Description:BACKGROUND
DOCUMENT REFERENCE
[0001] This application claims priority from the patent application no. 202241004995, which was filed in the Indian Patent Office (IPO) on January 29, 2022, as a patent of addition.
TECHNICAL FIELD
[0002] The present invention is generally related to the technical field of electrical machines, and, more specifically, with a stator assembly of the electrical machine in which an optimized stator core design and its manufacturing process are defined with the winding and mounting location of the optimized stator core and are integrated to achieve a standard structure of the stator assembly with a reduced amount of material usage.
DESCRIPTION OF THE RELATED ART
[0003] The stator is an essential part of electrical machines such as electric motors, generators, etc. Energy will flow from or to the rotational part of the component through a stator. The stator also performs many functions in an electrical machine, including establishing a part of the magnetic circuit, supporting the windings for magnetic flux linkage, facilitating electrical connections, and so on.Most commonly, the stator is divided into two types based on its relative position to the rotor: known as outer rotor and inner rotor type. The stator associated withthe outer rotor type is emphasized in this embodiment.
[0004] The stator is usually comprised of three major components: the core, insulation,and winding. Stacked laminationsare used to make the stator core, which is stamped from a lengthysheet of lamination material. The primary purpose of this core is to guide the magnetic flux to minimize the eddy current and hysteresis that causes magnetic losses in the core.In addition, the stator core assembly consists of lamination with limb, an insulation material (e.g. plastic) to provide insulation and hold the winding, holes with the desired orientation to facilitate mounting, electrical connection, and so on.
[0005] Conventionally, the stator core is specifically designed for manufacturing in order to obtain the stator assembly by stamping the stator core material on the circumferential structure or stamping each part of the stator core and assembling them to form the stator of the electrical machine.Moreover, the conventional method of stamping the stator core consumes a higher percentage of raw material scrap in order to achieve a standardized stator core structure.
[0006] For instance, FIGS. 1A and 1B illustrate an isometric view and an exploded view of a conventional stator assembly 100 of an electrical machine according to an embodiment inthe prior art. The conventional stator assembly 100 is comprised of a stator core 102, an OD (Outer Diameter) with a winding location of the stator core 104, an ID (Inner Diameter) with a mounting location of the stator core 106, a plurality limbs 108A-N circumferentially distributed, mounting holes 110, core terminals 112 for connection, and bobbin moulds 114 A-B for winding support provided over the core limbs 108A-N. The stator core 102 is made of a stamped plurality of laminated steels (or laminations) with designed specifications of the stator core's OD 104 and ID 106 together on a radial or circumferential structure with mounting holes 110, core terminals 112, and assembly holes for facilitating proper orientation and assembling purposes. While stamping the plurality of laminated steels, the stamping machine stamps the laminated steel at the specification (i.e., OD 104 and ID 106) of the stator core, so the stamping machine stamps the desired parts of the laminated steel in the circular geometry illustrated in Figs 1A and 1B and the remaining parts are scrapped. The stamped plurality of laminated steels is then stacked together on the stator core using assembly holes, with the mounting holes 110 and core terminals 112 of the stator core correctly and consistently aligned. After stacking the plurality of laminated steels, the stator core 102 is formed with the limb 108 (or poles) to support the winding for the stator 100. The bobbin moulds 114A and 114B are inserted and fixed over the top and bottom of the stator core 102 for insulation and winding support. Furthermore, this stator core is provided with winding and then assembled intothe designed standard structure in accordance with the designated requirements to achieve the stator assembly for the electrical machine.
[0007] This conventional method of stamping the stator core consumes a high percentage of raw material scrap.Hence, there is a need for design and different approaches to manufacturing stator cores are necessary to reduce material waste, provide a provision of a cost-effective mounting method, and enhance stator core electrical efficiency.
SUMMARY
[0008] In view of the aforementioned, an embodiment herein provides a stator for an electric machine. The stator includes a stator core, assembly holes and mounting holes.Thestator core includes a winding part,a mounting part, and one or more bent laminations. The winding part includes one or more developed sections of limbs. The mounting part mounts over the winding part. .The one or more bent laminations covers the winding part and the mounting part. The one or more bent laminations includes one or more limb up bent laminations and one or more limb down bent laminations, that are placed over a top and a bottom of the winding part and the mounting part, thereby forming the stator core.The assembly holes assembles and supports the stator core, and the mounting holes supports mounting of the stator core with the electrical machine.
