Stator bobbin for an electric machine with winding retainers and fluid flow surfaces

Abstract

A stator spindle includes a first winding support having an inner radial portion, an outer radial portion, and a winding space radially defined between the inner and outer radial portions relative to a rotation axis. The winding space is configured to receive a plurality of windings of a motor. The inner and outer radial portions extend along an axis between a first end and a second end of the stator spindle. The stator spindle also includes a winding retainer disposed at the first end and configured to receive and retain the end of the plurality of windings. Furthermore, the stator spindle includes a profiled flow surface disposed near the second end. The profiled flow surface defines a nonlinear flow path for the motor's fluid coolant.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to Indian Provisional Patent Application No. 202411005832, filed on January 29, 2024, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This technical field generally relates to stator shafts, and more specifically to a stator shaft for an electric motor with a winding retainer and a fluid flow surface. Background Technology

[0004] Turbines can be used for the operation of vehicles and other systems. For example, an HVAC system may include a compressor-type turbine that supplies temperature-controlled air to the passenger compartment of a vehicle.

[0005] Preferably, the turbine, such as the compressor in an HVAC system, is capable of operating efficiently under a variety of conditions. Additionally, these devices are preferably compact and lightweight. Furthermore, these turbines preferably have a low number of parts, are relatively easy to manufacture and assemble, and / or offer other manufacturing efficiencies. The turbine may include an electric motor, such as an electric motor and / or a generator. Preferably, the electric motor is a high-efficiency device, compact, with a low number of parts, and also capable of being manufactured efficiently.

[0006] However, some existing motors designed for turbines operate inefficiently under certain conditions. These motors may suffer from electromagnetic losses, which negatively impact efficiency. Furthermore, high operating temperatures can adversely affect motor operation. Additionally, some turbines and their included motors may be bulky, making them difficult to manufacture, assemble, and maintain.

[0007] Therefore, there is still a need for turbines that operate with high efficiency and have relatively small weight, size, and number of parts. Furthermore, there is still a need for turbines that also offer manufacturing efficiency. Summary of the Invention

[0008] This summary is provided to describe selected concepts in a simplified form, which will be further described in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used to assist in determining the scope of the claimed subject matter.

[0009] In one embodiment, a stator spool for a directly cooled motor is disclosed. The stator spool includes a plurality of winding supports arranged about an axis. The plurality of winding supports includes a first winding support. The first winding support includes an inner radial portion, an outer radial portion, and a winding space defined radially relative to the axis between the inner and outer radial portions. The winding space is configured to receive a plurality of windings of the motor. The inner and outer radial portions extend along the axis between a first end and a second end of the stator spool. The stator spool also includes a winding retainer disposed at the first end, the winding retainer being configured to receive and retain the ends of the plurality of windings. Furthermore, the stator spool includes a profiled flow surface disposed near the second end. The profiled flow surface defines a nonlinear flow path for the motor's fluid coolant.

[0010] In another embodiment, a turbine is disclosed, comprising a housing assembly and a rotating assembly supported for rotation about an axis within the housing assembly. The turbine also includes an electric motor operably configured as at least one of an electric motor and a generator. The electric motor is housed within the housing assembly and operably coupled to the rotating assembly. The housing assembly includes an inner surface defining a housing shroud surface for the motor. The electric assembly is attached to a fluid system that supplies it with a fluid coolant. The turbine also includes a stator spindle assembly for the motor. The stator spindle includes a plurality of winding supports arranged about an axis. The plurality of winding supports includes a first winding support. The first winding support includes an inner radial portion, an outer radial portion, and a winding space defined radially relative to the axis between the inner and outer radial portions. The winding space is configured to receive a plurality of windings of the motor. The inner and outer radial portions extend along the axis between a first end and a second end of the stator spindle. The stator spindle also includes a winding retainer disposed at the first end, the winding retainer being configured to receive and retain the ends of the plurality of windings. Furthermore, the stator shaft includes a profiled flow surface located near the second end. This profiled flow surface mates with the shroud surface to define a nonlinear flow path for the fluid coolant in the fluid system.

