US008154167B2

(12) United States Patent (10) Patent N0.2 US 8,154,167 B2

Tang (45) Date of Patent: *Apr. 10, 2012

(54) INDUCTION MOTOR LAMINATION DESIGN 6,034,460 A 3/2000 Tajima et al.

6,133,663 A 10/2000 Hoemann
. - 6,144,132 A 11/2000 Nashiki
(75) Inventor. Ylfan Tang, Los Altos, CA (US) 6,170,974 B1 V2001 Hyypio
. 6,218,760 B1 4/2001 Sak ' t l.
(73) Asslgneer Tesla Motors, Inc P2110 A110, CA (Us) 6,359,361 B1 * 3/2002 wakujflg 21,3 ,,,,,,,,,,,,,,,, ,, 310/179
6,465,923 B2 * 10/2002 Amrhein .................... .. 310/90.5
(*) Notice: Subject to any disclaimer, the term of this 6,570,290 B2 5/2003 KaZmiercZak
patent is extended or adjusted under 35 llzujinga
, , uJm a
U80 1546) by 0 days 6,768,411 B2 7/2004 Luttrell
This patent is Subject to a terminal dis- 6,806,614 B2* 10/2004 Kuroyanagiet al. ....... .. 310/215
Claimer 7,098,567 B2 8/2006 Ionel et al.
' 7,116,029 B2 10/2006 Kerlin
7,141,905 B2 11/2006 Vollmer
(21) APP1- NO-I 13/074,841 7,247,967 B2 7/2007 Ionel et al.
7,252,118 B2 8/2007 Reid
(22) Filed: Mar. 29, 2011 7,466,055 B2 12/2008 Toide et a1.
7,741,750 B1 6/2010 Tang
- - - 8,008,827 B1* 8/2011 Tang et al. .................. .. 310/184
(65) Pmr Pubhcatlon Data 2005/0134137 Al* 6/2005 Sweo ........ .. 310/211
Us 2011/0198962 A1 Aug 183 2011 2011/0198963 Al* 8/2011 Tang etal. .................. .. 310/208

Related US. Application Data OTHER PUBLICATIONS

(63) continuationdmpart of application NO 12/707 699 W. Ouyang et al., Analysis of Optimal Stator Concentric Winding
?led on Feb 18 2010 HOW Pat NO 8 069 555 s 3 Patterns Design, Proceedings ofthe Eighth International Conference
' a a i i a a i on Electrical Machines and Systems, Sep. 27-29, 2005, vol. 1, pp.

(51) Int. C]. 94-98

H02K1/00 (2006.01) * Cited by examiner
H02K 2/28 (2006.01)
(52) U..S. Cl. ...... 310/216.069; 310/184; 310/216.074 Primary Examiner i Tran Nguyen
(58) Field of Classi?cation Search ................ .. 310/166, (74) Attorney) Agent] OrFirm i Patent Law Of?ee OfDaVid
310/211, 216.069, 216.074, 180, 184, 198, 6 Beck
3100064208
See application ?le for complete search history. (57) ABSTRACT
(56) References Cited A high e?iciency, high torque density, high speed induction
motor is provided, the motor utilizing (i) stator teeth With
U.S. PATENT DOCUMENTS parallel side surfaces; (ii) rotor teeth With parallel side sur
4,644,210 A * 2/1987 Meisner et al. ............. .. 310/211
faces; (iii) Wide open stator slots; (iv) closed rotor slots With
5,182,483 A * 1/1993 Hibino et al. ............... .. 310/211 thick tooth bridges; and (v) deep stator and rotor slots.
5,753,991 A 5/1998 Couture et al.
5,793,139 A 8/1998 Nashiki 18 Claims, 18 Drawing Sheets
US. Patent Apr. 10, 2012 Sheet 1 0118 US 8,154,167 B2

101

/ 1/l/ \\\\a
103 00,111
FIG. 1
US. Patent Apr. 10, 2012 Sheet 2 0f18 US 8,154,167 B2

100

k~~105
203
N2": ............. _._ ____ _.

107/ "\
101

>

FIG. 2
US. Patent Apr. 10, 2012 Sheet 3 0f 18 US 8,154,167 B2

103

//

119

117

FIG. 3
US. Patent Apr. 10, 2012 Sheet 4 0f18 US 8,154,167 B2

103

409

FIG. 4
US. Patent Apr. 10, 2012 Sheet 5 0f 18 US 8,154,167 B2

101

FIG. 5
US. Patent Apr. 10, 2012 Sheet 6 0f 18 US 8,154,167 B2

101

In

601

FIG. 6
US. Patent Apr. 10, 2012 Sheet 7 0f 18 US 8,154,167 B2

S1
1 Layer S'ot
123456789101112131415161718192021222324252627282930
Upper A1 A1 B4 B4 A1 A1 A2 A2 ()1 c1 A2 A2
Lower A1 A1 A1 B4 B4 B4 A1 A1 A1 A2 A2 A2 C1 c1 C1 A2 A2 A2