[0009] In some embodiments, the one or more bent laminations can be built by bending the lamination sheets. In some embodiments, the one or more bent laminations can be can be built by placing small lamination sheets perpendicular or parallel to the one or more laminations sheets. The small lamination sheets may be placed on the one or more laminations sheets using any of welding or through adhesive pastes. In some embodiments, the small laminations sheets placed on the one or more laminations sheets can act as the one or more bent laminations.
[0010] Individual parts in the stator core are obtained by blanking one or more lamination sheets and folding the developed sections of lamination into a circle geometry by joining their ends with a snap-lock or welding, which forms the winding part.In some embodiments, the stator core is built with one or more developed sections of laminations that are obtained by blanking one or more laminations sheets. In some embodiments, the winding part with the one or more developed sections of limbs in a circular geometric disposition includes an outer diameter and an inner diameter. The winding part is formed by wrapping one or more developed sections of laminations on the circular geometry and joining ends of the one or more developed sections of laminations with any of the snap-lock or welding. The developed sections of limb that are formed supports the winding part of the stator.
[0011] In some embodiments, the one or more developed sections of limbs includes an optimised design to avoid limb width reduction due to strip layout constraints during blanking the laminations for the winding part.
[0012] In some embodiments, the one or more developed sections of laminations are stacked individually after being blanked. The mountingpart facilitatesa fitting of the electrical machine appropriately, which may be incorporated with the winding part.The mounting part includes an outer diameter and an inner diameter, which is incorporated with the winding part using an orientation profile.
[0013] In some embodiments, the one or more bent laminations with the one or more limb up bent laminations and the one or more limb down bent laminations is built using one or more developed sections of bent laminations. The one or more limb up bent laminations and the one or more limb down bent laminations are riveted or welded through the assembly holes.
[0014] In some embodiments, the one or more limb up bent laminations and the one or more limb down bent laminations in the one or more bent laminations maximizes an output power of the stator, thereby minimizing cogging torque in the electrical machine and laminations usage in the winding part.
[0015] In some embodiments, the assemblyholes in the stacked laminated core supports and assembles the stator core, and distributes along the periphery of the stator.In some embodiments, the mouting holes supports mounting guidance of the electrical machine. The one or more end laminationsare placed over the top and bottom of the incorporated winding part and mounting part of the stator core and riveted or welded through the assembly holes.
[0016] In some embodiments, the stator includes a bobbin that is placed over the stator core to provide insulation and support for the winding part of the stator. The mounting holes supports mounting guidance in the electrical machine. The one or more bent laminations supports the winding part of the stator core. Abobbin mould insert may be placed over the stator core, which provides the stator assembly for the electrical machine in accordance with requirements.
[0017] In some embodiments, the one or more developed sections of laminations for the winding part of the stator core is obtained by blanking straight from the one or more lamination sheets.
[0018] The present invention provides an approach for separating processes and reducing waste of lamination material used to form the stator core, as well as adapting the core-forming process to any required winding and mounting location by forming the appropriate developed section of the laminations to form the stator core at the required winding and mounting location. This enables the stator assembly to have an efficient design in terms of reduction of waste and the use of common parts to achieve different mounting orientations.
[0019] With reference to the following description, these and other aspects of the current subject matter will be better understood. This summary is provided to introduce a selection of concepts in a simplified form, in accordance with one embodiment of the present subject matter. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the claimed subject matter's scope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The embodiments herein will be better understood from the following detailed
description with reference to the drawings, in which the illustrations FIG-1 to FIG-6 are part of the original patent application to which this patent of addition is made and these figures are labelled “(Part of Original patent application 202241004995)".
