Patent Application
20170250588
The present disclosure relates to a connection support assembly for securing electrical jumper wires of a stator assembly of an electric machine.
The electric machine can convert electrical energy into mechanical energy, or vice-versa. For instance, an electric machine can covert an alternating current into mechanical energy.
The present disclosure describes a connection support assembly for a stator assembly of an electric machine. The connection support assembly can be used to secure electrical jumper wires of an electric machine. By securing at least some electrical jumper wires, the connection support assembly minimizes the stress in the weld joints of the electric machine. In one embodiment, the connection support assembly includes a support body and a catch protruding from the support body. The catch defines an opening. The connection support assembly further includes a clip coupled to the support body. The clip includes a clip body and a pin protruding from the clip body. The pin extends through the opening of the catch in order to couple the clip to the support body and clamp at least some electrical jumper wires between the support body and the clip. The present disclosure also relates to a stator assembly including the connection support assembly. The stator assembly includes a stator core defining slots spaced apart from each other, bar conductors disposed in each of the slots, and electrical jumper wires electrically connected to at least some of the bar conductors. The connection support assembly can secure at least one of the electrical jumper wires in order to minimize stress in the weld joints of the electric machine.
The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes for carrying out the teachings when taken in connection with the accompanying drawings.
Referring to the drawings, wherein like reference numbers correspond to like or similar components throughout the several figures, and beginning with
The vehicle can include an inverter for converting the direct current (DC) voltage from the battery array into alternating current (AC) voltage. The electric machine 10 can be configured to use the AC voltage from the inverter to generate rotational motion. The electric machine 10 can also be configured to generate electrical energy when provided with mechanical energy, such as the mechanical energy (torque) of an engine.
Referring to
The electric machine 10 also includes a rotor 16 rotatably supported by the housing 14. The rotor 16 can rotate relative to the stator assembly 12 about a longitudinal axis 18. The rotor 16 can include, for example, windings or permanent magnets that interact with the poles of the stator assembly 12 to generate rotation of the rotor 16 relative to the stator assembly 12. The rotor 16 can be an interior permanent magnet, a surface permanent magnet, an induction, synchronous, reluctance or a separately-excited/wound-field rotor. The rotor 16 is shown schematically in
Referring to
The stator core 20 extends between a first core end 32 and a second core end 34 along the longitudinal axis 18. The slots 22 are spaced from each other radially about the longitudinal axis 18 and each extends between the first and second core ends 32, 34 of the stator core 20. Therefore, the slots 22 can extend lengthwise along the longitudinal axis 18. In certain embodiments, there are exactly seventy-two slots 22 defined in the stator core 20, and the stator core 20 defines eight poles.
The stator core 20 can include an inner stator wall 36 defining a stator hole 38 along the longitudinal axis 18 such that the inner stator wall 36 is spaced radially away from the longitudinal axis 18. The rotor 16 is disposed in the stator hole 38 of the stator core 20 and is rotatable relative to the inner stator wall 36 of the stator core 20 when current is traveling through the stator core 20. Furthermore, the slots 22 can intersect the inner stator wall 36. The stator core 20 can also include an outer stator wall 40 opposing the inner stator wall 36. Therefore, the inner stator wall 36 and the outer wall 40 are spaced from each other transverse to the longitudinal axis 18. As such, the inner stator wall 36 defines an inner diameter, and the outer stator wall 40 defines an outer diameter greater than the inner diameter. The stator assembly 12 also includes a plurality of electrical jumper wires 60 electrically connected to a predetermined number of the bar conductors 24 in order to control the amount of current flowing through winding paths.
The stator assembly 12 can further include a plurality of stator connectors 62, with one or more of the terminals 64 being electrically connected to the stator connectors 62 to direct or transfer current into the stator core 20. The terminals 64 are configured to be electrically connected to the power source (e.g., a battery pack). Electrical leads 66 electrically connect the terminals 64 to the stator connectors 62. The stator connectors 62 are electrically connected to at least some of the bar conductors 24. For example, a weld joint J (
With reference to
The connection support assembly 100 includes lead couplers 104 for attaching the electrical leads 66 to the support body 102. The lead couplers 104 protrude from the support body 102 in a direction away from the stator core 20. Each lead coupler 104 includes a coupler body 106 and a pair of substantially parallel columns 108 protruding from the coupler body 106. At least one electrical lead 66 is disposed on the coupler body 106 and between the pair of substantially parallel columns 108.
With reference to
A fastener 116 directly interconnects the clip 114 to the support body 102. As a non-limiting example, a rivet 118 directly couples support body 102 to the clip 114. The clip 114 is wholly or partly made of a substantially rigid polymeric material and includes a clip body 120 directly coupled to the support body 102 through the fastener 116. The clip body 120 defines a clip hole 122 configured, shaped, and sized to receive the fastener 116. Accordingly, the fastener 116 is directly coupled to the clip body 120. An insert 129 is disposed inside the clip hole 122 and surrounds the fastener 116 in order relief stress in the fastener 116. Accordingly, the insert 129 can be configured as a collar and may be wholly or partly made of a metallic material. In the depicted embodiment, the insert 129 has an insert hole 131 configured, shaped, and sized to at least partially receive the fastener 116. The support body 102 defines a body hole 126 aligned with the clip hole 124. As such, the fastener 116 can extend through the body hole 126 and the clip hole 124.
The clip 114 further includes a pin 128 protruding from the clip body 120. The pin 128 extends through the opening 125 of the catch 117. Therefore, at least some of the electrical jumper wires 60 are clamped between the support body 102 and the pin 128. Specifically, some of the electrical jumper wires 60 are clamped between the pin 128 and the second surface 112 of the support body 102. A spring steel piece 130 may be partly or entirely disposed inside the pin 128 in order to enhance the structural integrity of the pin 128. For instance, the pin 128 may be molded over the spring steel piece 130.
With reference to
While the best modes for carrying out the teachings have been described in detail, those familiar with the art to which this disclosure relates will recognize various alternative designs and embodiments for practicing the teachings within the scope of the appended claims.
