End Winding Support Bracket

Abstract

Disclosed herein is a bracket connectable to a stator core of an electric machine. The bracket includes a comb portion having a plurality of teeth arranged in at least one row with a recess defined between each pair of adjacent teeth. Each recess is sized to receive a portion of a bus bar. The bracket further includes tabs sized and shaped to be received in mounting recesses defined in the stator core, and arms extending between the comb portion and the tabs such that the comb portion is offset from the tabs.

Description

[Technical Field]

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

[0002] The stator core of an electric machine includes conductive elements, such as stator winding coils, electrically coupled to one another through conductors that extend outside the stator core. For example, end winding leads may be electrically connected to bus bars that span the end windings around the circumference of the machine. During operation, electric machines may be subject to a variety of loads, including both electromagnetic forces generated within the machine and external forces applied to the machine during operation. Therefore, the conductive elements outside the stator core must be mechanically supported and configured to withstand vibration loads, shock loads, thermal expansion, or other loads that may be applied to the electric machine.

[0003] In many applications of known electric machines, particularly aerospace applications, it is essential to minimize the physical size and weight of the electric machine. Accordingly, there is a need for a support structure for use with an electric machine that supports the outer conductive elements of the stator core without significantly increasing the overall size and weight of the electric machine. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Patent Application Publication No. 2021 / 0408862 Summary of the Invention

[0005] Disclosed herein is an electric machine including a rotor and a stator magnetically coupled to the rotor. The stator includes a stator core having an outer surface and a plurality of circumferentially spaced mounting recesses defined in the outer surface, and a plurality of stator windings coupled to a radially inner surface of the stator core. Each stator winding includes an end winding portion extending outward from an axial end of the stator core and at least one lead extending from the end winding portion. The electric machine further includes at least one bus bar electrically coupled to at least two of the leads, and a bracket. The bracket includes a comb portion having a plurality of teeth arranged in at least one row with a recess defined between each pair of adjacent teeth. Each recess is sized and oriented to receive a portion of the bus bar. The bracket further includes tabs sized and shaped to be received in respective ones of the mounting recesses and arms extending between the comb portion and the tabs such that the comb portion is offset from the tabs.

[0006] Also disclosed herein is a bracket connectable to a stator core of an electric machine. The bracket includes a comb portion having a plurality of teeth arranged in at least one row with a recess defined between each pair of adjacent teeth. Each recess is sized and oriented to receive a portion of a bus bar. The bracket further includes tabs sized and shaped to be received in mounting recesses defined in the stator core, and arms extending between the comb portion and the tabs such that the comb portion is offset from the tabs.

[0007] Further disclosed herein is a method of assembling an electric machine including a rotor, a stator, a busbar, and a bracket. The bracket includes a comb portion having a plurality of teeth arranged in at least one row with a recess defined between each pair of adjacent teeth. The method includes positioning a tab of the bracket in a mounting recess defined in an outer surface of a stator core of the stator, inserting a portion of the busbar into one of the plurality of recesses, coupling a stator winding to a radially inner surface of the stator core, and coupling the busbar to leads extending from end turn portions of the stator winding.

[0008] Various refinements exist for the features described in connection with the above-described aspects of the present disclosure. Additional features may also be incorporated into the above-described aspects of the present disclosure. These refinements and additional features may exist individually or in any combination. For example, various features described below in connection with any of the illustrated embodiments of the present disclosure may be incorporated into any of the above-described aspects of the present disclosure, either alone or in any combination. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is an exploded perspective view of an exemplary electrical device. [Figure 2] 2 is a cross-sectional view of the exemplary electric machine shown in FIG. 1 taken along line 2-2. [Figure 3] 2 is a perspective view of an exemplary wedge portion of an axial end of a stator core of an electric machine. FIG. [Figure 4] 4 is another perspective view of an exemplary wedge portion of an axial end of a stator core of the electric machine shown in FIG. 3. [Figure 5] 5 is another perspective view of the example wedge portion shown in FIG. 4, further illustrating multiple end winding portions. [Figure 6] 6 is another perspective view of the example wedge portion shown in FIG. 5, further illustrating multiple bus bars. [Figure 7]7 is another perspective view of the exemplary wedge portion shown in FIG. 6, further illustrating multiple brackets. [Figure 8] FIG. 8 is a perspective view of one of the brackets shown in FIG. 7. [Figure 9] 8 is another perspective view of one of the brackets shown in FIG. 7. [Figure 10] 8 is another perspective view of one of the brackets shown in FIG. 7. [Figure 11] FIG. 10 is a perspective view of an alternative embodiment of the bracket. [Figure 12] FIG. 12 is a cross-sectional view of the bracket shown in FIG. [Figure 13] 8 is another perspective view of the exemplary wedge portion shown in FIG. 7, further showing an outer retaining ring. [Figure 14] 1. FIG. 1 is a partial cross-sectional view of the electric machine shown in FIG. 1 taken along line 14-14. DETAILED DESCRIPTION OF THE INVENTION

[0010] Corresponding reference characters indicate corresponding parts throughout the drawings.

[0011] The following detailed description illustrates, by way of example only, and not by way of limitation, exemplary end winding support brackets and their methods of use in electric machines. The description should enable one skilled in the art to make and use the brackets, and the description describes several exemplary embodiments of the brackets. The exemplary brackets are described herein in conjunction with the assembly of electric machines. However, the brackets are believed to have general applicability to a wide range of systems in various fields other than electric machines.

[0012] FIG. 1 is a perspective view of an exemplary electric machine 300. In the exemplary embodiment, electric machine 300 includes a stator 112 and a rotor 114 that are magnetically coupled and coaxially aligned about a central longitudinal axis 16 of electric machine 300. Electric machine 300 may be an electric motor, where rotor 114 rotates relative to stator 112 to convert electrical energy into mechanical energy. In a further embodiment, electric machine 300 may be a generator, where relative rotation between rotor 114 and stator 112 converts mechanical energy into electrical energy. In still further embodiments, electric machine 300 may be any other type of rotating electric machine, such as, for example, but not limited to, a synchronous machine, a polyphase electric machine, an electric machine with concentrated windings, an electric machine with distributed windings, a reluctance machine, an induction machine, a wound-field machine, a salient-pole electric machine, an interior permanent magnet (IPM) machine, an electric machine with permanent magnets arranged differently than an IPM machine (e.g., a surface PM machine, etc.), and / or any other suitable electric machine.

[0013] Stator 112 includes a stator core 18 extending between axial ends 111, with stator core 18 including a central opening 20 extending along central longitudinal axis 16. Rotor 114 extends a distance along central longitudinal axis 16 and includes a shaft 22 and a rotor core 24 attached to shaft 22. Shaft 22 rotates relative to stator core 18 about central longitudinal axis 16. Rotor core 24 is rotationally coupled to shaft 22 such that rotor core 24 rotates together with shaft 22 about central longitudinal axis 16.

