Method of making an electromagnetic transducer
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
H02K-015/02
H02K-015/10
출원번호
US-0081750
(1993-06-24)
발명자
/ 주소
Huang, Hao
Fisher, Gene A.
출원인 / 주소
Unique Mobility, Inc.
대리인 / 주소
Stevens, Davis, Miller & Mosher
인용정보
피인용 횟수 :
21인용 특허 :
104
초록▼
The method includes fabricating a plurality of elongated high permeability flux carrying members, and preparing n wire bundles each having a predetermined length. The n wire bundles are wound to provide a distributed winding configuration having a plurality of elongated open spaces. The plurality of
The method includes fabricating a plurality of elongated high permeability flux carrying members, and preparing n wire bundles each having a predetermined length. The n wire bundles are wound to provide a distributed winding configuration having a plurality of elongated open spaces. The plurality of flux carrying members are inserted into the plurality of open spaces to provide a winding/flux carrying member assembly. A bonding material is provided around the winding/flux carrying member assembly to provide a rigid structure.
대표청구항▼
1. A method of producing an armature for an electromagnetic transducer, said method comprising: (a) providing an armature wire winding configuration having a plurality of open spaces; (b) inserting a plurality of discrete flux carrying members into said plurality of open spaces, said open spaces
1. A method of producing an armature for an electromagnetic transducer, said method comprising: (a) providing an armature wire winding configuration having a plurality of open spaces; (b) inserting a plurality of discrete flux carrying members into said plurality of open spaces, said open spaces being interdigitated between a plurality of spaced-apart, elongated wire winding segments, adjacent ones of said winding segments being connected to one another, said discrete flux carrying members having an elongated shape corresponding to that of said open spaces; and (c) providing a non-electrically conductive bonding material around said winding/flux carrying member assembly to provide a substantially rigid structure. 2. A method of producing an armature for an electromagnetic transducer, said method comprising: (a) preparing a plurality of preformed discrete elongated high-permeability flux carrying members; (b) preparing n wire bundles, where in is at least two for a two-phase winding and at least three for a three phase winding, each said wire bundle having a predetermined length, each one of said wire bundles being formed of a plurality of substantially parallel wires; (c) winding said n wire bundles to provide a distributed winding configuration having a plurality of elongated open spaces; (d) inserting said plurality of flux carrying members into said plurality of open spaces in a one-to-one relationship such that one flux carrying member is in one open space to provide a winding/flux carrying member assembly; and (e) providing a bonding material around said winding/flux carrying member so as to provide a rigid structure. 3. The method as in claim 2, wherein said n wire bundles are wound to provide said distributed winding configuration and thereafter said plurality of flux carrying members are inserted into said plurality of open spaces. 4. The method as in claim 2, wherein the number of wire bundles is 6 and the number of said elongated open spaces is 144. 5. The method as in claim 2, wherein said open spaces are interdigitated between a plurality of spaced apart elongated wire winding segments, adjacent ones of said wire winding segments being connected to one another on each end by end wire turns, said flux carrying members having a shape corresponding to that of said open spaces. 6. The method of claim 5, wherein each said wire winding segment comprises a single turn of said wire bundles. 7. The method of claim 5, wherein each said wire winding segment comprises two turns of said wire bundles. 8. The method as in claim 5, wherein each said wire winding segment comprises three turns of said wire bundles. 9. The method as in claim 5, wherein each said wire winding segment comprises four turns of said wire bundles. 10. The method as in claim 2, wherein said rigid structure as in the shape of a cylindrical shell. 11. The method as in claim 2, wherein step (c) comprises winding said n wire bundles to provide said distributed winding configuration in the shape of a substantially cylindrical shell including a plurality of spaced-apart elongated winding segments wherein adjacent ones of said winding segments are connected to one another, said winding segments having said plurality of elongated open spaces interdigitated therewith. 12. The method as in claim 2, wherein step (b) comprises: (i) providing a wheel having a predetermined circumference, said circumference being approximately equal to a desired length of said plurality of wire bundles; (ii) winding wire onto said wheel to provide a first wire bundle formed of a predetermined number of turns of wire around said wheel; (iii) cutting said first bundle at a starting point on said wheel at which said winding operation was initiated to form two ends of said first bundle; (iv) providing a protective sleeve around said first bundle; (v) marking a center point of said first bundle between said two ends; and (vi) repeating steps (i)-(v) to form second through n wire bundles identical to said first bundle. 