Slot
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Upper C1 C1 C2 C2 B3 B3 C2 C2 B3 B3 B4 B4
Lower 01 c1 C1 C2 C2 C2 B3 B3 B3 C2 c2 c2 B3 B3 B3 B4 B4 B4

2nd Layer (in bold & italics) Slot

12 3 4 5 6 7 8 9101112131415161718192021222324252627282930

Upper A1 A1 03 c3 c3 c4 c4 C4 B4 B4 B1 B1 B1 A1 A1 A2 A2 c4 c4 c4 C1 C1 B1 B1 B1 B2 B2 B2 A2 A2
Lower A1 A1 A103 03 C4 c4 B4 B4 B4 B1 B1 A1 A1 A1 A2 A2 A2 c4 c4 C1 C1 C1 B1 B1 B2 B2 A2 A2 A2

Slot
31 32 33 34 35 36 37 38 39 4O 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

FIG. 7
US. Patent Apr. 10, 2012 Sheet 8 0f 18 US 8,154,167 B2

Phase A Phase B Phase C

Coil G0 Ret Span Turns Coil Go Ret Span Turns Coil Go Ret Span Turns

5% 0%
A
2431
- 8%
B4
1 43
123456789WHQ 12309865 436785 1420 12 123456789WHQ 2098 2543678 1_420 12 123456789WHQ 25413098 %Mn?543678 1420 21
a

FIG. 8
0%
6%
0%
_-
US. Patent Apr. 10, 2012 Sheet 9 0f 18 US 8,154,167 B2
US. Patent Apr. 10, 2012 Sheet 10 0f18 US 8,154,167 B2

A1 A3 B1 B3 C1 C3

A4 B2 B4 C2

FIG. 10
US. Patent Apr. 10, 2012 Sheet 11 0118 US 8,154,167 B2

FIG. 11
US. Patent Apr. 10, 2012 Sheet 12 0f18 US 8,154,167 B2

FIG. 12
US. Patent Apr. 10, 2012 Sheet 13 0f18 US 8,154,167 B2

FIG. 13
US. Patent Apr. 10, 2012 Sheet 14 0118 US 8,154,167 B2

v56s%5z:a

FIG. 14A

@1403

5X2m.E2:3 11. 5
21
4

29 40 88 129 140 '1 80 20C 220 280 30G

FIG. 14B
US. Patent Apr. 10, 2012 Sheet 15 0118 US 8,154,167 B2

(DvTeFnsliatu)yx

FIG. 15A

(_U 1. 1 1 . 1 1 . 1 1 . 1 I 1 1 11 11 1 1 l

<0 1 1
G) .
v
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C
a) 15 3
Q-ss /
><
2 1
LL

i
.21

a 2*: 4P a, we .w 4b 146 ha 125 "m 221.1 2% 2m, 2:14 06 ":0

Theta

FIG. 15B
US. Patent Apr. 10, 2012 Sheet 17 0f 18 US 8,154,167 B2

1801

1 803

-HI.Z O.I
Q
Q.
O
0
.U1Izr,Ek_,.