[0021] FIGS. 1A and 1B illustrate an isometric view and an exploded view of a typical stator assembly of an electrical machine according to an embodiment ofthe prior art;
[0022] FIGS. 2A and 2B illustrate an isometric view and an exploded view of a stator assembly of an electrical machine according to someembodimentsherein;
[0023] FIG. 3 is an exemplaryprocess flow diagram that illustrates assemblingthe stator assembly of the electrical machine of FIGS. 2A and 2B according to someembodimentsherein;
[0024] FIGS. 4A-4C illustrate an exemplary isometric view, an exploded view and a cross-sectional view of the stator assembly of the electrical machine in FIGS. 2A and 2B according to some embodiments herein;
[0025] FIGS. 5A and 5B are a flow diagram that illustrates a method for assembling the stator of the electrical machine of FIGS. 2A and 2B according to some embodiments herein;
[0026] FIGS. 6A and 6B is a flow diagram that illustrates a method for assembling the stator of the electrical machine of FIGS. 4A-C according to some embodimentsherein;
[0027] FIGS. 7A-7C illustrate an exemplary isometric view, an exploded view and a cross-sectional view of a stator assembly for an electrical machine with reduced waste of laminations according to some embodiments herein; and
[0028] FIGS. 8A-8Bare flow diagrams that illustrates a method for assemblingthe stator of FIGS. 7A-7C for the electrical machine according to someembodiments herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] The embodiments described herein, and their various features and advantageous details, are explained in considerable detail with reference to the non-limiting embodiments illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted to avoid obscuring the embodiments described herein. The examples provided herein are provided solely to facilitate an understanding of how the embodiments described herein may be practiced and to further enable those skilled in the art to practice the embodiments described herein. As a consequence, the examples should not be interpreted as limiting the scope of the embodiments described herein.
[0030] As mentioned, this description meetsthe need for design and alternative methods of manufacturing stator cores in order to minimize material use, increase stator core electrical efficiency,and achieve a different orientation of mounting cost-effectively. Referring now to the drawings, and more particularly to FIGS. 2 through 9, where similar reference characters consistently represent corresponding aspects throughout the figures, preferred embodiments are illustrated.
[0031] FIGS. 2A and 2B illustrate an isometric view and an exploded view of a stator assembly 200 of an electrical machine according to someembodimentsherein. The stator assembly 200 consists of a winding part 204, a mounting part 212, a plurality of developed sections of end laminations 220A-N, and a bobbin insert 228.The stator core 202 of the stator assembly 200 is built with a plurality of developed sections of laminations 210A-N that are obtained by blanking a plurality of lamination sheets. The isometric view and the exploded view of a stator assembly 200 include a stator core 202, a winding part 204 of the stator core 202, an outer diameter 206, and an inner diameter (ID) 208 of the winding part 204 of the stator core 202, a plurality of developed sections of laminations 210A-N for the winding part 204.
[0032] The winding part 204 that comprises an outer diameter (OD) 206, and inner diameter 208 is formed by wrapping a plurality of developed sections of laminations 210A-N for the winding part204 on a circular geometry and then joining their ends with a snap-lock 310 or weldingand the limbs 226 are formed by this wrapping around that are used to support the stator windings of the stator 200.
[0033] The mounting part 212 is used to facilitate the fitting of the electrical machine, wherein the mounting part 212 comprises an outer diameter (OD) 214, and inner diameter 216, whereinthe mounting part 212 is incorporated with the winding part 204 using an orientation profile [not shown in FIGS. 2A & 2B]. The orientation profile is used to aid in the proper fitment of the winding part and the mounting part i.e. the poka-yoke. The mounting part 212 may be built using a plurality of developed sections of laminations 218A-N. The complete assembly comprising of the mounting parts, namely the part 212 and the stator core 202, a pair of developed sections of end laminations 220A-N with assembly holes 222 and mounting holes 224 are used from either side as illustrated. In effect the one or more developed sections of end laminations 220A-N are placed over the top and bottom of the incorporated winding part 204 and mounting part 212 of the stator core 202 and then riveted or welded through assembly holes 222. Thethe stator core 202 has limbs 226 of the stator core 202, a bobbin mould insert 228 of the stator 200. This stator core needs to be formed. A plurality of developed sections of laminations for the winding part 204, the mounting part 212 with an outer diameter (OD) and inner diameter (ID) separately, and the plurality of developed sections of end laminations 210A-N of the stator core 202 are obtained by blanking a plurality of lamination sheets. The winding part 204 is formed by wrapping a plurality of developed sections of laminations 210A-N for the winding part 204 on a circular geometry and then joining their ends with a snap-lock or welding. The plurality of developed sections of laminations 210A-N for the winding part 204 of the stator core 202 is obtained by blanking straight from the plurality of lamination sheets and in accordance with the developed sections of the OD 206 and the ID 208 needed.
