between adjacent pairs of stator teeth 34. Each wedge 46 secures the stator winding 22 within the corresponding raceway 50.

[0044] Further reference Figures 2 to 4 Each spacer 36 can extend from a first end 52 adjacent to the stator base 32 to a second free end 54. The stator teeth 34 and spacers 36 can be circumferentially spaced around the stator base 32 in an alternating pattern, such that the spacers 36 are positioned between each pair of circumferentially adjacent stator teeth 34, and the stator teeth 34 are positioned between each pair of circumferentially adjacent spacers 36. The stator core 20 may include any number of stator teeth 34 and spacers 36.

[0045] The inner surface of the stator base 32 between each adjacent stator tooth 34 and the spacer 36 forms the radial inner surface 56 of the stator core 20. Figure 3 (As shown in the diagram). Each raceway 50 is partially defined by a radially inner surface 56, each pair of circumferentially adjacent spacers 36, and corresponding stator teeth 34 disposed between them. Each raceway 50 is shaped and sized to receive a stator winding 22 therein. Each stator winding 22 extends longitudinally through the stator core 20. The stator core 20 may include the same number of stator windings 22 as the raceways 50, or alternatively, the stator core may include fewer stator windings 22 than the raceways 50, such that at least one raceway 50 does not receive a stator winding 22 therein.

[0046] Still referencing Figures 2 to 4 The rotor core 26 is rotatable relative to the stator 14 about a central longitudinal axis 28. In the illustrated example, the rotor core 26 includes a rotor base 58, a plurality of magnetic segments 60 extending radially outward from the rotor base 58, and a plurality of non-magnetic segments 62 extending radially outward from the rotor base 58. In other examples, the plurality of magnetic segments 60 and / or the plurality of non-magnetic segments 62 may extend radially inward from the rotor base 58.

[0047] Magnetic segments 60 and non-magnetic segments 62 are arranged around the rotor periphery Cr of rotor core 26 in an alternating pattern of circumferentially spaced magnetic segments 60 and non-magnetic segments 62. In other words, the magnetic segments 60 are radially spaced around the central longitudinal axis 28 such that the magnetic segments 60 are circumferentially spaced a certain distance from it, and the non-magnetic segments 62 extend between circumferentially adjacent magnetic segments 60 spaced around the rotor periphery Cr of rotor core 26. In the illustrated example, rotor 16 is a toothed rotor, wherein the magnetic segments 60 define the rotor teeth 64 of rotor core 26.

[0048] The rotor base 58 includes a radial inner rotor surface 66 that defines a central opening 68 within the rotor core 26. The outer periphery of the rotor core 26 is defined by end faces 70 of magnetic segments 60 and non-magnetic segments 62. A gap G may be defined between the outer periphery of the rotor core 26 and the second end 40 of each stator tooth 34 of the stator core 20. The rotor base 58 may include one or more mortises, each sized and oriented to receive a corresponding tenon extending from the shaft 24 for mounting the rotor core 26 to the shaft 24. Other arrangements for mounting the rotor core 26 to the shaft 24 may be provided as supplements to or alternatives to the mortises and tenons.

[0049] The rotor core 26 may be formed from one or more stacks of multiple laminates, or alternatively, may be formed as a single piece of material. The rotor base 58 of the rotor core 26 may be made of a non-magnetic material and may be integrally formed with the magnetic segments 60. Alternatively or otherwise, the rotor base 58 may be integrally formed with the non-magnetic segments 62. For example, when the rotor core 26 is formed from a stack of laminates, the rotor base 58 of each laminate or layer within the stack may be integrally formed with the magnetic segments 60 and / or non-magnetic segments 62 of the laminate. Furthermore, for example, in an embodiment where the rotor core 26 is formed as a single piece of material, the rotor base 58 is a single piece of material integrally formed from a magnetic material and includes all the magnetic segments 60 and non-magnetic segments 62 of the rotor core 26. In the illustrated example, the magnetic segments 60 cooperate with the rotor base 58 to form the rotor 16 as a toothed rotor. In other words, in this embodiment, the rotor base 58 carries the magnetic flux. Whether constructed from a stack of laminates or from a single material, the toothed rotor structure of rotor 16 distinguishes it from a "segmented" rotor, which includes a rotor core 26 with magnetic segments 60, magnetically isolated or segmented from and from the rotor base 58. In the illustrated example, stator 14 and / or rotor 16 may include permanent magnets. In some alternative examples, rotor 16 is a segmented rotor.

[0050] The rotor core 26 may include any number of magnetic segments 60 and / or non-magnetic segments 62. Furthermore, the rotor core 26 may include any number of rotor teeth 64. In some cases, the rotor core 26 includes the same number of rotor teeth 64 as the stator core 20 includes stator teeth 34. Alternatively, the stator core 20 may include more or fewer stator teeth 34 than the number of rotor teeth 64 included in the rotor core 26.

[0051] Now for reference Figures 3 to 5 The illustration shows a wedge-shaped portion 74 of the axial end 44 of a stator core 20, including a subassembly 76. The illustrated wedge-shaped portion 74 may represent any circumferential portion of the stator core 20 at any of its axial end 44, and it should be understood that each wedge-shaped portion 74 included in each axial end 44 of the stator core 20 may include a portion with... Figures 3 to 5 The features and components shown are the same as those shown, or may include features and components similar to those shown. Figures 3 to 5 The features and components shown are different from those shown.