[0014] In the exemplary embodiment, rotor 114 extends within central opening 20 of stator core 18 and is rotatable relative to stator core 18 within central opening 20. That is, stator core 18 of electric machine 300 is sized to extend around rotor 114 such that rotor 114 can rotate within stator 112. In further embodiments, rotor 114 may be sized to extend around and rotate around stator 112.

[0015] FIG. 2 is a cross-sectional view of the example electric machine 300 shown in FIG. 1 taken along line 2-2 (shown in FIG. 1). In particular, the cross-sectional view of FIG. 2 illustrates both the stator 112 and the rotor 114 of the electric machine 300. In the exemplary embodiment, the stator core 18 includes a stator base 28, a plurality of circumferentially spaced stator teeth 30, and a plurality of circumferentially spaced partitions 33, with each stator tooth 30 and partition 33 extending radially inward from the stator base 28. With further reference to FIGS. 3 and 4 , each stator tooth 30 extends from a first end 31 adjacent the stator base 28 to a second free end 32. The second end 32 of each stator tooth 30 may partially define the central opening 20 of the stator core 18. In some embodiments, the second ends 32 of each stator tooth 30 are connected to one another. Each stator tooth 30 may define at least one wedge retaining groove 37 proximate its second end 32. Each wedge retaining groove 37 extends along the axial length of each stator tooth 30 between the axial ends 111 of the stator core 18. Each of a plurality of wedges 39 is shaped and sized to be received and retained in a respective pair of wedge retaining grooves 37 defined between adjacent pairs of stator teeth 30. Each wedge 39 secures a stator conductor 40 within a respective raceway 38. The raceways 38 are described in further detail below.

[0016] Each partition 33 extends from a first end 34 adjacent the stator base 28 to a second free end 35. The stator teeth 30 and partitions 33 are circumferentially spaced about the stator base 28 in an alternating pattern such that a partition 33 is located between each pair of circumferentially adjacent stator teeth 30 and a stator tooth 30 is located between each pair of circumferentially adjacent partitions 33. The stator core 18 may include any number of stator teeth 30 and partitions 33 that enables the electric machine 300 to function as described herein.

[0017] The inner surface of the stator base 28 between each adjacent stator tooth 30 and the partition walls 33 forms a radially inner surface 36 (shown in FIG. 3) of the stator core 18. A raceway 38 is defined in part by the radially inner surface 36, each pair of circumferentially adjacent partition walls 33, and the respective stator tooth 30 disposed therebetween. Each raceway 38 is shaped and sized to receive a stator conductor 40. Each stator conductor 40 extends longitudinally through the stator core 18 and couples to the radially inner surface 36 of the stator core 18. The stator core 18 may include the same number of stator conductors 40 as the raceways 38, or may include fewer stator conductors 40 than the raceways 38, such that at least one raceway 38 does not receive a stator conductor 40. The rotor 114 includes a shaft 22 (shown in FIG. 1) and a rotor core 24.

[0018] Rotor core 24 is rotatable relative to stator 112 about central longitudinal axis 16. In the exemplary embodiment, rotor core 24 includes a rotor base 44, a plurality of magnetic segments 46 extending radially outward from rotor base 44, and a plurality of non-magnetic segments 48 extending radially outward from rotor base 44. In other embodiments, segments 46 and 48 extend radially inward from rotor base 44.

[0019] The magnetic segments 46 and the non-magnetic segments 48 are arranged along the rotor circumference C of the rotor core 24. r 16. In other words, the magnetic segments 46 are radially spaced apart about the central longitudinal axis 16, such that the magnetic segments 46 are circumferentially spaced apart away from the central longitudinal axis 16, and the non-magnetic segments 48 extend between circumferentially adjacent magnetic segments 46 that are spaced apart about the rotor circumference Cr of the rotor core 24. In the exemplary embodiment, the rotor 114 is a toothed rotor, and the magnetic segments 46 define the rotor teeth 45 of the rotor core 24.

[0020] The rotor base 44 includes a radially inner rotor surface 50 that defines a central opening 52 in the rotor core 24. The outer periphery of the rotor core 24 is defined by end faces 47 and 49 of the magnetic and non-magnetic segments 46 and 48, respectively. An air gap G is defined between the outer periphery of the rotor core 24 and the second end 32 of each stator tooth 30 of the stator core 18. The rotor base 44 may include one or more mortises (not shown), each sized and oriented to receive a corresponding tenon (not shown) extending from the shaft 22 for use in attaching the rotor core 24 to the shaft 22. Other configurations for attaching the rotor core 24 to the shaft 22 may be provided in addition to or in place of the tenons and mortises.

[0021] The rotor core 24 may be formed from one or more laminations of multiple laminations, or may be formed as a single piece of material. The rotor base 44 of the rotor core 24 may be fabricated from a non-magnetic material and may be integrally formed with the magnetic segments 46. Alternatively, or in addition, the rotor base 44 may be integrally formed with the non-magnetic segments 48. For example, if the rotor core 24 is formed from a lamination of laminations, the rotor base 44 of each lamination or layer within the lamination may be integrally formed with the magnetic segments 46 and / or non-magnetic segments 48 of the laminations. Further, for example, in embodiments in which the rotor core 24 is formed as a single piece of material, the rotor base 44 is integrally formed from a magnetic material and is a single piece of material that includes all of the magnetic segments 46 and non-magnetic segments 48 of the rotor core 24. In an exemplary embodiment, the magnetic segments cooperate with the rotor base 44 to form the rotor 114 as a toothed rotor. In other words, in such embodiments, the rotor base 44 carries magnetic flux. The toothed rotor structure of rotor 114, whether constructed from laminations of laminations of thin plates or a single piece of material, distinguishes rotor 114 from "segmented" rotors in which magnetic segments are magnetically insulated or separated from the rotor base and from each other in a rotor core. In exemplary embodiments, stator 112 and / or rotor 114 may include permanent magnets. In some alternative embodiments, rotor 114 is a segmented rotor.

[0022] Rotor core 24 may include any number of magnetic segments 46 and / or non-magnetic segments 48. Additionally, rotor core 24 may include any number of rotor tines 45. In one embodiment, rotor core 24 includes the same number of rotor tines 45 as stator core 18 includes stator tines 30. Alternatively, stator core 18 may include more or fewer stator tines 30 than rotor core 24 includes rotor tines 45. In the exemplary embodiment, rotor core 24 includes 14 rotor tines 45, and electric machine 300 includes a greater number of stator tines 30 than rotor tines 45.

[0023] 3-7 and 13 each illustrate an exemplary wedge portion 90 at an axial end 111 of stator core 18. It should be understood that the illustrated wedge portion 90 may represent any circumferential portion of stator core 18 at either axial end 111 of stator core 18, and that each wedge portion 90 included at each axial end 111 of the stator core may include the same features and components or may include different features and components than those illustrated in FIGS. 3-7 and 13.