[0034] The plurality of developed sections of laminations 218A-N for the mounting part 212 of the stator core 202 in FIG-2Ais obtained byblanking radially or circumferentially from the plurality of lamination sheets and following the developed sections of the OD 214 and the ID 216 required. The plurality of developed sections of end laminations 220A-Nare placed over the top and bottom of the incorporated winding part 204 and mounting part 212 of the stator core 202 and then riveted through the assembly holes 222. The plurality of the developed sections of end laminations 220A-N are obtained byblanking radially or circumferentially from the plurality of lamination sheets. The plurality of developed sections of laminations is stacked individually after being blanked. The mounting part212 can be blanked and stacked with a magnetic or non-magnetic material (e.g. laminated steel, aluminium, etc.). The outer diameter 206 in the winding part 204 and the inner diameter 216 in the mounting part 212 are referred to as the OD and ID of the stator core 202 respectively, as illustrated in FIG. 2A. The assembly holes 222 are used to support and assemble the stator core 202are distributed along the periphery of the stator 202. The mounting holes 224 are used to support mounting guidance in the electrical machine. The limbs 226which are part of the developed sections are used to support the stator windings of the stator 200. The bobbin mould insert228 is placed over the stator core 202 to provide insulation and support for the stator winding.
[0035] FIG. 3 is an exemplaryprocess flow diagram that illustrates assemblingthe stator assembly of the electrical machine of FIGS. 2A and 2B according to someembodimentsherein. A process step 302 depicts the blanking and stacking of the plurality of developed sections of laminations 210A-N for the winding part 204 of the stator core 202. A process step 304 depicts the winding part 204 being formed by wrapping a plurality of developed sections of laminations 210A-N for the winding part 204 in a circular geometry and then joining their ends with a snap-lock 310or welding. A process step 306 depicts the mounting part 212(explained earlier in para [0020] with respect to Fig-2A and 2B) being incorporated inside the winding part 204 formed in step 304 using an orientation profile. In the next step, the plurality of developed sections of end laminations 220A-N are placed over the top and bottom and then riveted through the assembly holes 222. A process step 308 depicts the bobbin mould insert 228 is inserted over the stator core 202 to provide insulation and support for the stator winding. This manufacturing method of the developed sections of the lamination 210 A-N ensures that the wastage of punching out laminations in the circular geometry as illustrated in FIGs 1A and 1B is overcome.
[0036] FIGS. 4A-C illustrate an exemplary isometric view,an exploded view and a cross-sectional view of the stator assembly of the electrical machine in FIGS. 2A and 2B according to someembodimentsherein. . The exemplary isometric view and the exploded view of the stator 400 include the stator core 402, thewinding part404 of the stator core 402, the outer diameter (OD) 406, and the inner diameter (ID) 408 of the winding part 404, a plurality of developed sections of laminations 410A-N for the winding part 404, the plurality of developed sections of end laminations 412A-N of the stator core 402, a mounting location 414 with an inner diameter 416 of the stator core,a supporting bush or insert 418 of the stator core 402, the assembly holes 420 of the stator core 402, the mounting holes 422 of the stator core 402, the limbs 424 of the stator core 402, and a bobbin mould insert 426 of the stator 400.This stator core needs to be formed. A plurality of developed sections of laminations for the winding part404 with an outer diameter (OD) and inner diameter (ID), and the plurality of developed sections of end laminations 412A-N of the stator core 202 are obtained by blanking a plurality of lamination sheets. The winding part404 is formed by wrapping a plurality of developed sections of laminations 410A-N for the winding part 404 on a circular geometry and then joining their ends with a snap-lockor welding. The plurality of developed sections of laminations 410A-N for the winding part 404 of the stator core 402 is obtained by blanking straight from the plurality of lamination sheets and in accordance with the developed sections of the OD 406 and the ID 408 needed.The plurality of developed sections of end laminations 412A-Nare placed over the top and bottom of the winding part 404 of the stator core 402. The plurality ofdeveloped sections of laminations is stacked individually after being blanked.