[0052] exist Figures 3 to 5 In the illustrated example, the stator core 20 includes a radial outer surface 78 ( Figure 4The stator core 20 includes a flange 80 that defines the stator core 20 and extends radially outward from the radially outer surface 78. In the illustrated example, the flange 80 defines at least one mounting hole 82 therein, the shape and size of which are configured to receive a fastener passing through it. The stator core 20 also includes an outer surface 84 that extends substantially perpendicularly from the radially inner surface 56 of the stator core 20. Furthermore, the stator core 20 may include a plurality of recessed surfaces 86 and a plurality of recessed sidewalls 88. Each recessed sidewall 88 extends from the outer surface 84 to a corresponding recessed surface 86. Each recessed surface 86 and the corresponding recessed sidewall 88 define a mounting recess 90 extending from the outer surface 84 into the stator core 20. In the illustrated example, each mounting recess 90 is dovetail-shaped. In alternative embodiments, each mounting recess 90 may have any other suitable shape without departing from the teachings provided herein.

[0053] The outer surface 84 may also include a plurality of channels 92 defined therein. In the illustrated example, the channels 92 and mounting recesses 90 are circumferentially spaced around the outer surface 84 of the stator core 20 such that the channels 92 are defined between each pair of adjacent mounting recesses 90, and the mounting recesses 90 are defined between each pair of circumferentially adjacent channels 92. In an alternative embodiment, depending on the design of the stator core 20, at least some of the circumferentially spaced pairs of mounting recesses 90 do not include the channels 92 defined between them.

[0054] Further reference Figure 5 Multiple stator windings 22 can be received in corresponding raceways 50 ( Figure 2 (As shown in the illustration). In the illustrated example, the stator winding 22 is formed by winding a plurality of wires around one of the stator teeth 34 and in a raceway configuration between adjacent spacers 36. That is, these wires allow the stator winding 22 to extend longitudinally through the stator core 20 in a direction substantially parallel to the central longitudinal axis 28. Furthermore, at each axial end 44 of the stator core 20, these wires are wrapped around both sides of the stator tooth 34 and around the end of the stator tooth 34. A plurality of wedges 46 secure each respective stator winding 22 within a respective raceway 50.

[0055] In some embodiments, stator winding 22 may include one or more direct current (DC) windings and / or one or more alternating current (AC) windings. In other embodiments, stator winding 22 may include copper windings, Litz wire windings, fractional slot concentrated windings, and / or any other suitable type of stator winding. Each stator winding 22 may be or can represent any number of phases, such as, but not limited to, single-phase or three-phase. In further embodiments, stator winding 22 may be a rigid conductor with a similar shape.

[0056] The portion of each stator winding 22 surrounding the end of the stator tooth 34 forms an end winding portion 94 extending outward from the axial end 44 of the stator core 20. The ends of the plurality of wires forming each stator winding 22 may extend axially outward from the end winding portion 94 to form leads 96. The plurality of wires in each lead 96 may be brazed together to form a solid single lead, or they may be loosely bundled together. In some embodiments, each lead 96 is flexible and can be bent and / or manipulated into various configurations or orientations. In other embodiments, the lead 96 is rigid and fixed in a single configuration.

[0057] Figure 5 The wedge-shaped portion 74 shown includes four end winding portions 94 having a first lead 96a, a second lead 96b, a third lead 96c, and a fourth lead 96d. Each lead 96a-96d includes a radial portion 98a-98d and an axial portion 100a-100d, the radial portion extending radially inward toward the central longitudinal axis 28, and the axial portion extending axially away from the stator core 20, such that each portion 66a-66d is substantially parallel to the central longitudinal axis 28. In the illustrated example, the first lead 96a and the third lead 96c are formed identically, and the second lead 96b and the fourth lead 96d are formed identically but have different dimensions than 96a and 96c. That is, the radial portions 65a and 65c of the corresponding first lead 96a and third lead 96c each have a first radial length L. r1 Furthermore, the radial portions 65b and 65d of the corresponding second lead 96b and fourth lead 96d each have a length L greater than the first radial length. r1 The second radial length L r2 Similarly, the axial portions 66a and 66c of the corresponding first lead 96a and third lead 96c have a first axial length L. a1 Furthermore, the axial portion 100b of the corresponding second lead 96b and the axial portion 100d of the fourth lead 96d have a length greater than the first axial length L. a1 The second axial length L a2 In other implementations, all leads 96a-96d may have substantially the same dimensions, or may differ from each other in any other way.

[0058] In some embodiments, the stator core 20 also includes a plurality of slot liners, the dimensions and orientation of which are configured to be received within corresponding raceways 50. The slot liners may be made of a non-conductive material, such that the stator windings 22 are electrically insulated from the stator core 20. Each slot liner may be positioned between the radially inner surface 56 of the stator core 20 and the stator windings 22, and may extend longitudinally between the axial ends of the stator core 20.

[0059] Now for reference Figure 6The motor 10 may also include at least one busbar 102 electrically connected to at least two leads 96. In the illustrated example, three busbars 102a-c are shown, but the motor 10 may also include any suitable number of busbars 102 enabling the motor 10 to operate as described herein. Each busbar 102 may include an arcuate circumferential portion 104 and at least two axial protrusions 106. Each circumferential portion 104 has a depth d1 and a width w1, and extends a first arcuate length that allows the busbar 102 to extend between a pair of axial protrusions 106. In other embodiments, the circumferential portion 104 may extend circumferentially beyond one or both of the axial protrusions 106. Furthermore, the circumferential portion 104 may extend substantially linearly between at least two axial protrusions 106, or alternatively, the circumferential portion may be formed with a radius of curvature. In other embodiments, the circumferential portion 104 may form a complete annular loop such that the first arcuate length AL1 is the complete perimeter defined by the circumferential portion 104. In another embodiment, the circumferential portion 104 may be semi-circular.