[0024] In the exemplary embodiment, stator core 18 includes a radially outer surface 101 ( FIG. 4 ) and a flange 103 that circumscribes the stator core 18 and extends radially outward from the radially outer surface 101. In the exemplary embodiment, flange 103 defines at least one mounting hole 104 that is shaped and sized to receive a fastener (not shown) therethrough. Stator core 18 further includes an outer surface 105 that extends substantially perpendicularly from the radially inner surface 36 of stator core 18. Additionally, stator core 18 includes a plurality of recessed surfaces 107 and a plurality of recessed sidewalls 108, each extending generally axially. Each recessed sidewall 108 extends from outer surface 105 to a respective recessed surface 107. Each recessed surface 107 and corresponding recessed sidewall 108 define a mounting recess 109 that extends from outer surface 105 into stator core 18. A plurality of mounting recesses 109 are circumferentially spaced about each axial end 111 of stator core 18. In the exemplary embodiment, each mounting recess 109 is dovetail shaped. In alternative embodiments, each mounting recess 109 may have any other suitable shape that enables electric machine 300 to function as described herein.

[0025] Additionally, the outer surface defines a plurality of first openings 102. In the exemplary embodiment, the first openings 102 and mounting recesses 109 are circumferentially spaced apart about the outer surface 105 of the stator core 18 such that a first opening 102 is defined between each pair of adjacent mounting recesses 109 and a mounting recess 109 is defined between each pair of circumferentially adjacent first openings 102. In alternative embodiments, depending on the design of the stator core 18, at least some pairs of circumferentially spaced apart mounting recesses 109 do not include a first opening 102 defined therebetween.

[0026] FIG. 5 is a perspective view of a portion of the stator core 18, including a plurality of stator conductors 40 received within respective raceways 38 (shown in FIG. 2). In the exemplary embodiment, the stator conductors 40 are stator windings 40 formed by winding a plurality of wires (not shown) around one of the stator teeth 30 and between adjacent bulkheads 33 in a raceway configuration. That is, the wires enable the stator windings 40 to extend longitudinally through the stator core 18 in a direction substantially parallel to the central longitudinal axis 16. Furthermore, the wires wrap around both sides (not shown) of the stator teeth 30 and around the ends (not shown) of the stator teeth 30 at each axial end 111 of the stator core 18. A plurality of wedges 39 secure each stator winding 40 within its respective raceway 38.

[0027] In some embodiments, the stator windings 40 may include one or more direct current (DC) windings and / or one or more alternating current (AC) windings. In other embodiments, the stator windings 40 may include copper windings, Litz wire windings, fractional slot concentrated windings (not shown), and / or any other suitable type of stator winding. Each stator winding 40 may be or represent any number of phases, such as, but not limited to, single phase or three phases. In further embodiments, the stator conductors may be rigid conductors having similar shapes.

[0028] The portion of each stator winding 40 that wraps around the end of a stator tooth 30 forms an end winding portion 60 that extends outward from the axial end 111 of the stator core 18. Ends (not shown) of the multiple wires that form each stator winding 40 extend axially outward from the end winding portion 60 to form leads 64. The multiple wires of each lead 64 may be brazed together to form a solid, integral lead, or may be loosely bundled together. In some embodiments, each lead 64 is flexible and can be bent and / or manipulated into multiple configurations or orientations. In further embodiments, the leads 64 are rigid and fixed in a single configuration.

[0029] The exemplary wedge portion 90 shown in FIG. 5 includes four end winding portions 60, including first, second, third, and fourth leads 64a-64d. Each lead 64a-64d includes a radial portion 65a-65d extending radially inward toward the central longitudinal axis 16 and an axial portion 66a-66d extending axially away from the stator core 18, with each portion 66a-66d being substantially parallel to the central longitudinal axis 16. In the exemplary embodiment, the first and third leads 64a and 64c are identically formed, and the second and fourth leads 64b and 64d are identically formed but with different dimensions than 64a and 64c. That is, the radial portions 65a and 65c of the first and third leads 64a and 64c, respectively, each have a first radial length L r1 and radial portions 65b and 65d of second and fourth leads 64b and 64d, respectively, each have a first radial length L r1 a second radial length L that is longer than r2 Similarly, the axial portions 66a and 66c of the first and third leads 64a and 64c, respectively, have a first axial length L a1 and the axial portions 66b and 66d of the second and fourth leads 64b and 64d, respectively, have a first axial length L a1 a second axial length L that is longer than a2In other embodiments, all of the leads 64a-64d may have substantially the same dimensions.

[0030] In some embodiments, the stator core 18 further includes a plurality of slot liners (not shown) sized and oriented to be received within the corresponding raceways 38. The slot liners may be constructed from a non-conductive material such that the stator windings 40 are electrically insulated from the stator core 18. Each slot liner is disposed between the radially inner surface 36 of the stator core 18 and the stator windings 40 and extends longitudinally between the axial ends of the stator core 18.

[0031] Referring to FIG. 6 , the electric machine 300 includes at least one bus bar 70 electrically coupled to at least two leads 64. In the exemplary embodiment, three bus bars 70a-70c are shown, but the electric machine 300 may include any suitable number of bus bars 70 that enables the electric machine 300 to function as described herein. Each bus bar 70 may include an arcuate circumferential portion 72 and at least two axial tabs 74. Each circumferential portion 72 has a depth d1 and a width w1 and spans a first arcuate length AL1 that enables the bus bar 70 to extend between a pair of circumferentially adjacent axial tabs 74. In other embodiments, the circumferential portion 72 may extend circumferentially beyond one or both of the axial tabs 74. Furthermore, the circumferential portion 72 may extend substantially linearly between the at least two axial tabs 74, as shown in the exemplary embodiment, or may be formed with a radius of curvature R1. In other embodiments, the circumferential portion 72 may form a complete annular ring such that the first arcuate length AL1 is the entire circumference defined by the circumferential portion 72. In yet other embodiments, the circumferential portion 72 may be semicircular.

[0032] Each axial tab 74 extends from a first end 75 connected to circumferential portion 72 to a second free end 76. More specifically, in the exemplary embodiment, each axial tab 74 extends radially inward from the first end 75 to the second end 76. In other embodiments, axial tab 74 may extend in any other suitable direction that enables electric machine 300 to function as described herein. In the exemplary embodiment, the portion of axial tab 74 adjacent first end 75 is substantially flush with circumferential portion 72, and the portion of axial tab 74 adjacent second end 76 is substantially perpendicular to circumferential portion 72. In further embodiments, first and second ends 75 and 76 may both be substantially flush with circumferential portion 72, or both ends 75 and 76 may extend substantially perpendicular to circumferential portion 72.

[0033] In the exemplary embodiment, each axial tab 74 is coupled to the axial portion 66 of one of the leads 64 such that each bus bar 70 is electrically coupled to at least two leads 64. In other embodiments, the bus bar 70 and leads 64 may be coupled to each other in any other suitable manner, such as, for example, by coupling the axial tab 74 to the radial portion 65 of the lead 64. In still further embodiments, the bus bar 70 may not include the axial tab 74, and the circumferential portion 72 may be directly coupled to the at least two leads 64. The bus bar 70 may be brazed to each lead 64 or may be coupled in any other suitable manner. In the exemplary embodiment, a single bus bar 70 is coupled to each lead 64. In other embodiments, more than one bus bar 70 may be coupled to each lead 64.