[0037] The mounting location 414 with an inner diameter (ID) 416 of the stator core 402 that is formed by providing a supporting bush or insert 418 with reference to the mounting holes 422 in between the plurality of developed sections of end laminations 412A-N of the stator core 402 that is parallel to the winding part 404 and perpendicular to the plurality of developed sections of end laminations 412A-N ( as illustrated in FIGS. 4B and 4C), and then riveted or welded through the assembly holes 420. The supporting bush or insert 418 is used to provide mechanical strength to the mounting location 414 of the stator 402. The supporting bush or insert 418 can be made of a magnetic or non-magnetic material (e.g. laminated steel, aluminium, etc.). The outer diameter 406 in the winding part 404 and the inner diameter 416 in the mounting location 414 are referred to as the OD and ID of the stator core 402, as illustrated in FIG. 4A. The assembly holes 420 are used to support and assemble the stator core 402. The mounting holes 422 are used to support mounting guidance in the electrical machine. The limbs 424 which are part of the developed sections are used to support the stator windings of the stator 400. The bobbin mould insert 426 is placed over the stator core 202 to provide insulation and support for the stator winding.
[0038] FIGS. 5A and 5B are a flow diagram that illustrates a method for assemblingthe stator of the electrical machine of FIGS. 2A and 2B according to some embodiments herein. At step 502, the plurality of developed sections of laminations for the winding part 204 and a mounting part 212 with an outer diameter (OD) and an inner diameter (ID) separately, and the plurality of developed sections of end laminations 220A-N of the stator core 202 are obtained by blanking the plurality of lamination sheets. The plurality of developed sections of laminations 210A-N for the winding part 204 of the stator core 202 is blanked straight from the plurality of lamination sheets, and the plurality of developed sections of laminations 218A-N for the mounting part 212 and the plurality of developed sections of end laminations 220A-N of the stator core 202 are blanked radially or circumferentially from the plurality of lamination sheets. At step 504, the plurality of developed sections of laminations for the winding part 204, the mounting part 212, and the plurality of developed sections of end laminations 220A-N of the stator core 202 are individually stacked. At step 506, the winding part204 of the stator core 202 is obtained in a circular geometry form by wrapping a plurality of developed sections of laminations 210A-N for the winding part204 and joining their endswith a snap-lock 310 or welding. At step 508, the stacked winding part 204 and mounting part 212 of the stator core 202 are assembled with an aid of an orientation profile.
[0039] At step 510, the plurality of developed sections of end laminations 220A-N is placed over the top and bottom of the winding part 204 and mounting part 212 of the stator core 202 that is assembled. At step 512, the stator core 202 is obtained on a defined formation by incorporating the winding part 204, the mounting part 212, and the plurality of developed sections of end laminations 220A-N with a riveting or welding through assembly holes 222. At step 514, the bobbin mould insert 228 is inserted over the stator core 202 to provide insulation and support for the stator winding. Then, the stator core 202 is further processed to obtain the stator assembly 200 for the electrical machine in accordance with the requirements.
[0040] FIGS. 6A and 6B is a flow diagram that illustrates a method for assembling the stator of the electrical machine of FIGS. 4A-C according to someembodiments of the present subject matter. At step 602, the plurality of developed sections of laminations for the winding part 404 with an outer diameter (OD) 406 and an inner diameter (ID) 408, and the plurality of developed sections of end laminations 412A-N of the stator core 402 are obtained by blanking the plurality of lamination sheets. The plurality of developed sections of laminations 410A-N for the winding part 404 of the stator core 402 is blanked straight from the plurality of lamination sheets and the plurality of developed sections of end laminations 412A-N of the stator core 402 are blanked radially or circumferentially from the plurality of lamination sheets. At step 604, the plurality of developed sections of laminations for the winding part404, and the plurality of developed sections of end laminations 412A-N of the stator core 402 are individually stacked. At step 606, the winding part 404 of the stator core 402 is obtained in a circular geometry form by wrapping a plurality of developed sections of laminations 410A-N for the winding part404 and joining their endswith a snap-lock 310 or welding.
[0041] At step 608, the plurality of developed sections of end laminations 410A-N is placed over the top and bottom of the winding part404 of the stator core 402. At step 610, a mounting location 414is obtained with an inner diameter (ID) 416 of the stator core by inserting a supporting bush or insert 418with reference to the mounting holes in between the plurality of developed sections of end laminations 412A-N of the stator core 402that is parallel to the winding part 404 and perpendicular to the plurality of developed sections of end laminations 412A-N. At step 612, the winding part 404,the plurality of developed sections of end laminations 412A-N, and the supporting bush or insert418 with a riveting or welding through the assembly holes 420. After that, the bobbin mould insert426 is inserted over the stator core 402 to provide insulation and support for the stator winding. Then, the stator core 402 is further processed to obtain the stator assembly 400 for the electrical machine in accordance with the requirements.