[0011] In another embodiment, a method of manufacturing a turbine is disclosed, the method comprising: providing a housing, providing a rotating assembly, and providing a motor, the motor including providing a stator spindle. The method further comprises: supporting the rotating assembly for rotation about an axis within the housing. Additionally, the method comprises: housing the motor within the housing and operatively coupling the motor to the rotating assembly such that the motor is operatively configured as at least one of an electric motor and a generator. The housing assembly includes an inner surface defining a surface of a motor housing cover. The stator spindle assembly of the motor includes a plurality of winding supports arranged about an axis, the plurality of winding supports including a first winding support. The first winding support includes an inner radial portion, an outer radial portion, and a winding space radially defined relative to the axis between the inner and outer radial portions. The winding space is configured to receive a plurality of windings of the motor. The inner and outer radial portions extend along the axis between a first end and a second end of the stator spindle. The stator spindle also includes a winding retainer disposed at the first end, the winding retainer being configured to receive and retain the ends of the plurality of windings. The stator shaft also includes a profiled flow surface located near the second end. The profiled flow surface mates with the shroud surface to define a nonlinear flow path for the fluid coolant in the fluid system.

[0012] Furthermore, other desirable features and characteristics of this disclosure will become apparent from the following detailed description and the appended claims, which are discussed in conjunction with the accompanying drawings and the foregoing background information. Attached Figure Description

[0013] The present disclosure will now be described in conjunction with the accompanying drawings, wherein like reference numerals denote like elements, and wherein: Figure 1 This is a schematic diagram of a fluid system with a compressor device according to an exemplary embodiment of the present disclosure; Figure 2 A turbine constructed according to an exemplary embodiment of this disclosure, for example... Figure 1 A longitudinal sectional view of the compressor unit; Figure 3 yes Figure 2 An exploded perspective view of the turbine shown. Figure 4 It is along Figure 2 Axial sectional view of the turbine taken by line 4-4; Figure 5 It is along Figure 4 A longitudinal sectional perspective view of the turbine taken from line 5-5; Figure 6 It is along Figure 4 A longitudinal sectional perspective view of the turbine, taken from line 6-6; and Figure 7 yes Figure 2The diagram shows a perspective view of the turbine, including an axial sectional view. Detailed Implementation

[0014] The following detailed descriptions are exemplary in nature and are not intended to limit the scope of this disclosure or its applications and uses. The term "exemplary" as used herein means "serving as an example, instance, or illustration." Therefore, any embodiment described herein as "exemplary" is not necessarily to be construed as superior or advantageous over other embodiments. All embodiments described herein are exemplary embodiments provided to enable those skilled in the art to make or use this disclosure, without limiting the scope of the disclosure, which is defined by the claims. Furthermore, it is not intended to be limited by any express or implied theory presented in the foregoing technical field, background art, summary of the invention, or the following detailed descriptions.

[0015] In a broader sense, the exemplary embodiments disclosed herein include spools for electric motors, such as those provided for fluid compressor units or other turbines. The spool may include a radially outer surface comprising a first end and a second end separated along an axis. On and / or near the first end of the radially outer surface, the spool may include one or more winding retainers configured to receive, lay out, and / or retain end segments of the stator windings of the motor. The winding retainers provide convenience and allow for neat and compact windings. On and / or near the second end of the radially outer surface, the spool may include one or more profiled flow surfaces. The motor may be configured to receive a coolant flow, and the profiled flow surfaces may guide coolant fluid across, over, and through the motor for direct cooling. Therefore, the motor can be effectively cooled, resulting in efficient operation. The motor and turbine can also be manufactured efficiently.

[0016] Figure 1 This is a schematic diagram of the front end of a vehicle 10, such as a passenger car. The vehicle 10 may include a fluid system 102, such as a coolant fluid system, an air conditioning system, a refrigerant circulation system for an HVAC system, etc. The fluid system 102 may include a compressor unit 200 constructed according to an exemplary embodiment of this disclosure. The compressor unit 200 may compress a working fluid, such as a fluid refrigerant, and the pressurized fluid flow 150 may flow to a condenser 152 of the fluid system 102. The condenser 152 may exchange heat with the surrounding fluid, and the resulting fluid flow 154 may flow to an evaporator 156. The evaporator 156 may also be configured to exchange heat with the surrounding fluid, and the evaporator 156 may provide the resulting input flow 158 back to the compressor unit 200.

[0017] It should be understood that the evaporator 156 and / or condenser 152 may be operatively coupled to one or more fans (not shown) to enhance heat transfer with the surrounding fluid. It should also be understood that the fluid system 102 may include other standard components, such as expansion valves, dryers, etc., for use by the working fluid as it flows through the fluid system 102 in a thermodynamic cycle.

[0018] In the illustrated embodiment, the evaporator 156 can be used to supply temperature-controlled air 162 to the passenger compartment of the vehicle 10. In some embodiments, the fluid system 102 may be provided in an electric vehicle, a solar-powered vehicle, a fuel cell vehicle, or another vehicle 10.