[0060] Each axial protrusion 106 may extend from a first end 108 connected to the circumferential portion 104 to a second free end 110. More specifically, in the illustrated example, each axial protrusion 106 extends radially inward from the first end 108 to the second end 110. In other embodiments, the axial protrusions 106 may extend in any other suitable direction without departing from the teachings provided herein. In the illustrated example, the portion of the axial protrusion 106 adjacent to the first end 108 is substantially flush with the circumferential portion 104, and the portion of the axial protrusion 106 adjacent to the second end 110 is substantially perpendicular to the circumferential portion 104. In further embodiments, both the first end 108 and the second end 110 may be substantially flush with the circumferential portion 104, or both the first end 108 and the second end 110 may extend substantially perpendicular to the circumferential portion 104.

[0061] In the illustrated example, each axial protrusion 106 is coupled to the axial portion 100 of one of the plurality of leads 96, such that each busbar 102 is electrically coupled to at least two leads 96. In other embodiments, the busbar 102 and the leads 96 can be coupled together in any other suitable manner, for example, by coupling the axial protrusion 106 to the radial portion 98 of the lead 96. In a further embodiment, the busbar 102 may not include any axial protrusion 106, and the circumferential portion 104 is coupled to at least two leads 96. The busbar 102 may be brazed to each lead 96 or may be coupled in any other suitable manner. In the illustrated example, a single busbar 102 is coupled to each lead 96. In other embodiments, more than one busbar 102 may be coupled to each lead 96.

[0062] refer to Figures 7 to 10 In some examples, the motor 10 may also include at least one bracket 114 that provides mechanical support to at least one busbar 102. The bracket 114 may be positioned in a mounting recess 90 (in... Figure 4 (Not shown in the image). In the illustrated example, the first bracket 114a is received in the first mounting recess 90a, and the second bracket 114b is received in the second mounting recess 90b.

[0063] In various examples, each bracket 114 may include a comb-like portion 116, a protrusion 118, and an arm 120 extending between the comb-like portion 116 and the protrusion 118. In some cases, the comb-like portion 116 is offset from the protrusion 118. The comb-like portion 116 may include a plurality of teeth 122. For example, each bracket 114 may include a first upper row of 124 teeth 122 and a second lower row of 126 teeth 122. In other embodiments, the comb-like portion 116 may include any other suitable number of rows, such as, but not limited to, only one row of teeth 122 or more than two rows of teeth 122.

[0064] Each of the plurality of teeth 122 may extend substantially vertically downward from the lower surface 128 of each row of teeth 122 in the first row of 124 teeth 122 and / or the second row of 126 teeth 122. A notch 130 may be defined between each pair of adjacent teeth 122. Each row of teeth 122 in the first row of 124 teeth 122 and / or the second row of 126 teeth 122 of the comb-like portion 116 may include at least two teeth 122 defining a notch 130 between these at least two teeth. The size and shape of each notch 130 may be configured to receive a portion of the busbar 102 therein. More specifically, in the illustrated example, the size and shape of each notch 130 is configured to receive a portion of the circumferential portion 104 of the busbar 102 therein. Furthermore, in some cases, not every notch 130 of the bracket 114 receives a portion of the busbar 102. For example, in the illustrated example, at least some notches 125 may remain empty and not receive a portion of the busbar 102. For example, the first bracket 114a receives a portion of the first busbar 102a in a recess 130 defined in its upper row 124a, and a portion of the second busbar 102b is received in a recess 130 defined in its lower row 126b. Similarly, the second bracket 114b receives a portion of the third busbar 102c in a recess 130 defined in its upper row 124b. In the illustrated example, the other recesses 125 do not receive any portion of the busbar 102.

[0065] Each bracket 114 may also include a protrusion 118 formed by an inner surface 132, an outer surface 134, a top surface 136, and a plurality of side surfaces 138. In the example shown, the inner surface 132 is substantially parallel to the outer surface 134. Additionally or alternatively, the top surface 136 may be substantially perpendicular to the inner surface 132 and / or the outer surface 134. In an alternative embodiment, the inner surface 132, the outer surface 134, and the top surface 136 may be formed in any other suitable orientation relative to each other. The shape and size of each protrusion 118 may be configured to be received within a corresponding mounting recess 90 in the stator core 20. For example, if the mounting recess 90 is a dovetail recess, the protrusion 118 is formed as a dovetail protrusion. In an alternative embodiment, the bracket 114 may be coupled to the stator core 20 using any other suitable mechanical coupling features.

[0066] In various examples, each protrusion 118 is received in the mounting recess 90 such that the inner surface 132 engages with the recessed surface 86 of the stator core 20, and each of the top surface 136 and the side surface 138 engages with one of the recessed sidewalls 88 defined within the stator core 20.

[0067] Further reference Figures 7 to 10 Each bracket 114 may additionally include an arm 120 extending between the protrusion 118 and the comb-like portion 116. In various examples, the arm 120 may include an upper surface 140, a lower surface 142, and a pair of opposing side surfaces 144 extending between the upper surface 140 and the lower surface 142.

[0068] In various examples, the bracket 114 may additionally or alternatively include an instrument wiring recess 146 defined along the upper surface 148 of the upper row of 124 teeth 122. In the illustrated example, the instrument wiring recess 146 extends along the comb-like portion 116 and the arm 120. The shape and size of the instrument wiring recess 146 may be configured to receive one or more sensors therein, such that the sensors extend generally axially through the motor 10. Such sensors may be, for example, but not limited to, thermocouples or other temperature sensors. In several examples, the bracket 114 may additionally include at least one instrument rotation recess 150 defined in the upper surface 148 of the upper row of 124 teeth 122. The instrument rotation recess 150 may extend along the upper surface 148 and may at least partially intersect the instrument wiring recess 146. The shape and size of each instrument rotation recess 150 may be configured to at least partially receive one of the one or more sensors received in the instrument wiring recess 146, such that the sensor can be rewired from the axial direction to the circumferential direction. The example shown illustrates two different sizes of grooves, but other embodiments may include only grooves of the same size, or multiple different sizes of grooves.