[0042] FIGS. 7A-C illustrates an exemplary isometric view, an exploded view, and a cross-sectional view of a stator assembly 700 for an electrical machine with reduced waste of laminations according to some embodiments herein. The stator assembly 700 includes a stator core 702, assembly holes 723, and mouting holes 724. The stator core 702 includes a winding part 704with one or more developed sections of limbs 711A-N, a mounting part 712 that mounts over the winding part 704, and one or more bent laminations 720A-Nthat covers the winding part 704 and the mounting part 712. The one or more bent laminations include one or more limb up bent laminations 721 and one or more limb down bent laminations 722, that are placed over a top and a bottom of the winding part 704 and the moutingpart 712.In some embodiments, the one or more bent laminations are formed by bending the lamination sheets. In some embodiments, the one or more bent laminations can be constructed by placing small lamination sheets perpendicular or parallel to the one or more developed sections of limbs 711 A-N. The small lamination sheets could be placed on one or more lamination sheets using welding or adhesive pastes. In some embodiments, the small laminations sheets placed on the one or more laminations sheets can function as the one or more bent laminations.
[0043] The stator core 702 of the stator assembly 700 is built with one or more developed sections of laminations 710A-N that are obtained by blanking one or more lamination sheets and folding the developed sections of lamination into a circular geometry by joining their ends with a snap-lock or welding, which forms the winding part 704. The isometric view and the exploded view of a stator assembly 700 includes an outer diameter 706, and an inner diameter (ID) 708 of the winding part 704 of the stator core 702, one or more developed sections of laminations 710A-Nfor the winding part 704with one or more developed sections of limbs 711 A-N.
[0044] The winding part 704 includesan outer diameter (OD) 706, and inner diameter 708,that is formed by wrapping the one or more developed sections of laminations 710A-N on the circular geometry and joining their ends with snap-lockor welding and the one or more developed sections of limbs 711A-N are formed by wrapping that are used to support the stator windings of the stator 700.When blanking the laminations for the winding part 704 with the limb for the stator assembly in a conventional approach, the limb width is reduced due to strip layout constraints. The design of the one or more developed sections of limbs 711 A-N is being optimized in order to avoid this.
[0045] Themounting part 712 facilitates fitting of the electrical machine.The mounting part 712 includes an outer diameter (OD) 714, and inner diameter 716. The mounting part 712 may be incorporated with the winding part 704 using an orientation profile[not shown in FIGS. 7A-C]. In some embodiments, the orientation profile aids in a proper fitment of the winding part 704 and the mounting part 712 i.e. the poka-yoke, which aids in defining the orientation match between the winding part 704 and the mounting part 712. The mounting part 712 may be built usingone or more developed sections of laminations 718A-N.The stator 700 consists of the mounting parts 712 of the stator core 702, namely part 712, along with the assembly holes 723, the mounting holes 724, and a vent or weight-reduction hole 728, as shown in FIG. 7A.
[0046] In some embodimens,the one or more developed sections of bent laminations 720A-N with the one or more limb up bent laminations 721 and the one or more limb down bent laminations 722 are placed over the top and bottom of the incorporated the winding part 704 and the mounting part 712 of the stator core 702.The one or more developed sections of bent laminations 720A-N may be riveted or welded through the assembly holes 722 to support the stator core 702. The one or more limb up bent laminations 721 and the one or more limb down bent laminations 722 in the one or more bent laminations 720A-N intendsto maximize the output power of the stator assembly 700, thereby minimizing cogging torque in the electrical machine and lamination usage in the winding part 704, i.e., the one or more limb up bent laminations 721 intendsto attain the stator thickness requirement, and the one or more limb down bent laminations 722 intendsto reduce cogging torque caused by the electrical machine. Usage of the one or more limb up bent laminations 721, and the one or more limb down bent laminations 722 in the stator core 702 increases the flux coverage area of the stator 700, resulting in a greater change in flux, thereby enhancingthe output power of the stator assembly.