[0019] The compressor unit 200 may be a turbine incorporating one or more features of this disclosure. The compressor unit 200 may be constructed differently, incorporated into different systems, or otherwise differ from the illustrated embodiment without departing from the scope of this disclosure. Furthermore, features of this disclosure may be included on different turbines, such as an electric motor-assisted turbocharger, without departing from the scope of this disclosure.

[0020] Figures 2 to 7 A compressor device 200 according to an example embodiment is shown. First, refer to… Figure 2 The compressor unit 200 typically includes a housing assembly 201 and a rotating assembly 203. The rotating assembly 203 is supported within the housing assembly 201 by a bearing system 207 to rotate about a rotation axis 212.

[0021] The bearing system 207 can be of any suitable type, such as a fluid bearing (i.e., an air bearing, etc.). Accordingly, the bearing system 207 may include one or more journal members supporting the rotating assembly 203 against radial loads, and one or more thrust members supporting the rotating assembly 203 against axial loads, thereby supporting the rotating assembly 203 to rotate about axis 212. However, it should be understood that in additional embodiments of this disclosure, the bearing system 207 may be constructed differently, for example, including rolling element bearings.

[0022] Rotating assembly 203 may include a shaft 210, which is elongated and extends along axis 212. Shaft 210 may be substantially centered on axis 212. In some embodiments, the outer diameter surface of shaft 210 may be supported by one or more components of bearing system 207 to rotate relative to housing assembly 201. Rotating assembly 203 may also include an impeller 218, such as a compressor impeller 218. Compressor impeller 218 may include a plurality of blades extending outward relative to axis 212. Compressor impeller 218 may be fixedly attached to and supported on one end of shaft 210 to rotate with shaft 210.

[0023] Housing assembly 201 may include compressor housing 260, which is shaped and constructed according to compressor impeller 218. For example... Figure 2 As shown, the compressor housing 260 surrounds and houses the compressor impeller 218. The compressor housing 260, together with the compressor impeller 218, defines the compressor stage 240 of the compressor unit 200 for compressing the working fluid flowing therethrough, as will be described in detail below.

[0024] The housing assembly 201 may further include a motor housing 231. The motor housing 231 may be hollow, including an inner surface 237. The inner surface 237 may define a cylindrical motor cavity 233 therein. The motor housing 231 may be arranged end-to-end adjacent to the compressor housing 260 along axis 212. In some embodiments, at least a portion of the motor housing 231 and at least a portion of the compressor housing 260 may be defined by a single component, such that the motor housing 231 and the compressor housing 260 are at least partially integrally attached.

[0025] Furthermore, the compressor unit 200 may include a motor 270. The motor 270 may include a stator component 272 and a rotor component 274. The rotor component 274 may be supported on a shaft 210 and may be surrounded by the stator component 272. The stator component 272 may be fixedly attached to and supported within the motor cavity 233 of the motor housing 231. Therefore, the motor 270 and the motor housing 231 may define a motor stage 242 of the compressor unit 200.

[0026] In some embodiments, motor 270 may be configured to operate as an electric motor, and motor 270 drives shaft 210 and compressor impeller 218 to rotate about axis 212. Therefore, fluid flowing through compressor stage 240 can be compressed toward condenser 152. Figure 1 A pressurized fluid flow 150 is provided. In other embodiments, the motor 270 may be configured to operate as a generator, such that the motor 270 converts the rotational energy of the shaft 210 into electrical energy. In yet another embodiment, the motor 270 may operate as an electric motor under some conditions and as a generator under other conditions.

[0027] Features of the motor 270, other components of the compressor unit 200, and / or the fluid system 102 may be controlled by the control system 220. The control system 220 may be a computerized control system and may include processors, sensor systems, storage devices, and / or other known components. The control system 220 may be part of a larger vehicle control system that controls other systems of the vehicle (e.g., engine system, steering system, etc.). In some embodiments, the control system 220 may at least control the angular velocity of the shaft 210 about axis 212.

[0028] In some embodiments, the compressor unit 200 may be "directly cooled," such that coolant fluid flows through the motor housing 233. Coolant may flow through the motor 270, for example, to remove heat from the stator assembly 272 and / or other parts of the compressor unit 200. In some embodiments, the compressor unit 200 is operatively connected to the fluid system 102 (… Figure 1 The working fluid circulates through fluid system 102 and flows through motor 270. In some embodiments, motor stage 242 may be fluidly connected in series with compressor stage 240. For example, compressor stage 240 may be located downstream of motor stage 242. One or more fluid passages, paths, channels, orifices, etc., may define a corresponding flow path that passes through motor stage 242 and further downstream through compressor stage 240. Working fluid (e.g., in a gaseous state) may flow through motor stage 242 and then further downstream through compressor stage 240.