[0069] Still referencing Figures 7 to 10 The bracket 114 may further include at least one constraint aperture 152 defined therein, the constraint aperture extending through the comb portion 116 and / or any other portion of the bracket 114. The shape and size of each constraint aperture 152 may be configured to receive a restraint strap therein. In the illustrated example, each row 126 of the comb portion 116 includes four constraint apertures 152, but each row 126 may also include any other suitable number of constraint apertures 152, such as, but not limited to, more than four or fewer than four constraint apertures 152.

[0070] Now for reference Figures 11 to 15 In various examples, system 160 can be implemented to facilitate the formation of sub-assemblies 76 of motor 10 prior to installation within stator core 20. For example, system 160 may include clamps 162, one or more coil carriers 164, and / or anchors 166 to attach these components to each other prior to installation of one or more stator windings 22, one or more brackets 114, and / or one or more busbars 102 into stator core 20. In various examples, each of the stator windings 22, brackets 114, and / or busbars 102 implemented within motor 10 may be pre-assembled within system 160 as sub-assemblies 76 prior to installation within stator core 20. Additionally or alternatively, a portion of the stator windings 22, brackets 114, and / or busbars 102 implemented within motor 10 may be pre-assembled within system 160 as sub-assemblies 76 prior to installation within stator core 20. The system 160 disclosed herein can allow for a more compact motor 10 with reduced housing size and weight, and / or reduced spacing between active electrical components based on electrical clearance (voltage level) rather than mechanical considerations and in-situ space requirements of manufacturing processes (e.g., induction brazing).

[0071] like Figure 11 and Figure 12 As shown, the clamp 162 may include a clamp base 168 that defines a cavity 170. The cavity 170 may be defined by a cavity diameter, which may be approximately equal to the stator core diameter. However, the cavity 170 may have any size and geometry without departing from the teachings provided herein. Figure 11 and Figure 12 As shown, the clamp base 168 may include a plurality of circumferentially spaced clamp teeth 172. In the example shown, each clamp tooth 172 extends radially inward from the clamp base 168. For example, each clamp tooth 172 extends from a first end 174 adjacent to the clamp base 168 to a second free end 176. The second end 40 of each clamp tooth 172 may partially define a cavity 170 of the clamp base 168.

[0072] As shown in the figure, the clamp teeth 172 can define one or more fastening gaps 178. For example, in Figure 11 and Figure 12 In the example shown, the clamp teeth 172 may define a first fastening gap 178a extending radially outward into the clamp base 168. The clamp teeth 172 may further define a second fastening gap 178b extending radially outward into the clamp base 168, wherein the second fastening gap 178b is axially offset from the first fastening gap 178a. In various examples, each of the first fastening gap 178a and / or the second fastening gap 178b may include a fastening feature. For example, each of the first fastening gap 178a and / or the second fastening gap 178b may have threads within each respective gap, allowing for selective fastening of components thereto.

[0073] exist Figure 11 and Figure 12 In the illustrated example, the clamp base 168 may further define at least one mounting hole 180 therein, the shape and size of which are configured to receive a fastener passing through it. Furthermore, the clamp base 168 may define a plurality of recessed surfaces 182 and a plurality of recessed sidewalls 184. Each recessed sidewall 184 may extend from an outer surface 186 of the clamp base 168 to a corresponding recessed surface 182. Each recessed surface 182 and the corresponding recessed sidewall 184 define a mounting recess 188 extending from the outer surface 186 into the clamp base 168. In the illustrated example, each mounting recess 188 is dovetail-shaped. In alternative embodiments, each mounting recess 188 may have any other suitable shape without departing from the teachings provided herein.

[0074] Now for reference Figures 11 to 13 As provided herein, one or more stator windings 22 can be or may represent any number of phases, such as, but not limited to, single-phase or three-phase, which can be mounted along the stator core 20. The stator windings 22 can be operatively connected to one or more busbars 102 electrically connected to at least two leads 96. Figure 12 In the illustrated example, three busbars 102a-102c are shown, but the motor 10 may also include any suitable number of busbars 102 that enable the motor 10 to operate as described herein. The motor 10 may also include at least one bracket 114 that provides mechanical support to at least one busbar 102 and / or any other component.

[0075] In various examples, each stator winding 22, bracket 114, and / or busbar 102 may be a separate component prior to assembly. To facilitate the assembly of each of these components with respect to the others, system 160 may further include a coil carrier 164. The coil carrier 164 may include a carrier body 190 defining one or more fastener openings 192 through the carrier body 190. In the illustrated example, the carrier body 190 of the coil carrier 164 includes four fastener openings 192. However, without departing from the scope of this disclosure, the carrier body 190 may include any number of openings.

[0076] Further reference Figures 11 to 13 One or more fasteners 194 may be positioned through one or more fastener openings 192. Without departing from the teachings provided herein, one or more fasteners 194 may be constructed in any manner. In various examples, fastener 194 may include a first segment 196 having a first end 198 selectively held by and / or positioned through a fastener opening 192 of the carrier body 190 of the coil carrier 164. The first segment 196 of fastener 194 further includes a second end 200 extending away from the carrier body 190 of the coil carrier 164. In various examples, the first segment 196 may be constructed as a boss, tenon, and / or any other suitable means.

