Method for manufacturing adaptive machines

• US 7,204,011 B2
• Filed: 02/05/2004
• Issued: 04/17/2007
• Est. Priority Date: 02/06/2003
• Status: Expired due to Fees

• Current Assignee: Matra Manufacturing & Services SAS (Vivendi SE)
• Original Assignee: Matra Manufacturing & Services SAS (Vivendi SE)
• Inventors: Maslov, Boris A.
• Primary Examiner(s): Tugbang; A. Dexter
• Assistant Examiner(s): Phan; Tim
• Application Number:
  US10/771,496
• Publication Number:
  US 20040200057A1
• Time in Patent Office: 1,167 Days
• Field of Search: 295/96, 295/98, 295/921, 296/05, 297/36, 310/156.12, 310/216, 310/218, 700/95
• US Class Current: 29/596
• CPC Class Codes: B60K 1/00 Arrangement or mounting of electrical propulsion units B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00; electric transmission arrangements B60K17/12; electric equipment or propulsion of electrically-propelled vehicles per se B60L; current-collectors for power supply lines of electrically-propelled vehicles B60L5/00
• CPC Class Codes: B60L 8/00 Electric propulsion with power supply from forces of nature, e.g. sun or wind
• CPC Class Codes: H02K 1/141 consisting of C-shaped cores
• CPC Class Codes: H02K 1/187 to inner stators
• CPC Class Codes: H02K 11/049 Rectifiers associated with stationary parts, e.g. stator cores
• CPC Class Codes: H02K 16/04 Machines with one rotor and two stators
• CPC Class Codes: H02K 21/22 with magnets rotating around the armatures, e.g. flywheel magnetos
• CPC Class Codes: H02K 2213/06 Machines characterised by the presence of fail safe, back up, redundant or other similar emergency arrangements
• CPC Class Codes: H02K 2213/09 Machines characterised by the presence of elements which are subject to variation, e.g. adjustable bearings, reconfigurable windings, variable pitch ventilators
• CPC Class Codes: H02K 2213/12 Machines characterised by the modularity of some components
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02K 7/1838 Generators mounted in a nacelle or similar structure of a horizontal axis wind turbine
• CPC Class Codes: H02P 25/08 Reluctance motors
• CPC Class Codes: H02P 6/34 Modelling or simulation for control purposes
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/53161 : including deforming means

Abstract

A method for assembling machines using multiple, structurally equivalent components. The characteristics of each component are tested. The tested components are sorted into component classes using the test information. Individual components are selected from the classes and combined in a manner that, when combined, will provide desired price/performance characteristics in the machine. Machines with improved price/performance characteristics may be assembled without requiring change to the quality of the components, or the manner in which the components are manufactured.

Claims

1. A method for manufacturing an adaptive electric machine, comprising:

fabricating a plurality of electromagnetic core elements;

testing each of the electromagnetic core elements to identify electromagnetic core elements failing to meet quality control. criteria;

arranging the electromagnetic core elements that meet the quality control criteria into stator segments;

winding each stator segment with wire;

testing each of the stator segments to identify stator segments failing to meet quality control criteria;

assembling a stator from the stator segments meeting quality control criteria;

fabricating rotor magnet segments comprising either permanent magnet segments, electromagnet segments or combinations thereof;

testing each of the rotor magnet segments to identify rotor magnet segments failing to meet quality control criteria;

assembling a rotor having rotor magnet segments meeting the quality control criteria;

inserting the stator into the rotor to form an electric machine;

performing a quality control test on the electric machine and producing a quality control result; and

grading the electric machine in accordance with the result of the quality control test.

2. The method of claim 1 wherein each stator segment is electromagnetically isolated from other stator segments.

3. The method of claim 1 comprising assembling the stator in the rotor in a segmented manner or assembling the rotor in the stator in a segmented manner.

4. The method of claim 1 wherein the electromagnetic machine is assembled at the location where it is permanently installed.