Method of making a slotless, brushless, large air-gap electric motor
First Claim
1. A method of making a field winding for an electrical motor having a stator and a permanent magnet rotor, comprising the steps of:
- spirally winding a wire around a polygonal shaped form in a plurality of coil segments, each coil segment having a length corresponding to an arcuate length of a pole face of the permanent magnet rotor;
leaving unwound spaces between said coil segments, said spaces having a length substantially equal to the length of one of said coil segments;
collapsing opposite sides of said form so that portions of said coil segments fill said spaces substantially flattening said wire winding; and
forming said flattened winding into a hollow cylinder to form the field winding.
6 Assignments
0 Petitions
Accused Products
Abstract
A slotless brushless, large air gap electric motor comprises a stator having a field winding and field backiron, the field winding being composed of a plurality of successively offset polygonal shaped turns so as to provide a substantially flat winding, and a rotor disposed within the stator including a shaft with a permanent magnet mounted thereon. The field winding turns are preferably in the shape of a rectangle or a hexagonal. Also disclosed is a commutation scheme which dissipates energy stored in a section of the field winding previously energized to the section of the field winding subsequently energized; an integrated circuit for control of any motor using that commutation scheme; a winding configuration suitable for use with both an alternating and direct current power supply; and efficiency increasing magnetically permeable flux shorting elements.
67 Citations
20 Claims
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1. A method of making a field winding for an electrical motor having a stator and a permanent magnet rotor, comprising the steps of:
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spirally winding a wire around a polygonal shaped form in a plurality of coil segments, each coil segment having a length corresponding to an arcuate length of a pole face of the permanent magnet rotor; leaving unwound spaces between said coil segments, said spaces having a length substantially equal to the length of one of said coil segments; collapsing opposite sides of said form so that portions of said coil segments fill said spaces substantially flattening said wire winding; and forming said flattened winding into a hollow cylinder to form the field winding. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of making a field winding for an electrical motor having a stator and a permanent magnet rotor, comprising the steps of:
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spirally winding a wire around a polygonal shaped form in a plurality of coil segments, the number of said coil segments corresponding to a number of pole pairs of said rotor; leaving unwound spaces between said coil segments, said spaces having a length substantially equal to the length of one of said coil segments; collapsing two opposite sides of said form so that portions of said coil segments fill said spaces substantially flattening said wire winding; and forming said flattened winding into a hollow cylinder to form the field winding. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A method of making a polyphase field winding for an electrical motor having a stator and a permanent magnet rotor, comprising the steps of:
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spirally winding a wire around a polygonal shaped form in a plurality of coil segments, at least one dimension of the cross-section of said form being different for coil segments corresponding to different phases of the field winding; leaving unwound spaces between said coil segments, said spaces having a length substantially equal to the length of one of said coil segments; collapsing two opposite sides of said form so that portions of said coil segments fill said spaces substantially flattening said wire winding; and forming said flattened winding into a hollow cylinder to form the field winding.
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Specification