[0077] Additionally, the fastener 194 may include a second segment 202 extending from the second end 200 of the first segment 196. In some cases, the length of the second segment 202 outside the first segment 196 may be adjustable, such as by manipulating the head 204 of the fastener 194, which may be positioned at the first end 198 of the fastener 194. Additionally or alternatively, the second segment 202 of the fastener 194 may include threads corresponding to threads within the fastening gap 178 of the clamp 162. Thus, the second segment 202 of the fastener 194 may be selectively retained within the fastening gap 178.

[0078] In various examples, the first fastener 194a and the second fastener 194b can be operatively coupled to the carrier body 190 of the coil carrier 164. A first segment 196 of the first fastener 194a and a first segment 196 of the second fastener 194b can be positioned through an opening 206 defined by the first stator winding 22a. A second segment 202 of the first fastener 194a can be positioned within a first fastening gap 178a on the first clamping teeth 172a, and a second segment 202 of the second fastener 194b can be positioned within a second fastening gap 178b on the first clamping teeth 172a. As provided herein, the second segment 202 of the first fastener 194a can be adjusted or movable relative to the first segment 196 of the first segment 196 by manipulating the head 204 of the fastener 194 or by any other method, and / or the second segment 202 of the second fastener 194b can be adjusted relative to the first segment 196 of the second segment 202. Adjusting the second section 202 of the first fastener 194a and / or the second section 202 of the second fastener 194b can extend the corresponding second section 202 into the corresponding fastener gaps 178a, 178b. In such cases, the first stator winding 22a can be selectively attached to the clamp 162 via the coil carrier 164.

[0079] Additionally or alternatively, the third fastener 178c and the fourth fastener 178d can be operatively connected to the carrier body 190 of the coil carrier 164. The first section 196 of the third fastener 194c and the first section 196 of the fourth fastener 194d can be positioned through an opening 206 defined by the second stator winding 22b. The second stator winding 22b can be configured adjacent to the first stator winding 22a. The second section 202 of the third fastener 194c can be positioned within a first fastening gap 178a on the second clamping teeth 172b, and the second section 202 of the fourth fastener 194d can be positioned within a second fastening gap 178b on the second clamping teeth 172b. As provided herein, by manipulating the head 204 of fastener 194 or by any other method, the second segment 202 of the third fastener 194c can be adjusted relative to the first segment 196 of the first segment 196, and / or the second segment 202 of the fourth fastener 194d can be adjusted relative to the first segment 196 of the second segment 202. Adjustment of the second segment 202 of the third fastener 194c and / or the second segment 202 of the fourth fastener 194d can extend the respective second segments 202s into the respective fastener gaps 178a, 178b. In such cases, both the first stator winding 22a and the second stator winding 22b can be selectively attached to the clamp 162 via the common coil carrier 164. The third fastener may generally be referred to as the first fastener for the second stator winding, and the fourth fastener may generally be referred to as the second fastener for the second stator winding.

[0080] Further reference Figures 11 to 13 The coil carrier 164 may further include a mounting member 208 positioned on a radially inward portion of the coil carrier 164. The mounting member 208 may be configured to operatively engage one or more carriers 164 to an anchor 166. Engagement of one or more carriers 164 to the anchor 166 may allow transport of the subassembly 76 and / or facilitate installation of such components within the motor 10. In various examples, the mounting member 208 may include a retaining portion 210 attached to the carrier body 190 of the coil carrier 164. In some cases, the retaining portion 210 may be attached to the coil carrier 164 by one or more fasteners, adhesives, and / or by any other means. Additionally or alternatively, portions of the mounting member 208 may be integrally formed with any other portion of the coil carrier 164. A protrusion 212 may extend radially inward from the retaining portion 210. The protrusion 212 may extend from the retaining portion 210 at any angle relative to the retaining portion 210. In various examples, the protrusion 212 may define the protrusion slot 214.

[0081] In various examples, system 160 may further include a support 216. Support 216 may include an anchor portion 218 operably coupled to anchor 166. In some cases, such as Figure 12 and Figure 13 As shown, anchor portion 218 may surround anchor 166 and include one or more flanges 220 extending from anchor portion 218. Each flange of flange 220 may define flange slot 222. In operation, protrusion slot 214 may be aligned with flange slot 222, and retainer 224 may be positioned through each of protrusion slot 214 and flange slot 222. Retainer 224 may be configured to retain the relative position of flange slot 222 with respect to protrusion slot 214, the relative position of retainer 224 with respect to flange slot 222, and / or the relative position of retainer 224 with respect to protrusion slot 214. Thus, bracket 216, mounting member 208, and / or retainer 224 may be configured individually or in any combination to maintain a defined distance between anchor 166 and coil carrier 164.

[0082] In some cases, once each carrier in carrier 164 is attached to anchor 166, such as via bracket 216 and / or mounting member 208, the second section 202 of each fastener 194 can be removed from their respective fastener gap 178, thereby releasing the motor subassembly 76 from clamp 162. The subassembly 76 can then be placed in a defined position within motor 10, and the subassembly may include stator winding 22, bracket 114, busbar 102, and / or any other components.

[0083] Now for reference Figure 14 and Figure 15 Once positioned within the motor 10, each carrier 164 can be released from the support 216 and / or stator winding 22, thereby placing the subassembly 76 within the motor 10. In various examples, the anchor 166 can be manipulated, thereby changing the position of the carrier 164 and / or stator winding 22 relative to each other. Manipulation of the anchor 166 allows adjustment of the subassembly 76 within the motor 10. For example, adjustment of the subassembly 76 allows positioning each winding within a corresponding raceway 50 of the stator core 20.