[0034] Referring to FIG. 7 , the electric machine 300 further includes at least one bracket 100 in one of the mounting recesses 109 (shown in FIG. 4 ) that provides mechanical support to the at least one busbar 70. In the exemplary embodiment, a first bracket 100a is received in the first mounting recess 109a, and a second bracket 100b is received in the second mounting recess 109b. Referring to FIGS. 8-10 , each bracket 100 includes a comb portion 120, a tab 140, and an arm 160 extending between the comb portion 120 and the tab 140 such that the comb portion 120 is offset from the tab 140. The comb portion 120 includes a plurality of teeth 124 arranged in at least one row. In the exemplary embodiment, each bracket 100 includes a first upper row 121 of teeth 124 and a second lower row 122 of teeth 124 extending substantially parallel to the first row 121. In other embodiments, the comb portion 120 may include any other suitable number of rows, such as, for example, but not limited to, only one row of teeth 124 or three or more rows of teeth 124.

[0035] Each of the rows 121 and 122 of teeth 124 extends from a first end 127 to a second end 129 of the comb portion 120 by a length L c In the exemplary embodiment, each row 121 and 122 extends over a length L c , extending generally axially across the width w of the comb portion 120 and substantially parallel to the central longitudinal axis 16. Furthermore, each of the rows 121 and 122 includes an upper surface 110 and a lower surface 130 that is substantially parallel to the upper surface 110. Furthermore, in the exemplary embodiment, the upper surface 110 and the lower surface 130 each extend over a width w of the comb portion 120. c Approximately the same width as c In a further embodiment, the upper surface 110 and the lower surface 130 have different widths w c,u and w c,l(not shown), such that comb portion 120 does not have a constant width. Comb portion 120 further includes an end surface 134 located opposite tab 140 and extending substantially perpendicular to upper surface 110 and lower surface 130 of comb portion 120. A first outer opening 136 is defined in end surface 134 of each bracket 100, as will be described in further detail below.

[0036] Each of the plurality of teeth 124 extends substantially vertically downward from the lower surface 130 of each of the rows 121 and 122. A recess 125 is defined between each pair of adjacent teeth 124. Each of the rows 121 and 122 of the comb portion 120 includes at least two teeth 124, with the teeth 124 defining a recess 125 therebetween. Each recess 125 is sized and shaped to receive a portion of the busbar 70. More specifically, in the exemplary embodiment, each recess 125 is sized and shaped to receive a portion of the circumferential portion 72 of the busbar 70. Thus, each recess 125 has a width w that is greater than a depth d1 of the circumferential portion 72 of the busbar 70. i Each tooth has a width w determined at least in part by the voltage class of the electric machine 10 to provide the necessary electrical clearance and creepage distance between busbars 70 located in adjacent recesses 125. t It has.

[0037] Furthermore, in the exemplary embodiment, not all of the recesses 125 in the bracket 100 receive a portion of a busbar 70. More specifically, in the exemplary embodiment, at least some of the recesses 125 may remain empty and not receive a portion of a busbar 70. For example, referring to FIG. 7 , the first bracket 100a receives a portion of the first busbar 70a in the recesses 125 defined in its upper row 121a, and a portion of the second busbar 70b in the recesses 125 defined in its lower row 122b. Similarly, the second bracket 100b receives a portion of the third busbar 70c in the recesses 125 defined in its upper row 121b. In the exemplary embodiment, the other recesses 125 do not receive a portion of a busbar 70.

[0038] Each of the rows 121 and 122 of the bracket 100 has a different radius of curvature R c In an exemplary embodiment, the upper rows 121a and 121b of the first and second brackets 100a and 100b are circumferentially aligned along a first radius R1 (not shown) such that the portions of the first and third bus bars 70a and 70c received by the recesses 125 in the upper rows 121a and 121b are formed with the same radius of curvature R1. In some embodiments, the same bus bar 70 may extend through the recesses 125 formed in the upper rows 121a and 121b of both the first and second brackets 100a and 100b. Different recesses 125 formed in the same row 121 or 122 of the brackets may accommodate bus bars 70 having the same radius of curvature.

[0039] Similarly, the lower rows 122a and 122b of the first and second brackets 100a and 100b are circumferentially aligned at a second radius R2, and the second bus bar 70b is received in a recess 125 formed in the lower row 122a and is therefore formed with the same second radius of curvature R2. In some embodiments, the same bus bar 70 may extend through the recesses 125 formed in the lower rows 122a and 122b of both the first and second brackets 100a and 100b. In the exemplary embodiment, the second radius of curvature R2 is different from and smaller than the first radius of curvature R1. In the exemplary embodiment, no other recess 125 receives a portion of the bus bar 70.

[0040] Additionally, each bracket 100 includes a tab 140 formed with an inner surface 142, an outer surface 144, a top surface 145, and a plurality of side surfaces 146. In the exemplary embodiment, the inner surface 142 is substantially parallel to the outer surface 144, and the top surface 145 is substantially perpendicular to both the inner surface 142 and the outer surface 144. In alternative embodiments, the inner surface 142, the outer surface 144, and the top surface 145 may be formed with any other suitable orientation relative to one another. Each tab 140 is shaped and sized to be received in a respective mounting recess 109 of the stator core 18. For example, if the mounting recess 109 is a dovetail-shaped recess, the tab 140 is formed as a dovetail-shaped tab. That is, the tab 140 is formed with a shape substantially identical to the shape of the mounting recess 109 into which it is inserted. In alternative embodiments, any other suitable mechanical coupling mechanism can be used to couple the bracket 100 to the stator core 18.

[0041] 7 , in the exemplary embodiment, each tab 140 is received in a mounting recess 109 such that the inner surface 142 engages the recess surface 107 of the stator core 18 and the top surface 145 and side surface 146 each engage one of a plurality of recess sidewalls 108 defined within the stator core 18. In the exemplary embodiment, when the tab 140 is inserted into the mounting recess 109, the outer surface 144 is substantially parallel to the outer surface 105 of the stator core 18. In other embodiments, when the tab 140 is seated in the mounting recess 109, the outer surface 144 of the tab 140 may be oblique to the outer surface 105 of the stator core 18. In the exemplary embodiment, the depth d of the tab 140 is axially longer than the depth d of the tab 140 such that the outer surface 144 of the tab 140 extends axially beyond the outer surface 105 of the stator core 18. t The depth d of the corresponding mounting recess 109 mr In a further embodiment, the depth d of the tab 140 is greater than d so that the outer surface 144 of the tab 140 remains within the mounting recess 109. t The depth d of the corresponding mounting recess 109 mr In still further embodiments, the outer surface 144 of the tab 140 may be substantially flush with the outer surface 105.