[0029] Housing assembly 201 may include at least one fluid inlet 356 and at least one fluid outlet 358. In some embodiments, motor housing 231 may include at least one fluid inlet 356 extending from the outside of motor housing 231 and into a cavity 233 therein. Compressor housing 260 may also include at least one fluid outlet 358 configured to discharge fluid away from compressor impeller 218.

[0030] The compressor unit 200 may also define at least one flow path 360 (i.e., flow channel, passage, etc.) through which fluid flows from inlet 356 to outlet 358. In some embodiments, there may be multiple discrete flow paths 360 extending from inlet 356 to outlet 358. In some embodiments, the flow path 360 may be non-linear. As will be explained below, the fluid coolant, working fluid, etc. circulating through the fluid system 102 may also flow through the motor housing 231, for example, to cool the motor 270.

[0031] Now refer to Figure 2 and Figure 3 Other features of the compressor unit 200 will be described below. Figure 3 A motor housing 231 according to an exemplary embodiment is shown in detail. As shown, the motor cavity 233 and inner surface 237 of the motor housing 231 may include an open end 241. The open end 241 may be radially wide enough to provide passage and channel for the stator component 272 of the motor 270 to enter and exit the motor cavity 233. The inner surface 237 of the motor housing 231 may also include a tapering second end 245. As the second end 245 extends toward the compressor housing 260, the second end 245 may taper inward toward the axis 212.

[0032] The inner surface 237 of the motor housing 231 may include a base portion 238 and a plurality of longitudinal strips 239. The base portion 238 may define the maximum radial dimension of the inner surface 237. The longitudinal strips 239 may be raised regions of the inner surface 237 that project inwardly from the base portion 238 of the inner surface 237. Each strip 239 may extend longitudinally along axis 212. The strips 239 may be spaced apart at equal angular positions about axis 212. Thus, a plurality of gaps 259 may be defined between corresponding adjacent pairs of strips 239. In other words, the gaps 259 may be defined by the base portions 238 of the inner surface 237 between adjacent strips 239.

[0033] In some embodiments, as the strip 239 extends further along axis 212 from end 241 toward second end 245, at least one strip 239 may be stepped inward. More specifically, near the opening end 241, the strip 239 may project slightly inward from the base portion 238 toward axis 212. Further along axis 212 toward compressor housing 260, the strip 239 may include a first step 250 and may project further inward toward axis 212. Further along axis 212 toward compressor housing 260, the strip 239 may include a second step 252 and may project even further inward toward axis 212.

[0034] The inner surface 237 can be designed in shape, size, profile, etc., according to the exterior of the stator component 272 of the motor 270. Thus, the stator component 272 can fit against the inner surface 237 to be supported within the motor housing 233. In some embodiments, as described below, the inner surface 237 may include features defining flow channels for the fluid system 102.

[0035] In addition, near the second end 245, the motor housing 231 may include at least one through-hole 265. Figure 2 and Figure 6 Multiple through-holes 265 may exist and be arranged at an angle around axis 212. Through-holes 265 may be holes, openings or other orifices that extend between motor cavity 233 and compressor housing 260 and fluidly connect the two.

[0036] like Figure 3 As shown, the motor 270 may include a stator shaft 402 of the stator component 272. The stator shaft 402 may be spool-shaped, cylindrical, or hollow to accommodate the rotor component 274. Figure 2 Therefore, the stator shaft 402 may include an inner radial portion 408, an outer radial portion 410, a first end 412, and a second end 414. The stator shaft 402 may include multiple winding support portions 406 (i.e., teeth), which are arranged in a ring around the axis 212. Figure 4As shown, there may be six (6) winding support portions 406; however, it should be understood that the number of winding support portions 406 may vary without departing from the scope of this disclosure. Figure 4 As shown, the winding support portion 406 may be connected at the outer radial portion 410. Furthermore, the stator shaft 402 may include a slot 415 on the inner radial portion 408 between adjacent winding supports 406. The slot 415 may extend along the inner radial portion 408 and along axis 212. Figure 4 As shown in the cross-sectional view, the winding support 406 may also have an intermediate portion 407 radially included between the inner radial portion 408 and the outer radial portion 410. The intermediate portion 407 may have a narrower width than the width at the inner radial portion 408 (this width is measured in the circumferential direction about the axis 212). Thus, the outer radial portion 410 may be substantially annular, and the intermediate portion 407 of the winding support 406 may project radially inward toward the axis 212. At the inner radial portion 410, the winding support 406 may be wider, such that its cross-sectional profile is substantially T-shaped. Figure 4 ).

