Method of manufacturing a transverse flux electrical machine rotor

• US 9,331,531 B2
• Filed: 10/16/2013
• Issued: 05/03/2016
• Est. Priority Date: 10/17/2012
• Status: Active Grant

• Current Assignee: Eocycle Technologies Inc.
• Original Assignee: Eocycle Technologies Inc.
• Inventors: Adams, Eric, Cote, Simon, Nadeau, Raphael, Massicotte, Daniel, Fortin, Patrice, Bernier-Synnott, Jean-Francois
• Primary Examiner(s): Arbes, Carl
• Application Number:
  US14/055,450
• Publication Number:
  US 20140101927A1
• Time in Patent Office: 930 Days
• US Class Current: 1/1
• CPC Class Codes: H02K 1/27 Rotor cores with permanent magnets
• CPC Class Codes: H02K 1/2773 consisting of tangentially magnetized radial magnets
• CPC Class Codes: H02K 1/30 using intermediate parts, e.g. spiders
• CPC Class Codes: H02K 15/03 having permanent magnets
• CPC Class Codes: H02K 21/145 having an annular armature coil with homopolar co-operation H02K21/20
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 29/49012 Rotor

Abstract

A method of assembling a rotor portion adapted to be used in a rotatable transverse flux electrical machine (TFEM) is presented, the method comprising assembling at least one concentrator to a concentrator-receiving jig, applying bonding material between the concentrator and a magnet-and-concentrator supporting frame, assembling the concentrator-receiving jig to the magnet-and-concentrator supporting frame wherein a radial reference portion of the concentrator-receiving jig is material to set a distance between the concentrator assembled to the concentrator-receiving jig and the magnet-and-concentrator supporting frame, curing the bonding material to secure the concentrators to the magnet-and-concentrator supporting frame, and removing the concentrator-receiving jig without the at least one concentrator that remains secured to the magnet-and-concentrator supporting frame. A tool thereof is also encompassed by the present application.

Claims

1. A method of assembling a rotor portion adapted to be used in a rotatable transverse flux electrical machine (TFEM), the method comprising:

a) assembling at least one concentrator to a concentrator-receiving jig;

b) applying bonding material between the concentrator and a magnet-and-concentrator supporting frame;

c) assembling the concentrator-receiving jig to the magnet-and-concentrator supporting frame wherein a radial reference portion of the concentrator-receiving jig is material to set a distance between the concentrator assembled to the concentrator-receiving jig and the magnet-and-concentrator supporting frame;

d) repeating steps a) to c) for all the concentrators to assemble to the magnet-and-concentrator supporting frame;

e) curing the bonding material to secure the concentrators to the magnet-and-concentrator supporting frame; and

f) removing the concentrator-receiving jig without the at least one concentrator that remains secured to the magnet-and-concentrator supporting frame.

2. The method of claim 1, the method further comprising machining a radial-distal portion of the concentrators secured to the magnet-and-concentrator supporting frame to obtain a desired rotor portion outside diameter.

3. The method of claim 1, the method further comprising adding a magnet between adjacent pairs of concentrators secured to the magnet-and-concentrator supporting frame.

4. The method of claim 1, the method further comprising longitudinally locating the concentrator-receiving jig by abutting an axial jig-referencing-portion of the concentrator-receiving jig to the magnet-and-concentrator supporting frame.

5. The method of claim 1, the method further comprising longitudinally locating the at least one concentrator on the concentrator-receiving jig by abutting a longitudinal side of the at least one concentrator to an axial concentrator-referencing-portion of the concentrator-receiving jig.

6. The method of claim 1, wherein the at least one concentrator is a plurality of concentrators and the concentrator-receiving jig being adapted to simultaneously assemble a plurality of concentrators.

7. The method of claim 1, wherein the concentrator-receiving jig is adapted to be assembled to a multi-phase rotor portion.

8. The method of claim 1, the method further comprising aligning the concentrator-receiving jig with a concentrator-receiving portion comprised on the cylindrical frame.

9. The method of claim 1, wherein the concentrator-receiving jig comprises a magnet adapted to removably secure the at least one concentrator to the concentrator-receiving jig, the method further comprising magnetically securing the at least one concentrator to the concentrator-receiving jig.

10. The method of claim 1, wherein the concentrator-receiving jig comprises a concentrator-receiving recess, the method further comprising laterally locating the at least one concentrator to the concentrator-receiving jig by inserting the at least one concentrator in the concentrator-receiving recess.

11. A method of assembling concentrators and magnets on a magnets-and-concentrators supporting member, the method comprising:

locating the concentrators on the magnets-and-concentrators supporting frame; and

bonding the concentrators on the magnets-and-concentrators supporting frame.

12. The method of claim 11, the method further comprising machining an exterior diameter of the concentrators.

13. The method of claim 11, the method further comprising adding a magnet between adjacent pairs of concentrators on the magnets-and-concentrators supporting frame.

14. The method of claim 11, the method further comprising machining the exterior diameter of the concentrators on the magnets-and-concentrators supporting frame.

15. The method of claim 11, the method further comprising longitudinally locating the concentrators on a concentrator-receiving jig by abutting the concentrators to an axial concentrator-referencing-portion of the concentrator-receiving jig, the concentrator-receiving jig being positioned on the magnets-and-concentrators supporting frame to further locate the concentrators.

16. The method of claim 11, the method further comprising aligning the concentrators with concentrator-receiving portions comprised on the magnets-and-concentrators supporting frame.

17. The method of claim 11, wherein magnetism is material for temporarily positioning the concentrators in respect with the magnets-and-concentrators supporting frame.