[0042] Each bracket 100 further includes an arm 160 extending between the tab 140 and the comb portion 120. In the exemplary embodiment, each arm 160 has a length L measured from a first end 161 adjacent the inner surface 142 of the tab 140 to a second end 162 adjacent the first row 121 of teeth 124 of the comb portion 120. a As best seen in FIG. 7, arm 160 has a length L a 1, extending generally axially in a direction substantially parallel to the central longitudinal axis 16. The arm 160 includes an upper surface 164, a lower surface 166 substantially parallel to the upper surface 164, and a pair of opposite side surfaces 168 extending between the upper surface 164 and the lower surface 166. Additionally, the arm 160 includes an inner surface 169 that is substantially coplanar with the inner surface 142 of the tab 140.

[0043] Each tab 140 extends substantially perpendicular from the upper surface 164 of the arm 160 adjacent the first end 161 such that the inner and outer surfaces 142, 144 of the tab 140 are substantially perpendicular to the upper and lower surfaces 164, 166 of the arm 160. In the exemplary embodiment shown in FIGS. 8 and 10, the width w of the arm 160 adjacent the second end 162 is a The width of the comb part is 120 c , and the shape of the inner surface 169 is substantially similar to the shape of one of the bulkheads 33 (shown in FIG. 3). In further embodiments, the arms 160 may be formed in any suitable width or shape that enables the bracket 100 to function as described herein. Referring to FIG. 9, a radial offset r is provided between the upper surface 145 of the tab 140 and the upper surface 164 of the arms 160 such that the comb portion 120 is radially offset from the tab 140. off 7, the tabs 140 of each bracket 100 are spaced apart such that the comb portion 120 of the bracket 100 extends longitudinally and is radially offset r from the tabs 140. off 1. The mounting recess 109 is received in one of the mounting recesses 109 so as to be radially offset by .gtoreq.1.

[0044] Additionally, bracket 100 includes a gauge guide groove 116 defined along upper surface 110 of upper row 121 of teeth 124. In the exemplary embodiment, gauge guide groove 116 extends along the entire length L of comb portion 120. c and the length of the arm 160 L a In some alternative embodiments, the meter guide groove 116 may not extend into the arm 160 and / or may extend along a portion of the length L of the comb portion 120. c1. Gauge guide groove 116 is shaped and sized to receive one or more sensors (not shown) such that the sensors extend generally axially through electric machine 300. Such sensors may be, for example, but not limited to, thermocouples or other temperature sensors. In the exemplary embodiment, bracket 100 further includes at least one gauge turning groove 118 defined in top surface 110 of upper row 121 of teeth 124. Each gauge turning groove 118 extends along width w of top surface 110. c , and at least partially intersects with the gauge guide grooves 116. In the exemplary embodiment, the bracket 100 includes six gauge turning grooves 118, although the bracket 100 may include any other suitable number of gauge turning grooves 118. Each gauge turning groove 118 is shaped and sized to at least partially receive one of the one or more sensors received in the gauge guide grooves 116 and redirect the sensor from an axial to a circumferential direction. While the exemplary embodiment shows grooves of two different sizes, further embodiments may include only grooves of the same size or multiple grooves of different sizes.

[0045] Furthermore, the bracket 100 has a width w c At least one restraining opening 172 is defined extending therethrough. Each restraining opening 172 is shaped and sized to receive a restraining strap. In the exemplary embodiment, each row 122 of comb portion 120 includes four restraining openings 172, although each row 122 may include any other suitable number of restraining openings 172, such as, for example, without limitation, five or more restraining openings 172 or three or fewer restraining openings 172.

[0046] In the exemplary embodiment, each bracket 100 is constructed from a non-conductive, insulating material, such as, but not limited to, Torlon® or polyetheretherketone (PEEK). In other embodiments, bracket 100 may be constructed from any other suitable lightweight, high-strength, electrically insulating polymer or composite material. Each bracket 100 may be manufactured by injection molding, machining, casting, additive manufacturing, or any other suitable process.

[0047] An alternative embodiment of bracket 200 is shown in Figures 11 and 12. Bracket 200 includes a comb portion 220, a tab 240, and an arm 260 extending between comb portion 220 and tab 240. Bracket 200 further includes an instrument guide passage 212 extending along the axial length of bracket 200. Instrument guide passage 212 is shaped and sized to receive and pass sensor leads 216 from stator core 18 such that stator leads 216 can pass axially through electric machine 300.

[0048] In an exemplary embodiment, referring to FIG. 13 , an electric machine 300 further includes an inner retaining ring 180 coupled to the outer surface 105 of the stator core 18. The inner retaining ring 180 defines a plurality of circumferentially spaced second openings 182. The second openings 182 are positioned such that, when the inner retaining ring 180 is coupled to the stator core 18, each of the second openings 182 can be axially aligned with the first openings 102 of the stator core. The first openings 102 and the second openings 182 are shaped and sized to receive and pass fasteners 184 for securing the inner retaining ring 180 to the outer surface 105 of the stator core 18. In some embodiments, the portions of the inner retaining ring 180 defining each of the second openings 182 can be chamfered or countersunk so that the head of each fastener is substantially flush with the inner retaining ring 180 when fully installed on the stator core 18.

[0049] 13 , the electric machine 300 further includes an outer retaining ring 190. In the exemplary embodiment, the outer retaining ring 190 is coupled to the first end face 134 a of the first bracket 100 a and the second end face 134 b of the second bracket 100 b and extends arcuately therebetween. The outer retaining ring 190 defines a plurality of outer retaining apertures 192 spaced circumferentially about the outer retaining ring 190. The outer retaining apertures 192 are positioned such that each of the first outer aperture 136 a defined in the first bracket 100 a and the second outer aperture 136 b defined in the second bracket 100 b is aligned with one of the plurality of outer retaining apertures 192. The outer apertures 136 a and 136 b and the outer retaining apertures 192 are shaped and sized to receive and pass fasteners 194 for securing the outer retaining ring 190 to the first and second brackets 100 a and 100 b.

[0050] 14 is a cross-sectional view of a portion of an electric machine with at least one bracket 100 installed. An annular open area 320 extends axially through the electric machine 300 and has a radial offset r between the tabs 140 and the comb portion 120. off The open area 320 is defined in part by the radial offset r between the tab 140 and the comb portion 120. off That is, the empty space 320 is created when the bracket 100 is at a radial offset r off 3 represents the radial space that would otherwise be occupied by comb portions 120 of multiple brackets 100. Moving comb portions 120 radially inward into the space already occupied by multiple bus bars 70 allows for the most efficient use of the radial space in which bus bars 70 and end windings 64 reside. In the exemplary embodiment, open area 320 is used to house impingement cooling manifold plenum 310 for use in cooling end winding portions 60. In an alternative embodiment, no additional components are located in open area 320, and electric machine 300 may be constructed with a smaller housing 340 to reduce the overall size and weight of electric machine 300.

[0051] In an alternative embodiment of electric machine 10, outer surface 105 of stator core 18 is substantially coaxially aligned with radially inner surface 36 of stator core 18. Each tab 140 of each bracket 100 is received in a respective mounting recess 109 such that comb portion 120 of bracket 100 extends radially outward from stator core 18 and is longitudinally offset from tab 140. The longitudinal offset between tab 140 and comb portion 120 facilitates reducing the axial space required by busbar 70 and bracket 100, thereby creating space for other components or allowing the axial extent of electric machine 10 to be reduced.