[0047] One or more developed sections of laminations for the winding part 704with theone or more developed sections of limbs 711 A-N, the mounting part 712with the outer diameter (OD) and the inner diameter (ID) separately, and the one or more developed sections of bent laminations 710A-N with the one or more limb up bent laminations 721 and the one or more limb down bent laminations 722 bents of the stator core 702 may be obtained by blanking one or more lamination sheets. The one or more developed sections of laminations 710A-N for the winding part 704 of the stator core 702 may be obtained by blanking straight from the one or more lamination sheets and in accordance with the developed sections of the OD 706 and the ID 708 needed(as illustrated in FIG. 3).
[0048] In some embodiments, the one or more developed sections of laminations 718A-N for the mounting part 712 of the stator core 702 in FIG-7Acan be obtained by blanking radially or circumferentially from the one or more lamination sheets and following the developed sections of the OD 714 and the ID 716 required. In some embodiments, the one or more developed sections of bent laminations 720A-N can be obtained by blanking radially or circumferentially from the one or more lamination sheets. The one or more developed sections of laminations may bestacked individually after being blanked. The mounting part712 may be blanked and stacked with a magnetic or non-magnetic material (e.g. laminated steel, aluminium, etc.).In some embodiments, the outer diameter 706 in the winding part 704 and the inner diameter 716 in the mounting part 712 are referred to as the OD and ID of the stator core 702 respectively, as illustrated in FIG. 7A.
[0049] The assembly holes 723supports and assembles the stator core 702, anddistributesalong the periphery of the stator 702. The mounting holes 724 supports mounting guidance in the electrical machine. Theone or more developed sections of limbs 711 A-Nwhich are part of the developed sections supports the stator windings of the stator 700.
[0050] In some embodiments, the statot 700 includes a vent or a weight-reduction hole 728 that makes the stator 700 lighter in weight, increase ruggedness and durability. The vent or the weight-reduction hole 728 may act as a vent hole while the electrical machine is running(as illustrated in FIGS. 7B and 7C). In some embodiments, a bobbin 726 can be placed over the stator core 702 to provide insulation and support for the stator winding.
[0051] FIGS. 8A-8B are flow diagrams that illustrate a method for assembling the stator 700 of FIGS. 7A-7C for the electrical machine according to some embodiments herein. At a step 802, theone or more developed sections of laminations for the winding part 704 with the one or more developed sections of limbs 711A-N.the mounting part 712, and the one or more bent laminations 720A-N with the one or more limb up bent laminations 721 and the one or more limb down bent laminations 722 are obtained by blanking the plurality of lamination sheets. At a step 804, the one or more developed sections of laminations for the winding part 704, the mounting part 712, and the one or more bent laminations 720A-N of the stator core702 are stackedindividually. At a step 806, the winding part 704 with the one or more developed sections of limbs 711 A-N of the stator core 702 is obtained in the circular geometry form by wrapping the one or more developed sections of laminations 710A-N for the winding part 704 and joining their ends with the snap-lock or welding. At a step 808, the stacked winding part 704 and the mounting part 712 of the stator core 702 are assembled with an aid of the orientation profile.
[0052] At a step 810, the one or more bent laminations 720A-N are placed over the top and bottom of the winding part 704 and the mounting part 712 of the stator core 702. At a step 812, the stator core 702 is obtained on a defined formation by incorporating the winding part 704, the mounting part 712, and the one or more bent laminations 720A-N with riveting or welding through the assembly holes 723. At a step 814, the bobbin 726 is inserted over the stator core 702 to provide insulation and support for the stator windings, and the the stator core 702 obtains the stator assembly 700 for the electrical machine in accordance with the requirements.
[0053] The aforementioned description of the specific embodiments will sufficiently reveal the various aspects of the embodiments herein that others can readily modify and/or adapt such specific embodiments for various applications using current knowledge, and thus such adaptations and modifications should and are intended to be understood within the meaning and range of equivalents of the disclosed embodiments. It should be understood that the phraseology or terminology used herein is intended to describe rather than limit. While the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments can be modified within the spirit and scope of the appended claims. , Claims:I/We claim:
1. A stator (700) for an electric machine comprising:
characterized in that,
a stator core (702) that comprises:
a winding part (704) with a plurality of developed sections of limbs (711A-N);
a mounting part (712) that mounts over the winding part (704); and
a plurality of bent laminations (720A-N) that covers the winding part (704) and the mounting part (712), wherein the plurality of bent laminations (720A-N) comprises a plurality of limb up bent laminations (721) and a plurality of limb down bentlaminations (722), that are placed over a top and a bottom of the winding part (704) and the mounting part (712);
assembly holes (723) that assembles and supports the stator core (702); and
mounting holes (724) that supports mounting of the stator core (702) with the electric machine.

