Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
2000-06-28
2001-08-21
Mullins, Burton S. (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S089000, C310S254100, C310S06800R, C310S045000, C029S596000
Reexamination Certificate
active
06278206
ABSTRACT:
TECHNICAL FIELD
The present invention relates generally to rotating electrical machines and, more particularly, to a stator connection for a rotating electrical machine.
BACKGROUND
Electrical machines such as motors, generators, and alternators commonly have a stator. The stator is positioned inside a housing. Potting material is used to affix the winding end turns to the housing. Also in such configurations, the winding ends, that are electrically coupled to a rectifier bridge, are soldered to the rectifier bridge. One disadvantage of this configuration is that the stator cannot be removed from the housing once the stator is potted therein. Therefore, repair or remanufacturing a faulty alternator is impossible or cost prohibitive. Also, because the winding ends are soldered to the rectifier bridge, they also cannot be easily removed. Another disadvantage is that the process used to form the alternator assembly is complex, and labor intensive.
It would therefore be desirable to simplify the assembly process of the alternator as well as provide an alternator that is disassemblable for servicing.
SUMMARY OF THE INVENTION
It is therefore one object of the invention to provide a stator assembly that is detachable both electrically and physically from the alternator.
In one aspect of the invention, a stator assembly comprises a plurality of stator windings having a first set of end turns and a second set of end turns. The stator windings also have winding ends. A first end cap is disposed on the first set of end turns so that the plurality of winding ends extend therefrom. The second end cap is disposed on the second set of end turns. A thermally conductive material is disposed between the first end cap and the first set of end turns and the second end cap and the second set of end turns. A stud assembly having a plurality of studs and stud housing is coupled to the first end cap. A plurality of bushings disposed on a respective one of said plurality of studs is coupled to a respective one of the winding ends.
In a further aspect of the invention, a method of forming an electrical machine comprises the steps of:
placing a first end cap and a second end cap on end turns of a stator;
encapsulating the end turns of the stator with a thermally conductive material within the first end cap and the second end cap;
forming a stud assembly having a plurality of studs;
coupling the stud assembly to the first end cap;
placing a plurality of bushings on a respective one of said plurality of studs;
coupling a winding wire to a respective one of the bushings to form a stator assembly.
One advantage of the invention is that the stator is easily decouplable from the stator housing. Another advantage of the invention is that the end cap assembly is highly thermally conductive and therefore provides an efficient means for removing heat from the stator assembly.
Other objects and features of the present invention will become apparent when viewed in light of the detailed description of the preferred embodiment when taken in conjunction with the attached drawings and appended claims.
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Fougner Jayeson
Harris Richard
Yockey Steve
Kajander John R.
Mullins Burton S.
Visteon Global Technologies Inc.
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