[0052] An exemplary method of assembling the electric machine 300 described herein includes positioning the tabs 140 extending from the bracket 100 into the mounting recesses 109 defined in the outer surface 105 of the stator core 18. A portion of the busbar 70 is then inserted into one of the recesses 125 in the comb portion 120 of the bracket 100 offset from the tabs 140. The stator windings 40 are coupled to the radially inner surface 36 of the stator core 18, and the busbar 70 is coupled to the leads 64 extending from the end winding portions 60 of the stator windings 40.

[0053] In embodiments in which the outer surface 105 of the stator core 18 is oriented substantially perpendicular to the radially inner surface 36 of the stator core 18, disposing the tab 140 of the bracket 100 in the mounting recess 109 includes disposing the tab 140 in the mounting recess 109 such that the comb portion 120 of the bracket 100 extends longitudinally and is radially offset from the tab 140. As shown and described in connection with FIG. 15 , in embodiments in which the outer surface 405 of the stator core 18 is oriented substantially coaxially with the radially inner surface 36 of the stator core 18, disposing the tab 140 of the bracket 100 in the mounting recess 409 includes disposing the tab 140 in the mounting recess 409 such that the comb portion 120 of the bracket 100 extends radially and is longitudinally offset from the tab 140.

[0054] In an embodiment in which the busbar 70 includes a first busbar 70a having a first radius of curvature R1 and a second busbar 70b having a second radius of curvature R2 different from the first radius of curvature R1, and the plurality of teeth 124 of the comb portion 120 are arranged in at least a first upper row 121a and a second lower row 122a substantially parallel to the first row 121a, the method further includes inserting a portion of the second busbar 70b into the recess 125 of the second row 122a of the comb portion 120.

[0055] In an embodiment in which a plurality of first openings 102 are defined in the outer surface 105 of the stator core 18 and the inner retaining ring 180 defines a plurality of second openings 182, the method further includes coupling the inner retaining ring 180 to the outer surface 105 so that the first openings 102 and the second openings 182 are aligned to receive and pass fasteners, and inserting a plurality of fasteners through the plurality of first and second openings 102 and 182 to secure the inner retaining ring 180 to the outer surface 105 of the stator core 18.

[0056] The bracket 100 is defined on the upper surface 110 and has a length L of the comb portion 120. cIn embodiments further including a gauge guide groove 116 extending along the gauge guide groove 116, the method further includes inserting a portion of a sensor (not shown) into the gauge guide groove 116.

[0057] The electric machine and bracket embodiments described herein offer several advantages over prior designs. The offset between the tabs and the comb allows the bracket to be installed within the same physical area as the busbars, creating radial or axial space for installing other components or reducing the radial or axial extent of the machine. In an exemplary embodiment, the radial space created by the bracket's radial offset is occupied by an annular impingement cooling plenum that supplies cooling air through a number of small impingement slots to facilitate cooling of the end windings. If the bracket were configured without the radial offset, such that the comb extended substantially axially from the tabs, the bracket would likely interfere radially with the annular plenum. In such a case, the plenum would have to be configured with several different inner diameters around its circumference to achieve proximity to the end windings without interfering with the bracket. Parts with such complex geometries would be much more difficult and expensive to manufacture than the annular plenums enabled by radially offset brackets.

[0058] Additionally, the dovetail shape of the tabs prevents radial and circumferential movement of the brackets, allowing them to be installed one at a time without the need for any mounting hardware until the end of assembly. The inner retaining ring securely secures the tabs in the mounting recesses without requiring any fasteners to pass through the tabs themselves, improving the mechanical integrity of the tabs. If fastener holes are defined in the tabs, they must be countersunk to prevent the fastener heads from interfering with other mechanical components, further impacting the mechanical integrity of the tabs. Furthermore, by passing fasteners only through the inner retaining ring and stator core, the conductive ground plane of the metal hardware is advantageously isolated from the non-conductive brackets.

[0059] Furthermore, the same bracket design can be used in various configurations of electric machines, such as electric machines with different orientations of the end winding leads and busbars. In the exemplary embodiments of Figures 3-7, 13, and 14, the end windings extend substantially axially from the stator core, and the brackets provide a radial offset to reduce the radial space occupied by the busbars and brackets. In the exemplary embodiment of Figure 15, the end windings extend substantially radially from the stator core, and the brackets provide an axial offset to reduce the axial space occupied by the busbars and brackets.

[0060] Finally, by constructing the brackets from a non-conductive material, less electrical clearance is required between the busbars, allowing the busbars to be placed closer together, reducing the size requirements of the electric machine as a whole.

[0061] As used herein, the terms "about," "substantially," "essentially," and "approximately," when used in conjunction with a range of dimensions, concentrations, temperatures, or other physical or chemical properties or characteristics, are intended to encompass variations that may exist at the upper and / or lower limits of the range of the property or characteristic, such as variations resulting from rounding, measurement methods, or other statistical variations.

[0062] When introducing elements of the present disclosure or embodiments thereof, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the element. The terms "comprising," "including," "containing," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements. The use of specific orientational terms (e.g., "top," "bottom," "side," etc.) is for convenience of description and does not require a particular orientation of the described items.

[0063] Since various changes can be made in the above-described structures and methods without departing from the scope of the present disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

[0064] Further aspects of the present invention are provided by the subject matter of the following clauses.

[0065] Clause 1. An electric machine comprising: a rotor; a stator magnetically coupled to the rotor, the stator core including an outer surface and a plurality of circumferentially spaced mounting recesses defined in the outer surface; and a plurality of stator windings coupled to a radially inner surface of the stator core, each stator winding including an end winding portion extending outwardly from an axial end of the stator core and at least one lead extending from the end winding portion; at least one busbar electrically coupled to at least two of the leads; a bracket including a plurality of teeth arranged in at least one row, the bracket defining a comb portion having a recess defined between each pair of adjacent teeth, each of the recesses sized to receive a portion of the busbar; tabs sized and shaped to be received in respective ones of the plurality of mounting recesses; and arms extending between the comb portion and the tab such that the comb portion is offset from the tab.

[0066] Clause 2. The electric machine of clause 1, wherein the stator core outer surface extends substantially perpendicular to the radially inner surface, and the bracket tab is received in one of the mounting recesses defined in the stator core outer surface such that the comb portion is radially offset from the tab.

[0067] Clause 3. The electric machine of any preceding clause, wherein the stator core outer surface is substantially coaxially aligned with the radially inner surface, and the bracket tab is received in one of the mounting recesses such that the comb portion of the bracket extends radially and is longitudinally offset from the tab.

[0068] Clause 4. The electric machine of any preceding clause, wherein the at least one busbar includes a first busbar and a second busbar, the first busbar having a first radius of curvature and the second busbar formed with a second radius of curvature different from the first radius of curvature of the first busbar.