2. The stator (700) as claimed in claim 1, wherein the stator core (702) is built with a plurality of developed sections of laminations that are obtained by blanking a plurality of lamination sheets.

3. The stator (700) as claimed in claim 1,
wherein the winding part (704) with the plurality of developed sections of limbs (711A-N) in a circulargeometric disposition comprises an outer diameter (OD) (706), and an inner diameter (708),
wherein the winding part (704) is formed by wrapping a plurality of developed sections of laminations (710A-N) on a circular geometry and joining ends of the plurality of developed sections of laminations (710A-N) with any of a snap-lock or welding, wherein the developed sections of limb (726) that are formed supports the winding part (704) of the stator (700).

4. The stator (700) as claimed in claim 1, wherein the plurality of developed sections of limbs (711A-N) comprises an optimised design to avoid limb width reduction due to strip layout constraints during blanking the laminations for the winding part (704).

5. The stator (700) as claimed in claim 1,
wherein the mounting part (712) facilitatesa fitting of the electrical machine,wherein the mounting part (712) comprises an outer diameter (OD) (714), and an inner diameter (716),wherein the mounting part (712) is incorporated with the winding part (704) using an orientation profile.

6. The stator (700) as claimed in claim 1,
wherein the plurality of bent laminations (720A-N) with the plurality of limb up bent laminations (721) and the plurality of limb down bent laminations (722) is built using a plurality of developed sections of bent laminations, wherein the plurality of limb up bent laminations (721) and the plurality of limb down bent laminations (722) are riveted or welded through assembly holes (723).

7. The stator (700) as claimed in claim 6, wherein the the plurality of limb up bent laminations (721) and the plurality of limb down bent laminations (722) in the plurality of bent laminations (720A-N) maximizesan output power of the stator (700), thereby minimizing cogging torque in the electrical machine and laminations usage in the winding part (704).

8. The stator (700) as claimed in claim 1,
wherein the assembly holes (723) supports and assembles the stator core (702) and distributes along the periphery of the stator (702),
wherein the mounting holes (724) supports mounting guidance of the electrical machine.

9. Thestator (700) as claimed in claim 1, wherein the stator (700) comprises a bobbin (726) that is placed over the stator core (702) to provide insulation and support for the stator windings.

10. The stator (700) as claimed in claim 1, whereinthe plurality of developed sections of laminations (710A-N) for the winding part (704) of the stator core (702) is obtained by blanking straight from the plurality of lamination sheets.

11. The stator (700) as claimed in claim 1, wherein the plurality of developed sections of laminations (718A-N) for the mounting part (712) and the plurality of developed sections of bent laminations (720A-N) of the stator core (702) are obtained by blanking radially or circumferentially from the plurality of lamination sheets.

12. A method for assembling a stator (700) for an electric machine, the method comprises:
obtaining, a plurality of developed sections of laminations for a winding part (704) with a plurality of developed sections of limbs (726 A-N) and a mounting part (712) with an outer diameter (OD) and an inner diameter (ID) separately, and a plurality of bent laminations (720A-N) with a limb up (721) and limb down (722) bents by blanking a plurality of lamination sheets;
stacking, the plurality of developed sections of laminations for the winding part (704), the mounting part (712),and the plurality of bent laminations (720A-N) of the stator core (702) individually;
obtaining, the winding part (704) with the plurality of developed sections of limbs (711 A-N) of the stator core (702) in a circular geometry form by wrapping a plurality of developed sections of laminations (710A-N) for the winding part(704) and joining their endswith a snap-lock or welding;
assembling, the stacked winding part (704) and mounting part (712) of the stator core (702) with an aid of an orientation profile;
placing, the plurality of bent laminations (720A-N) over the top and bottom of the assembled winding part (704) and mounting part (712) of the stator core (702);
obtaining, the stator core (702) on a defined formation by incorporating the winding part (704), the mounting part (712), and the plurality of bent laminations (720A-N) with a riveting or welding through assembly holes (723);
inserting, a bobbin (726) over the stator core (702) to provide insulation and support for the stator windings, wherein the stator core (702) is further processed to obtain the stator assembly (700) for the electrical machine in accordance with the requirements.