[0084] Now for reference Figure 16 The diagram shows flowcharts of some embodiments of a method 300 for assembling an electric motor according to various aspects of the subject matter of the present invention. Generally, this document will refer to the above with respect to Figures 1 to 12. Figure 15 The method 300 is described using the described motor 10. However, those skilled in the art will understand that the disclosed method 300 can generally be used with any motor and / or can be combined with systems having any other suitable system configuration. Additionally, although... Figure 16 The steps performed in a particular order are depicted for illustrative and discussion purposes, but the methods discussed herein are not limited to any particular order or arrangement. Those skilled in the art will understand using the disclosure provided herein that the steps of the methods disclosed herein may be omitted, rearranged, combined, and / or modified in various ways without departing from the scope of this disclosure.

[0085] like Figure 16As shown, at (302), method 300 may include positioning a first fastener operatively coupled to a first coil carrier through a first opening defined by a first stator winding. Furthermore, at (304), method 300 may include selectively coupling the first fastener to a first fastener gap defined by a clamp. As provided herein, the clamp may include a clamp base 168 that may define a cavity. The cavity may be defined by a cavity diameter that may be substantially equal to the stator core diameter. However, the cavity may have any size and geometry without departing from the teachings provided herein. In some cases, the clamp base may include a plurality of circumferentially offset clamp teeth. The clamp teeth may extend radially inward from the clamp base. Furthermore, the clamp teeth may define one or more fastening gaps. For example, the clamp teeth may define a first fastening gap extending radially outward into the clamp base. The clamp teeth may further define a second fastening clearance that extends radially outward into the clamp base, wherein the second fastening clearance is axially offset from the first fastening clearance. In various examples, each of the first and / or second fastening clearances may include a fastening feature. For example, each of the first and / or second fastening clearances may have threads within each respective clearance, allowing for selective fastening of components thereto.

[0086] The coil carrier can be a multi-piece tool that utilizes one or more fasteners, including a first section and / or a second section, to hold the stator winding to the tool during processing and when it is located on the fixture itself.

[0087] At (306), method 300 may include positioning a second fastener operatively coupled to a second coil carrier through a second opening defined by a second stator winding. At (308), method 300 may include selectively coupling the second fastener to a second fastener gap defined by a clamp. By attaching the first stator winding and / or the second stator winding to the clamp, the first stator winding and / or the second stator winding may be axially and radially positioned on the motor relative to a fixed reference, and circumferentially (clock position) positioned relative to each other and any end winding connection points. The clamp may be a full 360-degree representation or arc segment of the actual stator core. The clamp may attach the first stator winding and / or the second stator winding to the inner diameter by simulating the slot geometry of the stator core bottom. Alternatively, the clamp may attach the first stator winding and / or the second stator winding to its outer diameter by simulating the slot geometry of the stator top. Additionally or alternatively, assuming that the coil lead length and connection are flexible and taken into account during motor assembly, the clamp may also be flat / straight.

[0088] At (310), method 300 may include positioning a bracket in a defined position on a clamp. The bracket may provide mechanical support to at least one busbar operatively coupled to a first stator winding and / or a second stator winding. The bracket may be positioned within a mounting recess of the clamp, which may be substantially aligned with a similar recess in the stator core. In some cases, the bracket and / or any other component may hold the busbar or phase loop in space in place. Once the busbar or phase loop is positioned in the defined position, the leads of the first stator winding and / or the second stator winding may terminate at each point in preparation for final electrical connection. In this case, the leads of the first stator winding and / or the second stator winding may be mechanically connected to the phase loop protrusion using a crimped collar connection.

[0089] At (312), method 300 may include connecting a first stator winding to a second stator winding via a busbar to form a phase loop. A portion of the busbar extends through a bracket. At (314), method 300 may include brazing a first connection point of the first stator winding to the busbar and / or a second connection point of the second stator winding to the busbar.

[0090] At (316), method 300 may include operatively coupling a first coil carrier to the anchor, the first coil carrier being positioned at a first distance from the central axis of the anchor. Similarly, at (318), method 300 may include operatively coupling a second coil carrier to the anchor, the second coil carrier being positioned at a second distance from the central axis of the anchor. In some cases, operatively coupling the first coil carrier to the anchor may further include operatively coupling a first mounting member of the first coil carrier to a first flange of a support of the anchor. Additionally or alternatively, operatively coupling the second coil carrier to the anchor may further include operatively coupling a second mounting member of the second coil carrier to a second flange of a support of the anchor.

[0091] At (320), method 300 may include inserting the anchor, the first coil carrier, the first stator winding, the second coil carrier, and the second stator winding into an opening defined by the stator core. At (322), method 300 may include moving the first coil carrier from a first distance defined between the central axes of the first coil carrier and the anchor to a third distance defined between the central axes of the first coil carrier and the anchor, the third distance being less than the first distance. Furthermore, at (324), method 300 may include rotating the anchor, the first coil carrier, the first stator winding, the second coil carrier, and the second stator winding within the opening defined by the stator core to align the opening of the first stator winding with the teeth of the stator core.

[0092] At (326), method 300 may include disengaging a first stator winding from a coil carrier to position the first stator winding within a first raceway defined by the stator core. Similarly, at (328), method 300 may include disengaging a second stator winding from a coil carrier to position the second stator winding within a second raceway defined by the stator core.

[0093] This written description uses examples to disclose the technology, including best practices, and also enables any person skilled in the art to practice the technology, including making and using any device or system and performing any combined methods. The scope of the invention claimed herein is defined by the appended claims and may include other examples not illustrated in the above exemplary embodiments that would occur to a person skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

[0094] Other aspects of the invention are provided by the subject matter of the following provisions:

[0095] A system for an electric motor, the system comprising: a clamp including a clamp base defining first clamp teeth, wherein a first fastening gap is defined by the first clamp teeth, the first fastening gap extending into the clamp base; a first stator winding defining a first opening therethrough; a coil carrier defining a carrier body; and a first fastener including a first segment and a second segment, the first segment being selectively held by the carrier body and positioned through the first opening defined by the first stator winding, the second segment being configured to be positioned within the first fastening gap.

