Method of making a laminated stator

• US 4,642,882 A
• Filed: 08/21/1985
• Issued: 02/17/1987
• Est. Priority Date: 08/21/1985
• Status: Expired due to Fees

• Current Assignee: Mechanical Technology Incorporated
• Original Assignee: Mechanical Technology Incorporated
• Inventors: Castiglione, Ralph M., Hurst, Ralph
• Primary Examiner(s): Hall, Carl E.
• Application Number:
  US06/767,905
• Time in Patent Office: 545 Days
• Field of Search: 29/596, 29/606, 310/42, 310/12-14
• US Class Current: 29/596
• CPC Class Codes: H02K 1/223 Rotor cores with windings and permanent magnets for additional excitation in synchronous motors or generators H02K21/042; in synchronous motors having additional short-circuited winding for starting as an asynchronous motor H02K21/46
• CPC Class Codes: H02K 15/12 Impregnating, heating or drying of windings, stators, rotors or machines
• CPC Class Codes: H02K 2213/03 Machines characterised by numerical values, ranges, mathematical expressions or similar information
• CPC Class Codes: H02K 3/30 Windings characterised by the insulating material
• CPC Class Codes: H02K 41/033 with armature and magnets on one member, the other member being a flux distributor
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

A method of making a laminated stator assembly for a dynamoelectric machine which comprises machining an inner stator member as a single detail having a plurality of winding retaining grooves and plurality of radial slots all of which terminate at or near a central core portion of the stator member. The material between the radial slots form spaced apart radially tapered sections which terminate in the central core portion and the stator member can serve as its own winding mandrel for winding coils in place in the grooves. After such winding an outer shell of magnetic material is fitted over the inner stator member. The coils, spaces between the radially tapered sections, and surfaces of the groove are provided with suitable, electrically insulating bonding material which after curing bonds such elements into a single unit. The central core portion is then machined away so that there is longer a direct connection between the interior ends of the tapered sections and the stator member.

Claims

1. A method of making a laminated stator for a linear electrodynamic machine comprising the steps of:

providing a cylindrical stator member of magnetic material defined by a cylinder of a predetermined radius;

forming a plurality of uniformly spaced, axially extending radial slots in said stator member each being of uniform width and of a first preselected radial depth which is less than said predetermined radius to form radially tapered laminations which remain joined together at their radially inward ends by a cylindrical core portion;

forming a plurality of uniformily spaced circumferential grooves of a second preselected radial depth and uniform cross section in the cylindrical stator member;

electrically insulating on all the surfaces of the circumferential grooves;

electrically insulating all the surfaces of a preselected one of the axially extending radial slots to form an insulated wireway extending between the ends of the cylindrical stator member;

winding a plurality of turns of a continuous wire in each of the circumferential grooves to form toroid-shaped coils therein such that the continuous wire is passed in sequence to each adjacent circumferential groove through the insulated wireway;

providing a cylindrical stator shell of magnetic material and having an inner dimension adapted to fit tightly over the stator member outer periphery to form a stator assembly and having on the inner dimension surface axially extending radial slots of the same spacing as the radial slots on the stator member;

introducing an uncured bonding material into all the voids in the stator assembly;

curing the bonding material in the stator assembly; and

forming a bore of a preselected radius in the stator assembly such that the core portion is completely removed and the radially tapered laminations are separated from the adjacent laminations by cured bonding material and held in radial compression by the cylindrical stator shell.

2. A method of making a laminated stator as set forth in claim 1, further comprising the steps of:

providing a second layer of electrically insulating material in the wireway to insulate the end portion of the continuous wire as it is passed from the last circumferential groove back through the wireway to a position near the start portion of the continuous wire for connection of both to an energy source.

3. A method of making a laminated stator as set forth in claim 2, further comprising the steps of:

sealing the ends of the stator assembly with gas tight seals;

evacuating the stator assembly; and

introducing the uncured bonding material into the voids by drawing it into the vacuum created in the stator assembly.