[0037] The stator component 272 may also include a plurality of windings 416. The windings 416 may include multiple cables, etc., wound around a winding support 406. The windings 416 may be wound around a central portion 407 of the winding support 406. During manufacturing, as the windings 416 are wound onto the winding support 406, slots 415 may provide passageways for the cables. Furthermore, the windings 416 may include corresponding ends 418 extending away from the winding support 406. Figure 2 and Figure 3 In some embodiments, end 418 may be located at and extend away from the first end 412 of the stator spindle 402.

[0038] In addition, such as Figure 2As shown, the spool 402 may include, comprise, a metallic inner member 420 (i.e., a first member) and a non-metallic outer member 422 (i.e., a second member, a cover member, etc.), and / or the spool 402 may be defined by the metallic inner member 420 and the non-metallic outer member 422. In some embodiments, the outer member 422 may be made of a polymeric material or other material that is more electrically insulating than the inner member 420. Furthermore, the inner member 420 may include a plurality of thin sheets stacked along axis 212. Additionally, in some embodiments, the outer member 422 may be overmolded onto the inner member 420 during manufacturing in an insert molding process. In other embodiments, the spool 402 may be additively manufactured, for example, by a 3D printing process. The inner member 420 may be slightly annular, hollow, or cylindrical, and centered on axis 212. The inner member 420 may be axially disposed between a first end 412 and a second end 414 of the stator member 272. The outer member 422 may also be slightly annular, hollow, cylindrical, and centered on axis 212. The outer member 422 may extend axially away from the inner member 420 to define a first end 412 of the stator shaft 402. Furthermore, the outer member 422 may extend axially away from the inner member 420 to define a second end 414 of the stator shaft 402. The inner member 420 and the outer member 422 may cooperatively define an inner radial portion 408 and an outer radial portion 410. A portion of the outer member 422 may also pass through holes and / or other openings in the inner member 420 to attach to both the inner member 420 and the outer member 422 of the stator shaft 402. Thus, the outer member 422 and the inner member 420 may cooperatively define a stator shaft 402 including a plurality of winding supports 406. The outer member 422 and the inner member 420 can cooperate to define the outer diameter surface 440 of the stator shaft 402, which faces radially outward from the axis 212.

[0039] In some embodiments, the stator spool 402 may include at least one winding retainer 475. Figure 3 , Figure 5 and Figure 6 In some embodiments, the winding retainer 475 may include at least one circumferential wiring portion, such as a recess 477, which extends circumferentially about axis 212 on the outer diameter surface 440 of the stator spool 402. As shown in the illustrated embodiment, the outer member 422 may define three recesses 477 at a first end 412 of the stator spool 402. The recesses 477 may receive a corresponding cable end 418 of the winding 416. Thus, the end 418 can be securely and easily routed and retained within the recesses 477. Furthermore, the winding retainer 475 may also include at least one terminal latch 479. Figure 3 and Figure 5As shown in the figure, three latches 479 may be provided, and the latches 479 may axially protrude from the first end 412 of the stator spool 402. The latches 479 may include corresponding openings 481 on the outer diameter surface 440, and the openings 481 may receive corresponding terminal ends 419 of the cable end 418. Thus, the latches 479 can securely and conveniently retain the terminal ends 419 and guide the terminal ends 419 away from the first end 412 of the stator spool 402 for attachment to the control system 220. Figure 2 ).

[0040] The stator component 272 may also include an end fluid deflection member 502. The end fluid deflection member 502 may be a thin plate of substantially constant thickness. The end fluid deflection member 502 may include a cover plate 504 extending orthogonally to axis 212, and a side lip 506 extending circumferentially around the periphery of the cover plate 504. The side lip 506 may be sized to fit onto a first end 412 of the stator spindle 402 and a winding retainer 475 fitting onto the first end 412. In this position, the cover plate 504 may extend over and cover the first end 412 of the stator spindle 402. The cover plate 504 may also include a central opening 522 for the shaft 210. The central opening 522 may also include a plurality of cuts 524 spaced at an angle around axis 212. Furthermore, the lip 506 may be interrupted in the circumferential direction by an edge opening 558. When the end fluid deflection member 502 is attached to the first end 412 of the stator spindle 402, the edge opening 558 can receive the winding retainer 475 of the stator spindle 402.