[0069] Clause 5. The electric machine of any preceding clause, wherein the tab is dovetail-shaped and each of the plurality of mounting recesses is dovetail-shaped.

[0070] Clause 6. The electric machine of any preceding clause, wherein the stator core outer surface further defines a plurality of first openings, the electric machine further comprising an inner retaining ring defining a plurality of second openings, the inner retaining ring coupling to the outer surface such that the first openings are substantially aligned with the second openings.

[0071] Clause 7. The electric machine of any preceding clause, wherein the bracket includes a first bracket disposed in a first mounting recess of the plurality of mounting recesses, the first bracket defining a first outer opening on a first end face opposite the tab, and the electric machine further includes a second bracket disposed in a second mounting recess of the plurality of mounting recesses, the second bracket defining a second outer opening on a second end face opposite the second bracket, and an outer retaining ring defining a plurality of outer retention openings and extending in an arc between the first end face and the second end face.

[0072] Clause 8. A bracket connectable to a stator core of an electric machine, the bracket comprising: a plurality of teeth arranged in at least one row, with a recess defined between each pair of adjacent teeth, each said recess comprising: a comb portion sized to receive a portion of an electrical bus bar; a tab sized and shaped to be received in a mounting recess defined in the stator core; and an arm extending between the comb portion and the tab such that the comb portion is offset from the tab.

[0073] Clause 9. The bracket of clause 8, made from a non-conductive material.

[0074] Clause 10. The bracket of any preceding clause, wherein the at least one busbar includes a first busbar and a second busbar, the first busbar having a first radius of curvature, the plurality of teeth of the comb portion arranged in at least a first row and a second row substantially parallel to the first row, each recess in the second row sized to receive a portion of the second busbar, and the second busbar formed with a second radius of curvature different from the first radius of curvature of the first busbar.

[0075] Clause 11. The bracket of any preceding clause, comprising a gauge guide groove defined in an upper surface of the bracket and extending along the length of the comb portion.

[0076] Clause 12. The bracket of any preceding clause, further comprising at least one gauge turning groove defined in the upper surface of the bracket, the gauge turning groove extending along a width of the comb portion and at least partially intersecting the gauge guide groove.

[0077] Clause 13. The bracket of any preceding clause, wherein the tab is dovetail shaped.

[0078] Clause 14. The bracket of any preceding clause, wherein the bracket further defines at least one restraining aperture extending through the comb portion, each restraining aperture being sized and shaped to receive and thread a strap.

[0079] Clause 15. A method of assembling an electric machine including a rotor, a stator, a busbar, and a bracket, the method including: positioning tabs of the bracket in mounting recesses defined in an outer surface of a stator core of the stator, the bracket including a comb portion offset from the tabs, the comb portion having a plurality of teeth arranged in at least one row with a recess defined between each pair of adjacent teeth; inserting a portion of the busbar into one of the plurality of recesses; coupling a stator winding to a radially inner surface of the stator core; and coupling the busbar to leads extending from end turn portions of the stator winding.

[0080] Clause 16. The method of clause 15, wherein an outer surface of the stator core is oriented substantially perpendicular to a radially inner surface of the stator core, and wherein disposing the tab of the bracket in the mounting recess includes disposing the tab in the mounting recess such that a comb portion of the bracket is radially offset from the tab.

[0081] Clause 17. The method of any preceding clause, wherein an outer surface of the stator core is oriented substantially coaxially with a radially inner surface of the stator core, and wherein disposing the tab of the bracket in the mounting recess includes disposing the tab in the mounting recess such that a comb portion of the bracket is longitudinally offset from the tab.

[0082] Clause 18. The method of any preceding clause, wherein the busbars include a first busbar and a second busbar, the first busbar having a first radius of curvature, the plurality of teeth of the comb portion arranged in at least a first row and a second row substantially parallel to the first row, the method further including inserting a portion of the second busbar into the recesses of the second row of the comb portion, the second busbar being formed with a second radius of curvature different from the first radius of curvature of the first busbar.

[0083] Clause 19. The method of any preceding clause, wherein the stator core outer surface defines a plurality of first openings, the method further including: coupling an inner retaining ring defining a plurality of second openings to the outer surface such that the first openings and the second openings are aligned to receive and pass fasteners; and inserting a plurality of fasteners through the plurality of first and second openings to couple the inner retaining ring to the stator core outer surface.

[0084] Clause 20. The method of any preceding clause, wherein the bracket further comprises a gauge guide groove defined in a top surface of the bracket, the gauge guide groove extending along a length of the comb portion, the method further including inserting a portion of the sensor into the gauge guide groove. [Explanation of symbols]

[0085] 10 Electrical Machinery 16 central longitudinal axis 18 Stator core 20 central opening 22 shaft 24 rotor core 28 Stator base 30 stator teeth 31 (of stator tooth) first end 32 (of the stator tooth) second end 33 Bulkhead 34 (of bulkhead) first end 35 (of bulkhead) second end 36 (of stator core) radially inner surface 37 Wedge retaining groove 38 Raceway 39 Wedge 40 Stator conductor, stator winding 44 Rotor base 45 rotor teeth 46 magnetic segments 47 (Magnetic segment) end face 48 non-magnetic segments 49 (Non-magnetic segment) end face 50 radially inner rotor surface 52 Central opening 60 End winding section 64 leads, end wound 64a First Lead 64b Second Lead 64c Third Lead 64d 4th lead 65 Radial portion (of lead) 65a Radial section 65b Radial section 66 (Lead) Axial Section 66a Axial section 66b Axial section 66c Axial section 66d Axial section 70 Busbar 70a 1st busbar 70b Second busbar 70c 3rd busbar 72 Circumferential portion (of busbar) 74 (busbar) axial tab 75 (axial tab) first end 76 (Axial tab) second end 90 Wedge part 100 Bracket 100a First bracket 100b Second bracket 101 (of stator core) radially outer surface 102 First opening 103 (stator core) flange 104 mounting holes 105 (of stator core) outer surface 107 Recessed surface 108 Recessed side wall 109 Mounting recess 109a Mounting recess 109b Mounting recess 110 Top surface 111 Axial end 112 Stator 114 Rotor 116 Instrument guide groove 118 Instrument Turning Groove 120 Comb part 121 First row (of teeth) 121a upper row 121b Upper row 122 Second row (of teeth) 122a Lower Row 122b Lower row 124 teeth 125 depression 127 (of the comb part) first end 129 (of the comb part) second end 130 Bottom 134 (bracket) end face 134a first end face 134b second end face 136 (bracket) first outer opening 136a first outer opening 136b Second outer opening 140 tabs 142 (Tab) Inner Surface 144 (Tab) Outer Surface 145 (tab) top 146 (Tab) Side 160 Arm 161 (of arm) first end 162 (of arm) second end 164 (Arm) Top 166 (Arm) Underside 168 (Arm) Side 169 (Arm) Inner Surface 172 Restricted opening 180 Inner retaining ring 182 Second Opening 184 Fasteners 190 Outer retaining ring 192 Outer retention opening 194 Fasteners 200 bracket 212 Instrument guideway 216 Sensor lead wire, stator lead wire 220 Comb part 240 tabs 260 Arm 300 Electrical Machinery 310 Impingement cooling manifold plenum 320 free space 340 Housing 405 Exterior 409 Mounting recess C r Rotor circumference d1 (depth of the circumferential part of the busbar) d mr Depth (of mounting recess) d t (Tab) Depth G void L a (Arm) Length L a1 First axial length L a2 Second axial length L c (Comb part) length L r1 First Radial Length L r2 Second Radial Length r off Radial Offset W a (Arm) Width W i (indentation) width W t (tooth) width

