Modular motor construction

Details Modular motor construction Modular motor construction

1999-02-11

2001-09-11

Ramirez, Nestor (Department: 2834)

Electrical generator or motor structure

Dynamoelectric

Rotary

Reexamination Certificate

active

06288470

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates generally to electric motors, and particularly to a modular stator assembly that facilitates motor construction.
BACKGROUND OF THE INVENTION
Currently, electric motors, particularly elongate motors such as those used in electrical submergible pumping systems for pumping petroleum, are constructed with unitary stators. Traditionally, individual stator laminations have been stacked together to the full length of the desired stator, and conductive wires have been wound through corresponding openings formed longitudinally through the stator laminations.
Depending on the horsepower required of the motor, electric submergible pumping system motors can utilize stator assemblies thirty feet long or more. Preparation of the stator windings requires long, thin polished rods that serve as needles for pulling the insulated, conductor wires through the lengthy assembly of stator laminations during winding of the motor. This conventional process is a comparatively slow and expensive process for manufacturing such motors. Additionally, repair or rebuilding of such motors often requires complete destruction or tear down of the motor with little component repair value due to the unitary stator assembly.
It would be advantageous to have a modular stator that could be used to construct motors, such as motors utilized in electric submergible pumping systems. Benefits of such a modular construction would include reduced cost and assembly time, reduced repair time and reduced motor component inventory.
SUMMARY OF THE INVENTION
The present invention features a modular stator for use in an electric motor. The stator comprises a plurality of stator sections and a plurality of connectors. The connectors are disposed between sequential stator sections, and the stator sections are selectively coupleable with the plurality of connectors to form stators in a variety of desired lengths.
According to another aspect of the invention, an electric motor is provided that utilizes a modular stator assembly. The electric motor includes an outer housing having a generally hollow interior. A stator is sized to fit within the hollow interior and is formed from a plurality of stator sections. The stator includes at least a first stator section and a second stator section. The first stator section includes a plurality of first stator section conductors extending therethrough. Similarly, the second stator section includes a plurality of second stator section conductors extending therethrough. A connector region is disposed between the first and second stator sections and permits the first and second stator section conductors to be selectively electrically coupled together.
According to another aspect of the invention, a method is provided for facilitating the assembly of an electric motor. The method includes assembling individual stator laminations into a plurality of modular stator sections. Each stator section has a plurality of electrical conductors that may selectively be coupled to each other. The method further includes determining a desired motor length for a given application, and electrically coupling an appropriate number of the modular stator sections to construct the desired motor.


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