Granted Patent B2

US 11,177,711 · App. 16/045,134 · Granted Nov 16, 2021

Inventors: Sunming Shiao (Cerritos, CA); Kour Thay Chau (Rancho Palos Verdes, CA)

Assignee: GARRETT TRANSPORTATION I INC

H02K3/28H02K3/12H02K15/00H02K15/02H02K15/024H02K21/24

Abstract

Claims (55)

1. A method of manufacturing a stator assembly for an electrified rotary system comprising:

attaching a first tooth and a second tooth to an inner support including extending the first tooth and the second tooth radially away from the inner support and including defining an outer diameter opening between the first tooth and the second tooth, the first tooth and the second tooth respectively including an outer radial end, a side, and a tapered flange at a transition between the outer radial end and the side, the side including a notch that defines a step;

attaching a winding about the first tooth including moving a conductive member radially into the outer diameter opening to attach the conductive member to the first tooth;

attaching an outer support to the first tooth and the second tooth including receiving, respectively, the outer radial end, the tapered flange, and the step of the first tooth and the second tooth in the outer support, and including closing off the outer diameter opening with the outer support; and

removing the inner support from the first tooth and the second tooth after attaching the outer support.

2. The method of claim 1 , wherein attaching the first tooth and the second tooth to the inner support includes inserting a first inner radial end of the first tooth into a first aperture of the inner support and inserting a second inner radial end of the second tooth into a second aperture of the inner support.

3. The method of claim 2 , wherein the inner support is arcuate and substantially centered about an axis;

wherein the first aperture is a first slot that extends substantially parallel to the axis;

wherein the second aperture is a second slot that extends substantially parallel to the axis;

wherein attaching the first tooth and the second tooth to the inner support includes advancing the first tooth within the first slot along the axis and advancing the second tooth within the second slot along the axis.

4. The method of claim 3 , wherein the tapered flange is a first flange, and the transition is a first transition;

wherein the first tooth includes a first inner flange at a second transition between the inner radial end and the side; and

wherein attaching the first tooth includes inserting the first inner flange within an undercut channel of the inner support.

5. The method of claim 4 , wherein the undercut channel is a first undercut channel;

wherein the first tooth includes a second inner flange that extends in a direction opposite the first inner flange; and

wherein attaching the first tooth includes inserting the first inner flange within a first undercut channel of the inner support and inserting the second inner flange within a second undercut channel of the inner support.

6. The method of claim 1 , wherein the outer radial end of the first tooth is a first outer radial end, and wherein the outer radial end of the second tooth is a second outer radial end;

wherein attaching the outer support to the first tooth and the second tooth includes inserting the first outer radial end of the first tooth into a first aperture of the outer support and inserting the second outer radial end of the second tooth into a second aperture of the outer support.

7. The method of claim 6 , wherein the outer support is arcuate and substantially centered about an axis;

wherein the first aperture is a first slot that extends substantially parallel to the axis;

wherein the second aperture is a second slot that extends substantially parallel to the axis;

wherein attaching the first tooth and the second tooth to the outer support includes advancing the first tooth within the first slot along the axis and advancing the second tooth within the second slot along the axis.

8. The method of claim 7 , wherein the tapered flange is a first flange; and

wherein attaching the outer support includes inserting the first flange within an undercut channel of the outer support.

9. The method of claim 8 , wherein the undercut channel is a first undercut channel of the outer support;

wherein the first tooth includes a second flange that extends in a direction opposite the first flange; and

wherein attaching the first tooth to the outer support includes inserting the first flange within the first undercut channel and inserting the second flange within a second undercut channel of the outer support.

10. The method of claim 1 , wherein the first tooth, the second tooth, and the outer support are made of the same material; and

further comprising integrally attaching the outer support to the first tooth and the second tooth.

11. The method of claim 10 , wherein integrally attaching the outer support to the first tooth and the second tooth includes at least one of welding and brazing the outer support to the first tooth and the second tooth.

12. The method of manufacturing of claim 1 , wherein the side is a first side of the first tooth, the transition is a first transition of the first tooth, and the tapered flange is a first tapered flange at the first transition;

wherein the first tooth includes a second side and a second tapered flange at a second transition between the second side and the outer radial end of the first tooth; and

wherein the first tapered flange projects outward from the first side, and the second tapered flange projects outward from the second side.

13. A manufacturing system for manufacture of a stator assembly for an electrified rotary system, the manufacturing system comprising:

at least one attachment system;

a winding system; and

an inner support;

the at least one attachment system configured to attach a first tooth and a second tooth to the inner support to form a first construction, the first tooth and the second tooth extending radially away from the inner support, an outer diameter opening defined between the first tooth and the second tooth, the first tooth and the second tooth respectively including an outer radial end, a side, and a tapered flange at a transition between the outer radial end and the side, the side including a notch that defines a step;

the winding system configured to attach a winding about the first tooth of the first construction via the outer diameter opening to form a second construction;

the at least one attachment system configured to attach an outer support to the second construction, including receiving, respectively, the outer radial end, the tapered flange, and the step of the first tooth and the second tooth in the outer support to thereby close off the outer diameter opening with the outer support and thereby form a third construction; and

the attachment system configured to remove the inner support from the third construction to thereby form the stator assembly.

14. The manufacturing system of claim 13 , wherein the inner support is annular; and

wherein the outer support is annular.

15. The manufacturing system of claim 13 , wherein the at least one attachment system is configured to insert an inner radial end of the first tooth into a first aperture of the inner support; and

wherein the at least one attachment system is configured to insert an outer radial end of the first tooth into a second aperture of the outer support.

16. The manufacturing system of claim 15 , wherein the tapered flange is a first tapered flange, wherein the inner radial end of the first tooth includes a first inner flange; and

wherein the at least one attachment system is configured to insert the first inner flange within a first undercut channel of the inner support; and

wherein the at least one attachment system is configured to insert the first tapered flange within a second undercut channel of the outer support.

17. The manufacturing system of claim 13 , wherein the at least one attachment system includes a press.

18. The manufacturing system of claim 17 , further comprising a conveyor system configured to convey at least two of the first tooth, the second tooth, the inner support, and the outer support relative to the press.

19. The manufacturing system of claim 13 , wherein the first tooth, the second tooth, and the outer support are made of the same material; and

wherein the at least one attachment system is configured to integrally attach the outer support to the first tooth and the second tooth.

20. The manufacturing system of claim 13 , wherein the side is a first side of the first tooth, the transition is a first transition of the first tooth, and the tapered flange is a first tapered flange at the first transition;

wherein the first tooth includes a second side and a second tapered flange at a second transition between the second side and the outer radial end of the first tooth; and

wherein the first tapered flange projects outward from the first side, and the second tapered flange projects outward from the second side.

Assignments (7)