[0096] A system / method according to one or more of these provisions and / or any of the appended claims, wherein a second fastening gap is defined by the first clamping teeth, and the second fastening gap extends into the clamping base at an offset position relative to the first fastening gap.

[0097] The system / method according to one or more of these provisions and / or any one of the appended claims further comprises: a second fastener comprising a first segment and a second segment, the first segment being selectively held by the carrier body and positioned through the first opening defined by the first stator winding, the second segment being configured to be positioned within the second fastening gap.

[0098] A system / method according to one or more of these provisions and / or any of the appended claims, wherein the clamp base defines a second clamp tooth circumferentially offset from the first clamp tooth, and wherein a first fastening gap of the second clamp tooth is defined by the second clamp tooth, the second fastening gap extending into the clamp base at an offset position relative to the first fastening gap.

[0099] The system / method according to one or more of these provisions and / or any one of the appended claims further comprises: a second stator winding defining a second opening therethrough, the second stator winding being circumferentially offset from the first stator winding; and a first fastener for the second stator winding, the first fastener comprising a first segment and a second segment, the first segment being selectively held by the carrier body and positioned through the second opening defined by the second stator winding, the second segment being configured to be positioned within the first fastening gap of the second clamping teeth.

[0100] The system / method according to one or more of these provisions and / or any one of the appended claims, wherein the second fastening gap of the second clamping tooth is defined by the second clamping tooth, the second fastening gap of the second clamping tooth extending into the clamping base at an offset position relative to the first fastening gap of the second clamping tooth.

[0101] The system / method according to one or more of these provisions and / or any one of the appended claims further includes: a second fastener for the second stator winding, the second fastener comprising a first segment and a second segment, the first segment being selectively held by the carrier body and positioned through a second opening defined by the second stator winding, the second segment being configured to be positioned within a second fastening gap of the second clamping teeth.

[0102] The system / method according to one or more of these provisions and / or any one of the appended claims further comprises: an anchor; and a bracket operatively connected to the anchor and the coil carrier, wherein the bracket is configured to maintain a defined distance between the anchor and the coil carrier.

[0103] The system / method according to one or more of these provisions and / or any one of the appended claims further comprises: an anchor; and a mounting member operatively coupled to the coil carrier, the mounting member being configured to maintain a defined distance between the anchor and the coil carrier.

[0104] The system / method according to one or more of these provisions and / or any of the appended claims further comprises: an anchor; a bracket operably coupled to the anchor, the bracket including a flange defining a flange slot; a mount operably coupled to the coil carrier, the mount including a protrusion defining a protrusion slot; and a retainer configured to be positioned through the flange slot and the protrusion slot to maintain a defined distance between the anchor and the coil carrier.

[0105] A method for assembling an electric motor, the method comprising: positioning a first fastener operably coupled to a first coil carrier through a first opening defined by a first stator winding; selectively coupling the first fastener to a first fastener gap defined by a clamp; positioning a second fastener operably coupled to a second coil carrier through a second opening defined by a second stator winding; selectively coupling the second fastener to a second fastener gap defined by the clamp; positioning a bracket at a defined position on the clamp; connecting the first stator winding and the second stator winding to form a phase loop via a busbar, wherein a portion of the busbar extends through the bracket; brazing a first connection point between the first stator winding and the busbar; and brazing a second connection point between the second stator winding and the busbar.

[0106] The system / method according to one or more of these provisions and / or any one of the appended claims further comprises: operably coupling the first coil carrier to the anchor, the first coil carrier being positioned at a first distance from the central axis of the anchor; and operably coupling the second coil carrier to the anchor, the second coil carrier being positioned at a second distance from the central axis of the anchor.

[0107] The system / method according to one or more of these provisions and / or any one of the appended claims, wherein operably coupling the first coil carrier to the anchor further comprises operably coupling a first mounting member of the first coil carrier to a first flange of a bracket of the anchor, and wherein operably coupling the second coil carrier to the anchor further comprises operably coupling a second mounting member of the second coil carrier to a second flange of the bracket of the anchor.

[0108] The system / method according to one or more of these provisions and / or any of the appended claims further includes: inserting the anchor, the first coil carrier, the first stator winding, the second coil carrier, and the second stator winding into an opening defined by the stator core.

[0109] The system / method according to one or more of these provisions and / or any one of the appended claims further includes: moving the first coil carrier from a first distance defined between the first coil carrier and the central axis of the anchor to a third distance defined between the first coil carrier and the central axis of the anchor, the third distance being less than the first distance.

[0110] The system / method according to one or more of these provisions and / or any of the appended claims further comprises: rotating the anchor, the first coil carrier, the first stator winding, the second coil carrier, and the second stator winding within an opening defined by the stator core to align the opening of the first stator winding with the teeth of the stator core.

[0111] The system / method according to one or more of these provisions and / or any of the appended claims further includes: disengaging the first stator winding from the first coil carrier to position the first stator winding within a raceway defined by the stator core.

[0112] A system for an electric motor, the system comprising: a clamp including a clamp base defining clamp teeth, wherein a fastening gap is defined by the clamp teeth and the fastening gap extends into the clamp base; a stator winding defining an opening therethrough; a coil carrier defining a carrier body, the coil carrier being configured to operatively connect the stator winding to the clamp base; an anchor; and a bracket operatively connected to the anchor and the coil carrier, wherein the bracket is configured to maintain a defined distance between the anchor and the coil carrier.