1
.1
120 CL ion 2:31] am 240

Exii3w68x3m:6zb095E FIG. 18
Theta

ul381.U&:2H754)EJ0Z
1 _O
BY.
l
54
6
1a.37,
2 I

N.
16G ZOO 240
Theta

FIG. 19
US. Patent Apr. 10, 2012 Sheet 18 0118 US 8,154,167 B2

aw. F20IG.
1%

(elsei) msuecl Xn|=|

 US 8,154,167 B2
1 2
INDUCTION MOTOR LAMINATION DESIGN utiliZation, Wide constant poWer range at high speeds, high
speed torque capability, high maximum speed, While also
CROSS-REFERENCES TO RELATED requiring that the resultant motors achieve high reliability,
APPLICATIONS small siZe, loW Weight, mass manufacturability and loW cost.
Accordingly, What is needed is a loW cost and easily manu
This application is a continuation-in-part of Us. patent factured electric motor Which achieves the very demanding
application Ser. No. 12/707,699, ?led Feb. 18, 2010, the performance requirements of electric and hybrid vehicles.
disclosure of Which is incorporated herein by reference for The present invention provides such a motor design.
any and all purposes.
SUMMARY OF THE INVENTION
FIELD OF THE INVENTION
The present invention provides an induction motor that
The present invention relates generally to electric motors includes a stator and a rotor. The stator is comprised of a stator
and, more particularly, to a lamination design that achieves yoke having a stator yoke thickness and a plurality of stator
improved ?ux distribution for improved ef?ciency, torque teeth extending radially inWard toWard the stator center axis,
density and high speed poWer. Where the stator teeth have a common tooth length and Where
the tooth side surfaces for each stator tooth are parallel to one
BACKGROUND OF THE INVENTION another. The rotor, mounted Within the stator bore, is com
prised of a rotor yoke having a rotor yoke thickness; a plural
The trend toWards designing and building fuel e?icient, 20 ity of rotor teeth With a common rotor tooth length extending
loW or Zero emission on-road and off-road vehicles has radially aWay from the rotor center axis, Where the tooth side
increased dramatically in recent years, With signi?cant surfaces for each rotor tooth are parallel to one another; and a
emphasis being placed on the development of hybrid and plurality of rotor slots interposed betWeen the rotor teeth,
all-electric vehicles. This has led, in turn, to a greater empha Where the top region of each rotor slot that is proximate to the
sis being placed on electric motors, either as the sole source of 25 stator is closed by a rotor tooth bridge. The ratio of the stator
propulsion (e.g., all-electric vehicles) or as a secondary diameter to the stator length is preferably at least 1511. The
source of propulsion in a combined propulsion system (e.g., stator tooth side surfaces may further comprise an extended
hybrid or dual electric motor vehicles). The electric motor in lip portion proximate to the stator bore, Where the extended
such an application may utiliZe either an AC or DC permanent lip portions extend partially across the corresponding stator
magnet motor design or an AC induction motor design. 30 slot. The stator yoke thickness may be betWeen 30% and 70%
Regardless of the type of electric motor, it must be designed larger than the common stator tooth length. The rotor yoke
to achieve the desired e?iciency, torque density and high thickness may be betWeen 30% and 70% larger than said
speed torque With an acceptable motor siZe and Weight. common rotor tooth length. The sum of the stator yoke thick
In a multi-phase AC induction motor, a rotating magnetic ness and the stator tooth length may be approximately equal
?eld is generated by a plurality of circumferentially distrib 35 to the sum of the rotor yoke thickness and the common rotor
uted multi-phase coil Windings secured Within a plurality of tooth length. The length of the stator teeth may be betWeen 4
circumferentially distributed slots in the inner periphery of and 6 times the Width of the stator teeth. The length of the
the motors stator, the coil Windings being coupled to a multi rotor teeth may be betWeen 4 and 6 times the Width of the rotor
phase AC poWer source controlled With certain desired fre teeth. Preferably the total number of rotor teeth is at least 15%
quencies and certain desired levels of voltage or current in 40 higher than the total number of stator teeth. The ratio of the
each phase. The magnetic ?eld generated Within the stator common stator tooth Width to the common rotor tooth Width
core induces multiple-phase alternating currents in the rotor may be betWeen 1:1 and 1.211. The air gap distance betWeen
Windings Which in turn interact With the stator magnetic ?eld. the stator bore and the rotor is preferably betWeen 0.5 milli
The resultant rotating ?eld causes the desired shaft torque and meters and 0.8 millimeters. The rotor tooth bridge thickness is
rotation of the motors rotor at the desired speed, the rotor 45 preferably betWeen 10% and 70% larger than the air gap
being comprised of one or more magnetic pole pairs With the distance. The stator preferably includes 60 teeth; the rotor
same number of pole-pairs as that of the stator Windings of preferably includes 74 teeth.
each phase. In another aspect, the induction motor of the invention may
For decades AC induction motors have been the Work be a three-phase, four pole motor With a dual Winding layer
horses of modern society, such motors being designed and 50 arrangement. The ?rst Winding layer may be comprised of six
manufactured With a variety of characteristics to match the coil groups, and more speci?cally of a ?rst and a second ?rst
vast range of desired applications. In general, the various phase coil group, a ?rst and a second second phase coil group
electrical, thermal and mechanical aspects of a motor are and a ?rst and a second third phase coil group. The second
designed to meet the performance speci?cations and cost Winding layer may be comprised of a second set of six coil
constraints for a speci?c application. On one end of the spec 55 groups, and more speci?cally of a third and a fourth ?rst phase
trum of applications economic considerations dominate, as coil group, a third and a fourth second phase coil group and a
exhibited by manufacturing and maintenance costs, such third and a fourth third phase coil group. The ?rst and second
applications including appliances, factory process controls, ?rst phase coil groups comprise a ?rst pole pair of the ?rst
and most other applications of induction motors. On the other phase, the third and fourth ?rst phase coil groups comprise a
end of the spectrum of applications performance dominates, 60 second pole pair of the ?rst phase, the ?rst and second second
Where high performance requirements such as high poWer phase coil groups comprise a ?rst pole pair of the second
density and high dynamic response are met using speci?c phase, the third and fourth second phase coil groups comprise
materials and manufacturing processes, typically at higher a second pole pair of the second phase, the ?rst and second
costs. Some applications, hoWever, require both high perfor third phase coil groups comprise a ?rst pole pair of the third
mance and loW cost. For example, electric vehicles have very 65 phase, and the third and fourth third phase coil groups com
demanding performance requirements, e.g., high ef?ciency, prise a second pole pair of the third phase. Preferably the ?rst
high torque density, high poWer factor and drive converter inter-pole connection electrically connecting the ?rst and