[0041] In addition, stator component 272 may include one or more isolation barrier components 550 ( Figure 3 , Figure 4 and Figure 5 In some embodiments, multiple barrier members 550 may be present (e.g., one per slot 415). Figure 3 and Figure 5 As shown, the barrier member 550 may include a thin, generally rectangular plate 552. The barrier member 550 may also include an inner radial edge 554. Figure 4 As shown, the inner radial edge 554 is removably received in a corresponding slot 415 to attach and engage with the stator spool 402. The barrier member 550 may include a ridge 556 that provides a cross-shaped cross-sectional profile for the barrier member 550, engaging with the spool 402 and substantially filling the slot 415 between adjacent winding supports 406. Figure 3As shown, the barrier member 550 may further include a hook-shaped axial end 555. The hook-shaped axial end 555 is removably received in a corresponding notch 524 to attach and engage with the end fluid deflector member 502 and / or the spool 402. Thus, in this position, the barrier member 550 may extend radially between the inner radial portion 408 and the outer radial portion 410 of the stator spool 402. Figure 4 In some embodiments, the outer radial edge 557 of the barrier member 550 may engage with and / or abut against the outer radial portion 410 of the stator shaft 402.

[0042] like Figure 2 and Figure 3 As shown, the stator shaft 402 may include one or more profiled flow surfaces 490. The profiled flow surface 490 may be present at the second end 414 of the outer diameter surface 440. The flow surface 490 may be gradually profiled and may be convex, thus profiled inward toward the axis 212. In other words, at least one of the profiled flow surfaces 490 may be three-dimensionally profiled. Thus, the flow surface 490 may be flexed about the axis 212. Figure 4 ), and the flow surface 490 may be convexly curved in a radial plane partially defined by axis 212 and orthogonal to axis 212 ( Figure 2 Therefore, the outer diameter surface 440 of the stator shaft 402 can have a substantially constant radius from the first end 412 of the stator shaft 402 and axially toward the second end 414, and along the flow surface 490, the radius of the outer diameter surface 440 can gradually decrease and the size can be tapered. Figure 3 As shown, multiple similar flow surfaces 490 may exist, and the multiple flow surfaces 490 are equidistantly spaced around axis 212 on the second end 414. In addition, the stator shaft 402 may include recesses 424 disposed at an angle between the flow surfaces 490.

[0043] Stator component 272 can be received in motor housing 233, and the outer diameter surface 440 of spool 402 can be fitted and adjacent to the inner surface 237 for support. As shown, the second end 414 of spool 402 can be disposed adjacent to the constricted second end 245 of the inner surface 237. In addition, recess 424 can receive a corresponding strip 239 of the inner surface 237 to restrict rotation of spool 402 relative to housing assembly 201 (i.e., support resists relative rotation).

[0044] Other components of shaft 210 and rotating assembly 203 can also be supplied using known manufacturing techniques. Additionally, end plate 202 can be provided. Figure 2) is used to further accommodate the motor 270. Before encapsulating the motor 270 and the rotating assembly 203 within the housing assembly 201, the terminal ends 418 can be electrically connected to the corresponding circuitry, thereby electrically connecting and operably connecting the motor 270 to the control system 220. Figure 2 and Figure 5 ).

[0045] Now refer to Figure 2 ,and Figures 4 to 7 One or more flow paths 360 through the compressor unit 200 will be described according to an example embodiment. Multiple branching and / or merging flow paths 360 may exist for fluid flow through the fluid system 102. One or more flow paths 360 may define a downstream direction, and the embodiment is described as moving downstream from inlet 356 toward outlet 358. In some embodiments, the downstream direction may generally be defined from a first end 412 and axially toward a second end 414. Various features of the stator member 272 may guide the flow path through the compressor unit 200 for efficient cooling.

[0046] like Figure 2 and Figure 6 As shown, the flow path 360 may include a first outer segment 362 in fluid communication with the inlet 356. The first outer segment 362 may be defined by a mating of the outer diameter surface 440 of the spool 402 and the base portion 238 of the inner surface 237. In other words, the first outer segment 362 may be a gap radially defined between the base portion 238 of the inner surface 237 and the outer diameter surface 440. Further downstream, the spool flow surface 490 may mate with an opposing shroud surface 236 defined by the inner surface 237 to define a radial segment 377 of the flow path 360. Similar to the flow surface 490, the shroud surface may be three-dimensionally contoured to guide the flow path 360 radially inward as the fluid flows downstream.

[0047] The radial segment 377 may be fluidly connected downstream to a radial chamber 379, which is axially and cooperatively defined between the axial end of the motor 270 and the constricted second end 245 of the inner surface 237. The radial chamber 379 may extend at least partially radially above the axial end of the motor 270. Through-hole 265 ( Figure 6 It can extend through housing assembly 201 to fluidly connect chamber 379 to compressor stage 240. Therefore, as... Figure 6 As shown, some fluid in the radial chamber 379 can move axially through the through-hole 265 into the compressor stage 240.

