Electrical machine and method of manufacture

Abstract

An electrical rotor machine and a method of manufacturing the same are disclosed. According to at least one aspect of the present disclosure, the method includes forming a stator core from two or more subcores and inserting the separate subcores into a housing before windings are wound through and around the subcores to form a stator. In such embodiments, the housing includes a locating feature structured to position and support the subcores such that a flow channel is formed between the subcores. The locating feature enables both radial and axial cooling of the stator core while reducing pressure losses within the cooling flow path.

1 . A method of manufacturing an electrical machine, the method comprising:
 fabricating two or more subcores, the subcores including a plurality of winding channels along an axial length of each subcore, the winding channels structured to receive stator windings;   fabricating a housing having a wall defining a volume, the housing structured to support the subcores within the volume, the housing further including an aperture through the wall and a locating feature structured to position the subcores;   inserting each subcore into the volume of the housing, wherein the subcores seat against opposing sides of the locating feature, whereby a flow channel is formed between the subcores, the flow channel aligned and in communication with at least one of the aperture of the housing; and   installing the stator windings in the winding channels of the subcores to form a stator within the housing, whereby the stator windings extend through the winding channels of adjacent subcores.   
     
     
         2 . The method of  claim 1 , the method further comprising inserting a rotor and shaft assembly into the housing within the stator. 
     
     
         3 . The method of  claim 1 , wherein the aperture and the flow channel form a cooling path through the stator, the cooling path configured to enable a coolant to flow between the subcores and over the stator windings, wherein the locating feature is positioned outside the cooling path. 
     
     
         4 . The method of  claim 3 , wherein the cooling path is substantially perpendicular to a longitudinal axis of the machine. 
     
     
         5 . The method of  claim 1 , wherein the subcores are shrink-fit to the housing. 
     
     
         6 . The method of  claim 1 , wherein the subcores are fastened to the housing by a mechanical fastener or an adhesive. 
     
     
         7 . The method of  claim 1 , wherein the stator comprises two subcores positioned by the locating feature therebetween. 
     
     
         8 . The method of  claim 1 , wherein the housing comprises a plurality of apertures circumferential spaced about the wall and comprises a plurality of locating features positioned between the apertures. 
     
     
         9 . The method of  claim 1 , wherein the locating feature is fabricated separately from the housing and attached thereto. 
     
     
         10 . A method of manufacturing an electrical rotor machine, the method comprising:
 fabricating a plurality of stator laminations, each lamination including a plurality of slots;   manufacturing at least two subcores by assembling a prescribed portion of the plurality of laminations to form each subcore, wherein the plurality of slots of the laminations are aligned to form a plurality of winding channels through each subcore along a longitudinal axis, the winding channels structured to receive stator windings;   fabricating a housing defining a cavity, the housing structured to support the subcores within the cavity and including a plurality of apertures formed therethrough to enable a flow of a coolant into the cavity, wherein the housing further includes a feature structured to locate the subcores within the cavity, wherein the feature is disposed within the cavity between the apertures;   inserting each subcore into the housing such that the subcores are separated by the feature of the housing to form a flow channel between each subcore, the flow channel in fluid communication with at least one of the apertures of the housing;   installing the stator windings in the winding channels of the subcores to form a stator within the housing, whereby the stator windings extend through the winding channels of adjacent subcores; and   inserting a rotor and shaft assembly into the housing within the stator.   
     
     
         11 . The method of  claim 10 , wherein the apertures and the flow channel form a cooling path through the stator, the cooling path configured to enable a coolant to flow between the subcores and over the stator windings, wherein the feature of the housing is positioned outside the cooling path. 
     
     
         12 - 16 . (canceled)