[0113] The system / method according to one or more of these provisions and / or any one of the appended claims further comprises: a fastener including a first segment and a second segment, the first segment being selectively held by the carrier body and positioned through the opening defined by the stator winding, the second segment being configured to be positioned within the fastening gap.

[0114] A system / method according to one or more of these provisions and / or any of the appended claims, wherein the second segment of the fastener is movable relative to the first segment of the fastener.

Claims

1. A system for an electric motor (10, 12), the system comprising: A clamp (162) includes a clamp base (168) that extends circumferentially and defines first clamp teeth (172, 172a), wherein a first fastening gap (178, 178a) is defined by the first clamp teeth and extends into the clamp base; A first stator winding (22, 22a) is defined by a first opening (206) through which the first stator winding passes. Coil carrier (164), the coil carrier defining the carrier body (190). and A first fastener (194a) includes a first section (196) and a second section (198), the first section being selectively held by the carrier body (190) and positioned through the first opening defined by the first stator winding, and the second section being configured to be positioned within the first fastening gap.

2. The system according to claim 1, wherein the second fastening gap (178b) is defined by the first clamping tooth (172a), and the second fastening gap extends into the clamping base (168) at an offset position relative to the first fastening gap.

3. The system according to claim 2, further comprising: The second fastener (194b) includes a first segment and a second segment, the first segment being selectively held by the carrier body (190) and positioned through the first opening (206) defined by the first stator winding (22a), and the second segment being configured to be positioned within the second fastening gap (178b).

4. The system according to any of the preceding claims, wherein the clamp base defines a second clamp tooth (172b) circumferentially offset from the first clamp tooth (172a), wherein a first fastening gap of the second clamp tooth is defined by the second clamp tooth.

5. The system according to claim 4, further comprising: A second stator winding (22b) defines a second opening through which the second stator winding is circumferentially offset from the first stator winding (22a); and A first fastener (194c) for the second stator winding, the first fastener comprising a first segment and a second segment, the first segment being selectively held by the carrier body and positioned through a second opening defined by the second stator winding (22b), the second segment being configured to be positioned within the first fastening gap (178c) of the second clamping teeth.

6. The system according to any one of claims 4 or 5, wherein the second fastening gap (178d) of the second clamping tooth (172b) is defined by the second clamping tooth, the second fastening gap of the second clamping tooth extending into the clamping base (168) at an offset position relative to the first fastening gap (178c) of the second clamping tooth, and specifically, further comprising a second fastener (194d) for the second stator winding (22b), the second fastener comprising a first segment and a second segment, the first segment being selectively held by the carrier body and positioned through the second opening defined by the second stator winding, the second segment being configured to be positioned within the second fastening gap of the second clamping tooth.

7. The system according to any one of the preceding claims, further comprising: An anchor (218) and at least one of a bracket (216) and / or a mounting (208), the bracket being operatively connected to the anchor and the coil carrier (164), wherein the bracket is configured to maintain a defined distance between the anchor and the coil carrier, and the mounting is operatively connected to the coil carrier (164), the mounting being configured to maintain a defined distance between the anchor and the coil carrier.

8. The system according to any one of the preceding claims, further comprising: Anchoring element (218); A bracket (216) operably connected to the anchor, the bracket including a flange (220) wherein the flange defines a flange slot (222). Mounting member (208), operably connected to the coil carrier (164), the mounting member including a protrusion (212) defining a protrusion slot (214); and A retainer (224) is configured to be positioned through the flange slot (222) and the protrusion slot (214) to maintain a defined distance between the anchor (218) and the coil carrier (164).

9. The system according to any of the preceding claims, wherein the first segment (196) and the second segment (198) of at least one fastener (194) are movable relative to each other.

10. A method (300) for assembling motors (10, 12), the method comprising: The first fastener, which is operably connected to the first coil carrier, is positioned by passing through the first opening defined by the first stator winding (302). The first fastener is selectively coupled (304) to the first fastener gap defined by the clamp; The second fastener, which is operably connected to the second coil carrier, is positioned through the second opening defined by the second stator winding (306). The second fastener is selectively coupled (308) to the second fastener gap defined by the clamp; Position the bracket (310) at a defined position on the clamp; The first stator winding is connected to the second stator winding via a busbar (312) to form a phase loop, wherein a portion of the busbar extends through the bracket; Brazing (314) the first connection point between the first stator winding and the busbar; and / or The second connection point between the second stator winding and the busbar is brazed.

11. The method of claim 10, further comprising: The first coil carrier is operably connected (316) to the anchor, the first coil carrier being positioned at a first distance from the central axis of the anchor, and the second coil carrier is operably connected (318) to the anchor, the second coil carrier being positioned at a second distance from the central axis of the anchor. Specifically, operably connecting the first coil carrier to the anchor further includes operably connecting a first mounting member of the first coil carrier to a first flange of the support of the anchor, and operably connecting the second coil carrier to the anchor further includes operably connecting a second mounting member of the second coil carrier to a second flange of the support of the anchor.

12. The method of claim 11, further comprising: The anchor, the first coil carrier, the first stator winding, the second coil carrier, and the second stator winding are inserted into (320) the opening defined by the stator core.

13. The method of claim 12, further comprising: The first coil carrier is moved (322) from a first distance defined between the first coil carrier and the central axis of the anchor to a third distance defined between the first coil carrier and the central axis of the anchor, the third distance being less than the first distance.

14. The method of claim 13, further comprising: The anchor, the first coil carrier, the first stator winding, the second coil carrier, and the second stator winding are rotated (324) within an opening defined by the stator core to align the opening of the first stator winding with the teeth of the stator core.

15. The method of claim 14, further comprising: Disconnect the first stator winding from the first coil carrier (326) to position the first stator winding within the raceway defined by the stator core.

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