[0048] Another portion of the fluid flow in the radial chamber 379 can be axially returned and flow along the second inner section 378 of the flow path 360. For example... Figure 2As shown, the second inner section 378 may be defined in the gap between the linear shaft 402 and the rotating assembly 203. In some embodiments where the bearing system 207 includes an air bearing system, the second inner section 378 of the flow path 360 may be arranged through one or more portions of the bearing system 207. Figure 2 Therefore, flow path 360 can provide working fluid to one or more journal members of bearing system 207 to support against radial loads on rotating assembly 203, and / or provide working fluid to thrust members of bearing system 207 to support against thrust loads on rotating assembly 203. However, generally, the second inner section 378 can define an axially extending downstream flow direction opposite to the downstream direction of the first outer section 362.

[0049] The second inner section 378 may extend toward the end fluid deflector 502, and the cover may deflect the flow path 560 and define the second radial section 381, wherein the flow path 560 is turned radially outward. Further downstream, the flow path 560 may extend around the winding 416; however, as Figure 6 As indicated by the middle arrow 501, the downstream flow within the spool 402 and around the winding 416 can generally proceed axially from the first end 412 toward the second end 414. This flow can re-merge with the flow along the radial section 377. The flow can exit from the motor housing 231, flow through the through-hole 265, and enter the compressor housing 260.

[0050] It should be understood that the working fluid can flow along the flow path 360, directly cooling the stator winding 416, spool 402, and / or other parts of the motor 270 before passing through the compressor stage 240. Cooling can occur primarily through convective heat transfer. This can be highly efficient cooling across a wide range of operating conditions, which benefits the operating efficiency of the motor 270. Furthermore, the fluid can be routed through the bearing system 207 (e.g., air bearings) to support the rotation of the rotating assembly 203 relative to the housing assembly 201. The compressor unit 200 can also be relatively compact, lightweight, and have a relatively small number of parts. Additionally, the compressor unit 200 can be manufactured, assembled, etc., efficiently.

[0051] While at least one exemplary embodiment has been presented in the foregoing detailed descriptions of this disclosure, it should be understood that numerous variations exist. It should also be understood that one or more example embodiments are merely illustrative and are not intended to limit the scope, applicability, or construction of this disclosure in any way. Rather, the foregoing detailed descriptions will provide those skilled in the art with a convenient roadmap for implementing exemplary embodiments of this disclosure. It should be understood that various changes can be made to the function and arrangement of the elements described in the example embodiments without departing from the scope of this disclosure as set forth in the appended claims.

Claims

1. A stator spindle for a direct-cooled motor, comprising: A plurality of winding supports are arranged about an axis. The plurality of winding supports include a first winding support, the first winding support including an inner radial portion, an outer radial portion, and a winding space radially defined relative to the axis between the inner radial portion and the outer radial portion. The winding space is configured to receive a plurality of windings of the motor. The inner radial portion and the outer radial portion extend along the axis between a first end and a second end of the stator shaft. A winding retainer is disposed at the first end and configured to receive and retain the ends of the plurality of windings; as well as A contoured flow surface is disposed near the second end, the contoured flow surface defining a non-linear flow path for the fluid coolant of the motor.

2. The stator spindle according to claim 1, characterized in that, The second end portion includes a radially outer surface that is substantially outward from the axis; and The contoured flow surface is defined on the radial outer surface.

3. The stator spindle according to claim 2, characterized in that, The contoured flow surface is three-dimensional, curved about the axis, and also convex in a plane, the axis being located in the plane, and the plane being orthogonal to the axis.

4. The stator spindle according to claim 2, characterized in that, As the outer diameter surface extends away from the first end and toward the second end, the profiled flow surface is profiled radially inward toward the axis in the downstream direction.

5. The stator spindle according to claim 2, characterized in that, The profiled flow surface is one of a plurality of profiled flow surfaces disposed near the second end and spaced apart around the axis; and It also includes recesses on the outer diameter surface, the recesses being angled between the plurality of contoured flow surfaces.

6. The stator spindle according to any of the preceding claims, characterized in that, It also includes a first component and a second component, the first component being metallic and the second component being more electrically insulating than the first component, the first component and the second component cooperatingly defining the stator spindle.

7. The stator shaft according to any of the preceding claims, characterized in that, The winding retainer includes a circumferential wiring portion that extends around the axis and is configured to receive the ends of the plurality of windings.

