The disclosure relates generally to the field of electric motors and generators and, particularly, to the construction of stators for such motors and generators.
Electric motors of various types are commonly found in industrial, commercial, and consumer settings. In industry, such motors are employed to drive various kinds of machinery, such as pumps, conveyors, compressors, fans and so forth, to mention only a few. Turning to the drawings,
Within the frame 12, there are a stator 22 and rotor 24. Rotation of the rotor is effected by routing current through the stator. A rotor shaft 26 coupled to the rotor rotates in conjunction with the rotor. That is, rotation of the rotor translates into a corresponding rotation of the rotor shaft 26. As appreciated by those of ordinary skill in the art, the rotor shaft 26 may couple to any number of drive machine elements, thereby transmitting torque to the given drive machine element. By way of example, machines such as pumps, compressors, fans, conveyors, and so forth, may harness the rotational motion of the rotor shaft 26 for operation.
The stator 22 comprises a plurality of stator laminations 30 juxtaposed and aligned with respect to one another to form a lamination stack, such as a contiguous stator core 32. In the exemplary motor 10, the stator laminations 30 are substantially identical to one another, and each includes features that cooperate with adjacent laminations to form cumulative features for the contiguous stator core 32. For example, each stator lamination 30 includes a central aperture that cooperates with the central aperture of adjacent laminations to form a rotor chamber 34 that extends the length of the stator core 32 and that is sized to receive the rotor. Additionally, each stator lamination 30 includes a plurality of stator slots disposed circumferentially about the central aperture. These stator slots cooperate to receive two or more stator windings 36, which are illustrated as coil sides in
The rotor 24 resides within the rotor chamber 34. Similar to the stator core 32, the rotor 24 comprises a plurality of rotor laminations 42 aligned and adjacently placed with respect to one another. Thus, the rotor laminations 42 cooperate to form a contiguous rotor core 44. The exemplary rotor 24 also includes an end plate assembly 46, disposed on each end of the rotor core 44, that cooperates to secure the rotor laminations 42 with respect to one another. When assembled, the rotor laminations 42 cooperate to form a shaft chamber that extends through the center of the rotor core 44 and that is configured to receive the rotor shaft 26 therethrough. The rotor shaft 26 is secured with respect to the rotor core 44 such that the rotor core 44 and the rotor shaft 26 rotate as a single entity—the rotor 24.
To support the rotor, the exemplary motor 10 includes front and rear bearing sets 50, 52, respectively, that are secured to the rotor shaft 26 and that facilitate rotation of the rotor within the stationary stator core 32. During operation of the motor 10, the bearing sets 50, 52 facilitate transfer of the radial and thrust loads produced by the rotor to the motor housing. Each bearing set 50,52 includes an inner race 54 disposed circumferentially about the rotor shaft 26. The tight fit between the inner race 54 and the rotor shaft 26 causes the inner race 54 to rotate in conjunction with the rotor shaft 26. Each bearing set 50, 52 also includes an outer race 56 and ball bearings 58, which are disposed between the inner and outer races 54, 56. The ball bearings 58 facilitate rotation of the inner races 54 while the outer races 56 remain stationary and mounted with respect to the end caps 14,16. Thus, the bearing sets 50, 52 facilitate rotation of the rotor while supporting the rotor within the motor housing, i.e., the frame 12 and the end caps 14,16. To reduce the coefficient of friction between the races 54,56 and the ball bearings 58, the ball bearings may be coated with a lubricant.
To maintain the stator laminations in compression at the stator tooth tips, a retainer 100 is used. As will be explained below in greater detail, the retainer 100 may be fitted in the stator slots adjacent the windings to hold the stack of laminations of the contiguous stator core 32 in compression at the stator tooth tips. Thus, the retainer 100 together with the axial weld bead 41, or other outer diameter fixation means, provide improved structural integrity for the stator 22.
As best shown in
During installation, the second retainer portion 104 is received in the stator slot 90 adjacent the windings 36 and preferably toward or adjacent the distal end of adjacent stator teeth 92 with the second retainer portion face capturing surface 110 engaging the axial face 38 of the stator core. The second retainer portion 104 may abut the windings 36 extending through the stator slot 90. The first retainer portion 102 is received in the stator slot 90 adjacent the second retainer portion 104 preferably closer in distance toward the central aperture 34 than the second retainer portion and adjacent the distal end of adjacent stator teeth 92. The first retainer portion 102 may then be moved axially relative to the stator core centerline such that the first retainer portion face capturing surface 106 engages the opposite axial face 40 of the stator. As the first retainer portion 102 is moved into position, the serrations 116 of the second retainer portion engage the first retainer portion tab 114, locking the assembly with the first retainer portion face capturing surface 106 engaging one axial face 40 of the stator and the second retainer portion face capturing surface 110 engaging the opposite axial face 38 of the stator. By providing a plurality of rows serrations 116, the length of the retainer assembly may be adjusted as necessary to accommodate variations in manufacturing tolerances in the axial dimension of the contiguous stator core. The clip or retainer may also be formed monolithically at a dimension that enables the face capturing surfaces of the retainer to abut the axial opposite faces of the stator to hold the stator laminations in compression. The configuration may also be reversed among the first and second retainer portions.
In some constructions of electrical machine stators, such as that shown in
As best shown in
While specific embodiments have been described in detail in the foregoing detailed description and illustrated in the accompanying drawings, those with ordinary skill in the art will appreciate that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed were meant to be illustrative only and not limited as to the scope of the invention which is to be given the full breadth of the appended claims and any equivalents thereof.