Claims

1. A rotor, a stator magnetically coupled to the rotor, a stator core (18) having an outer surface (105) and defining a plurality of circumferentially spaced mounting recesses (109); a plurality of stator windings (40) coupled to the radially inner surface (36) of the stator core (18); Each stator winding (40) comprises: an end winding portion (60) extending outward from an axial end (111) of the stator core (18); at least one lead (64) extending from said end winding portion (60); a stator comprising: at least one bus bar (70) electrically coupled to at least two of said leads (64); Bracket (100) and Equipped with The bracket (100) a comb portion (120) comprising a plurality of teeth (124) arranged in at least one row (121), with a recess (125) defined between each pair of adjacent teeth (124), each recess (125) sized to receive a portion of the busbar (70); a tab (140) sized and shaped to be received in a respective one of said plurality of mounting recesses (109); an arm (160) extending between the comb portion (120) and the tab (140) so as to offset the comb portion (120) from the tab (140); An electric machine (300) comprising:

2. 2. The electric machine of claim 1, wherein the stator core outer surface extends substantially perpendicular to the radially inner surface, and the bracket tab is received in one of the mounting recesses defined in the stator core outer surface so as to radially offset the comb portion from the tab.

3. 2. The electric machine of claim 1, wherein the stator core outer surface is substantially coaxially aligned with the radially inner surface, and the bracket tab is received in one of the mounting recesses such that the comb portion is longitudinally offset from the tab.

4. 2. The electric machine of claim 1, wherein the at least one busbar includes a first busbar and a second busbar, the first busbar having a first radius of curvature and the second busbar formed with a second radius of curvature different from the first radius of curvature of the first busbar.

5. The electric machine (300) of claim 1, wherein the tab (140) is dovetail shaped and each of the plurality of mounting recesses (109) is dovetail shaped.

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

7. The bracket (100) includes a first bracket (100a) disposed in a first mounting recess (109) of the plurality of mounting recesses (109), the first bracket (100a) defining a first outer opening (136a) on a first end surface (134a) opposite the tab (140); The electric machine (300) a second bracket (100b) disposed in a second mounting recess (109) of the plurality of mounting recesses (109), the second bracket (100b) defining a second outer opening (136b) on a second end surface (134b) opposite the second bracket (100b); an outer retaining ring (190) defining a plurality of outer retaining openings (192) and extending in an arc between said first end face (134a) and said second end face (134b); The electric machine (300) of claim 1 further comprising:

8. A bracket (100) connectable to a stator core (18) of an electric machine (300), comprising: a comb portion (120) comprising a plurality of teeth (124) arranged in at least one row (121), with a recess (125) defined between each pair of adjacent teeth (124), each recess (125) sized to receive a portion of an electrical bus bar (70); a tab (140) sized and shaped to be received in a mounting recess (109) defined in said stator core (18); an arm (160) extending between the comb portion (120) and the tab (140) so as to offset the comb portion (120) from the tab (140); A bracket (100) comprising:

9. 9. The bracket (100) of claim 8, made from a non-conductive material.

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

11. 9. The bracket (100) of claim 8, further comprising a gauge guide groove (116) defined in a top surface (110) of the bracket (100) and extending along the length of the comb portion (120).

12. 12. The bracket (100) of claim 11, further comprising at least one gauge turning groove (118) defined in the upper surface (110) of the bracket (100), the gauge turning groove (118) extending along a width of the comb portion (120) and at least partially intersecting with the gauge guide groove (116).

13. The bracket (100) of claim 8, wherein the tab (140) is dovetail shaped.

14. 9. The bracket (100) of claim 8, wherein the bracket (100) further defines at least one restraining opening (172) extending through the comb portion (120), each restraining opening (172) being sized and shaped to receive and pass a strap therethrough.

15. A method of assembling an electric machine (300) including a rotor, a stator, a busbar (70), and a bracket (100), comprising the steps of: Positioning tabs (140) of the bracket (100) in mounting recesses (109) defined in an outer surface (105) of a stator core (18) of the stator, the bracket (100) including a comb portion (120) offset from the tabs (140), the comb portion (120) having a plurality of teeth (124) arranged in at least one row (121), with a recess (125) defined between each pair of adjacent teeth (124); inserting a portion of the busbar (70) into one of the plurality of recesses (125); coupling a stator winding (40) to the radially inner surface (36) of the stator core (18); coupling the busbars (70) to leads (64) extending from the end winding portions (60) of the stator winding (40); A method comprising:

16. 16. The method of claim 15, wherein the outer surface (105) of the stator core (18) is oriented substantially perpendicular to the radially inner surface (36) of the stator core (18), and wherein disposing the tab (140) of the bracket (100) in the mounting recess (109) includes disposing the tab (140) in the mounting recess (109) such that the comb portion (120) of the bracket (100) is radially offset from the tab (140).

17. 16. The method of claim 15, wherein the outer surface (105) of the stator core (18) is oriented substantially coaxially with the radially inner surface (36) of the stator core (18), and wherein disposing a tab (140) of the bracket (100) in a mounting recess (109) includes disposing the tab (140) in the mounting recess (109) such that the comb portion (120) of the bracket (100) is longitudinally offset from the tab (140).

18. 16. The method of claim 15, wherein the busbars (70) include a first busbar (70a) and a second busbar (70b), the first busbar (70a) having a first radius of curvature, the plurality of teeth (124) of the comb portion (120) being arranged in at least a first row (121) and a second row (122) substantially parallel to the first row (121), and the method further includes inserting a portion of the second busbar (70b) into a recess (125) of the second row (122) of the comb portion (120), the second busbar (70b) being formed with a second radius of curvature different from the first radius of curvature of the first busbar (70a).

19. A plurality of first openings (102) are defined in the stator core outer surface (105); The method comprises: coupling an inner retaining ring (180) defining a plurality of second openings (182) to the outer surface (105) such that the first openings (102) and the second openings (182) are aligned to receive and pass fasteners; inserting a plurality of fasteners through the plurality of first and second openings (102, 182) to couple the inner retaining ring (180) to the stator core outer surface (105); 16. The method of claim 15, further comprising:

20. 16. The method of claim 15, wherein the bracket further comprises a gauge guide groove defined in a top surface of the bracket, the gauge guide groove extending along a length of the comb portion, and the method further comprises inserting a portion of a sensor into the gauge guide groove.

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