8. The stator spindle according to any of the preceding claims, characterized in that, The winding retainer includes a terminal latch configured to receive and retain the terminal ends of the plurality of windings.

9. A turbine, comprising: Housing assembly; A rotating assembly, which is supported for rotating about an axis within the housing assembly; An electric motor, operably configured as at least one of an electric motor and a generator, the motor being housed within the housing assembly and operably coupled to the rotating assembly, the housing assembly including an inner surface defining a housing cover surface of the motor, the electric motor being attached within a fluid system that provides a fluid coolant to the motor; The stator spindle assembly of the motor, the stator spindle assembly comprising: A plurality of winding supports are arranged around the axis, the plurality of winding supports including a first winding support, the first winding support including an inner radial portion, an outer radial portion and a winding space radially defined relative to the axis between the inner radial portion and the outer radial portion, the winding space being configured to receive a plurality of windings of the motor, the inner radial portion and the outer radial portion extending along the axis between a first end and a second end of the stator shaft; A winding retainer, the winding retainer being disposed at the first end and configured to receive and retain the ends of the plurality of windings; and A contoured flow surface is disposed near the second end and is matched with the shield surface to define a nonlinear flow path for the fluid coolant in the fluid system.

10. The turbine according to claim 9, characterized in that, The contoured flow surface is three-dimensionally contoured by bending about the axis and also by convex bending in a plane, the axis being located in the plane and the plane being orthogonal to the axis.

11. The turbine according to claim 9, characterized in that, The contoured flow surface is contoured to the shield surface to define a downstream direction away from the first end and toward the second end, the downstream direction being radially inward toward the axis.

12. The turbine according to claim 11, characterized in that, It also includes a radial chamber that is cooperatively defined between the axial end of the motor and the inner surface; Wherein, the flow path is fluidly connected to the radial chamber downstream; and It also includes an internal section of the flow path, which is cooperatingly defined by the stator shaft and the rotating assembly, and the radial chamber is fluidly connected to the internal section downstream.

13. The turbine according to claim 12, characterized in that, It also includes a bearing system, wherein the inner section of the flow path is guided through the bearing system to fluid support the rotation of the rotating assembly relative to the housing assembly.

14. The turbine according to claim 12 or 13, characterized in that, It also includes the compressor stage; and The housing assembly includes a through-hole that fluidly connects the radial chamber to the compressor stage.

15. The turbine according to any one of claims 9 to 14, characterized in that, The profiled flow surface is one of a plurality of profiled flow surfaces disposed near the second end and spaced apart around the axis; It also includes recesses on the outer diameter surface, the recesses being angled between the plurality of contoured flow surfaces; The inner surface includes a protruding region projecting inward toward the axis; and The recess receives the raised area on the inner surface.

16. The turbine according to any one of claims 9 to 15, characterized in that, The stator spindle includes a first component and a second component, the first component being metallic and the second component being more electrically insulating than the first component, the first component and the second component cooperatingly defining the stator spindle.

17. The turbine according to any one of claims 9 to 16, characterized in that, The winding retainer includes a circumferential wiring portion extending about the axis, the circumferential wiring portion being configured to receive the ends of the plurality of windings.

18. The turbine according to any one of claims 9 to 17, characterized in that, The winding retainer includes a terminal latch configured to receive and retain the terminal ends of the plurality of windings.

19. A method for manufacturing a turbine, comprising: Provide housing; Provide rotating groups; Provide motors, including stator spindles; The rotating assembly is supported for rotation about an axis within the housing; The motor is housed within the housing and operatively coupled to the rotating assembly such that the motor is operatively functioning as at least one of an electric motor and a generator, the housing assembly including an inner surface defining the surface of a motor housing cover; The stator shaft component of the motor includes: A plurality of winding supports are arranged around the axis, the plurality of winding supports including a first winding support, the first winding support including an inner radial portion, an outer radial portion and a winding space radially defined relative to the axis between the inner radial portion and the outer radial portion, the winding space being configured to receive a plurality of windings of the motor, the inner radial portion and the outer radial portion extending along the axis between a first end and a second end of the stator shaft; A winding retainer, the winding retainer being disposed at the first end and configured to receive and retain the ends of the plurality of windings; and A contoured flow surface is disposed near the second end and mates with the shroud surface to define a non-linear flow path for the fluid coolant used in the motor.

20. The method according to claim 19, characterized in that, The stator spindle includes a first component and a second component, the first component being metallic and the second component being more electrically insulating than the first component, the second component covering the first component to define the stator spindle in a cooperative manner with the first component.

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