Exemplary embodiments pertain to the art of electric machines and, more particularly, to a component for an electric machine.
Many electric machines include a stator and a rotor that are shifted relative to one another to create an electromotive force. In many cases, a fan is mounted relative to the rotor. In operation, the rotor spins the fan which, in turn, provides a cooling airflow to the electric machine. At present, the particular mounting of the fan to the rotor creates limitations on electric machine size. More specifically, mounting the fan to the rotor requires certain mounting structures on both components. As electric machines become smaller, pulleys and other components are mounted closer to the rotor. The particular structure required for mounting the fan limits the distance that the pulley, or other such components, can be mounted relative to the rotor.
Disclosed is an electric machine component including a rotor assembly having at least one claw pole member including a number of pole members, an outer fan member support surface, and a central hub projecting from the outer fan member support surface. The central hub includes at least one anti-rotation member and a substantially planar bearing surface.
Also disclosed is an electric machine including a housing, a stator fixedly mounted relative to the housing, and a rotor assembly rotatably mounted relative to the stator. The rotor assembly includes at least one claw pole member having a number of pole members, an outer fan member support surface, and a central hub projecting from the outer fan member support surface. The central hub includes at least one anti-rotation member and a substantially planar bearing surface. A fan member is mounted to the rotor assembly. The fan member includes a hub portion and a number of fan blades that project radially outwardly from the hub portion. The fan member is configured and disposed to be staked to the at least one claw pole member through the central hub.
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
With reference to
In accordance with an exemplary embodiment, rotor 10 includes a central hub 28 having a substantially planar bearing surface 38 that may abut first bearing 23. Central hub 28 includes a curvilinear portion 44 and a substantially linear portion 46 that forms a locating and anti-rotation member 48. Anti-rotation member 48 is shown as being substantially linear, however it should be understood that other geometries including protrusions, divots and the like may also be employed. A fan member 60 is mounted to claw pole member 15 at outer fan member support surface 19, as will be discussed more fully below. Fan member 60 includes a hub portion 64 and a plurality of fan blades 68. Fan blades 68 project radially outwardly from hub portion 64. Hub portion 64 includes an opening 72 having a curvilinear section 74 and a substantially linear section 78 that defines an anti-rotation element 79. While shown and described as being substantially linear, anti-rotation element 79 may take on any one of a number of geometries that cooperate with anti-rotation member 48. Opening 72 is configured to receive central hub 28 of claw pole member 15.
In further accordance with the exemplary embodiment, fan member 60 is positioned at outer fan member support surface 19 with central hub 28 projecting through opening 72 beyond, hub portion 64. At this point it should be understood that fan member 60 may directly abut outer fan member support surface 19 or a gap may exist between hub portion 64 and outer fan member support surface 19. Substantially linear portion 46 and substantially linear section 78 cooperate to establish a desired alignment of fan member 60 and claw pole member 15. Substantially linear portion 46 and substantially linear section 78 also cooperate to constrain rotation of fan member 60 relative to first claw pole member 15. Once in position, the central hub 28 is staked or deformed to create a mechanical bond between central hub 28 and hub portion 64. Bearing surface 38 may be exposed to a deformation force that extends continuously along curvilinear portion 44 or, alternatively, to a number of discrete deformation forces about curvilinear portion 44. The number of discrete deformation forces may be applied in unison or in a predetermined sequence.
Reference will now follow to
In further accordance with the exemplary embodiment shown, discrete step members 98 include a first step member 102, a second step member 104, a third step member 106 and a fourth step member 108. First, second, and third step members 102, 104, and 106 are arrayed about curvilinear portion 90 and fourth step member 108 is arranged on substantially linear portion 94. First step member 102 defines a first fan member mounting surface 111, second step member 104 defines a second fan member mounting surface 112, third step member 106 defines a third fan member mounting surface 113, and fourth step member 108 defines a fourth fan member mounting surface 114. In addition, first, second, third, and fourth step members 102, 104, 106, and 108 define a substantially planar bearing surface 118 that may abut first bearing 23.
In a manner similar to that discussed above, fan member 60 is positioned at outer fan member support surface 19 with central hub 87 projecting through opening 72 and each step member 102, 104, 106 and 108 terminating at, or projecting beyond, hub portion 64. At this point it should be understood that fan member 60 may directly abut outer fan member support surface 19 or a gap may exist between hub portion 64 and outer fan member support surface 19. Substantially linear portion 94 and substantially linear section 78 cooperate to establish a desired alignment of fan member 60 and first claw pole member 15. Substantially linear portion 94 and substantially linear section 78 also cooperate to constrain rotation of fan member 60 relative to first claw pole member 15. Once in position, each fan member mounting surface 111-114 is, staked or deformed, to create a mechanical bond between central hub 87 and hub portion 64.
At this point it should be apparent that by forming the fan member mounting surface(s) into the central hub, tooling and manufacturing steps may be simplified and production and component costs can be reduced. Reducing component costs by as little as a few cents per unit can result in a significant cost savings over time. Further, by forming the fan member mounting surface(s) at the central hub, the number and size of connection points can be reduced. Reducing the number and size of connection points enables the rotor assembly to be formed having a shorter axial dimension. The shorter axial dimension enables electric machine to be formed having a more compact form factor.
While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims.
This application is a Continuation-In-Part of U.S. application Ser. No. 14/021,797 filed Sep. 9, 2013, the disclosure of which is incorporated by reference herein in its entirety.
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Number | Date | Country | |
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Number | Date | Country | |
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Parent | 14021797 | Sep 2013 | US |
Child | 14197947 | US |