13. The method as in claim 2 wherein step (c) comprises: (i) providing a winding mandrel comprising a cylinder having a plurality of slots on its surface oriented parallel to a longitudinal axis of said cylinder, said slots being uniformly spaced around a circumference of said cylinder; (ii) providing a plurality of removable blades having one end positioned in said plurality of slots and another end oriented substantially perpendicular to a surface of said cylinder, said blades having a thickness and width as said flux carrying members, adjacent ones of said blades forming a space therebetweeen; (iii) inserting a first bundle of said n wire bundles into a first space between adjacent ones of said blades such that a linear center point of said first bundle is generally positioned at a midpoint of said space; (iv) inserting second through nth bundles successively into second through nth adjacent spaces between adjacent ones of said blades in a first direction around said circumference of said cylinder such that said second through nth bundles have said linear center points positioned respectively at midpoints of said spaces; (v) moving said two ends of said first bundle in said first direction under said second through nth bundles toward a next adjacent space n+1 adjacent to said second through nth adjacent spaces, inserting said two ends into said next adjacent space n+1 and tensioning said two ends to form a loop between said first space and said n+1 space; (vi) repeating step (v) for each successive second through nth bundle by moving said two ends of said second through nth bundles successively in said first direction toward next adjacent spaces, inserting said two ends in said respective next adjacent spaces and tensioning said two ends to form loops; (vii) repeating steps (v) and (vi) until said first through nth bundles have been inserted into final ones of said spaces around said circumference of said cylinder; (viii) terminating the ends of said first through nth bundles after said first through nth bundles have been inserted into said final ones of said spaces; (ix) removing said blades from said slots in said cylinder; and (x) separating said first through nth bundles from said cylinder, whereby the wire bundles braided as in steps (i)-(ix) form said distributed winding configuration. 14. The method as in claim 13, wherein step (vii) is repeated for a predetermined number of times in said first direction around said circumference of said cylinder whereby for each time around said cylinder the number of turns of said first through nth bundles per each said space is increased at least two. 15. The method as in claim 2, wherein step (a) includes preparing said flux carrying member by producing a plurality of insulated fine iron powder particles and pressing said insulated fine iron powder particles together to form said flux carrying members. 16. The method as in claim 2 wherein step (c) comprises: (i) providing a winding mandrel comprising a cylinder having a plurality of slots on its surface, and slots being uniformly spaced around a circumference of said cylinder; (ii) providing a plurality of removable blades each having one end positioned in one of said plurality of slots and another end oriented to project from said surface of said cylinder, said blades having a thickness and width as said flux carrying members, adjacent ones of said blades forming a space therebetweeen; (iii) inserting a first bundle of said n wire bundles into a first space between adjacent ones of said blades such that a linear center point of said first bundle is generally positioned at a midpoint of said first space; (iv) inserting second through nth bundles successively into second through nth adjacent spaces between adjacent ones of said blades in a first direction around said circumference of said cylinder such that said second through nth bundles have said linear center points positioned respectively generally at midpoints of said spaces; (v) moving said two ends of said first bundle in said first direction under said second through nth bundles toward a next adjacent space n+2 adjacent to said second through nth+1 adjacent spaces, inserting said two ends into said n+2 adjacent space and tensioning said two ends to form a loop between said first space and said nth+2 adjacent space; (vi) moving said two ends of said second bundle in said first direction under third through nth bundles to a next adjacent space n+1 adjacent to said third through nth+1 adjacent spaces, inserting said two ends of said first bundle into said nth+1 adjacent space and tensioning said two ends to form a loop between said second space and said nth+1 adjacent space; (vii) repeating step (v) for each successive pair of second through nth bundle by moving said two ends of each bundle toward alternating next adjacent spaces, inserting said two ends in said respective next adjacent spaces and tensioning said two ends to form loops; (viii) repeating steps (v)-(vii) until said second through nth bundles have been inserted into final ones of said spaces around said circumference of said cylinder; (ix) terminating the ends of said first through nth bundles after said first through nth bundles have been inserted into said final ones of said spaces; (x) removing said blades from said slots in said cylinder; and (xi) separating said first through nth bundles from said cylinder, whereby the wire bundles braided as in steps (i)-(x) form said distributed winding configuration. 17. A method of producing an armature for an electromagnetic transducer, said method comprising: (a) preparing a plurality of preformed, discrete elongated high-permeability flux carrying members by producing a multiplicity of insulated fine iron powder particles and pressing a predetermined amount of said insulated fine iron particles together to yield said plurality of said flux carrying members; (b) preparing n wire bundles each having a predetermined length, each one of said wire bundles being formed of a plurality of parallel wires; (c) providing a winding mandrel comprising a cylinder having a plurality of slots on its surface oriented parallel to a longitudinal axis of said cylinder, said slots being uniformly spaced around a circumference of said cylinder; (d) providing a plurality of removable blades each having one end positioned in one of said plurality of slots and another end oriented to project from said surface of said cylinder, said blades having a thickness and width generally as said flux carrying members, adjacent ones of said blades forming a space therebetween; (e) inserting a first bundle of said n wire bundles into a first space between adjacent ones of said blades such that a linear center point of said first bundle is positioned generally at a midpoint of said first space; (f) inserting second through nth ones of said n wire bundles successively into said second through nth adjacent spaces between adjacent ones of said blades in a first direction around said circumference of said cylinder such that said second through nth bundles have respective linear center points positioned respectively generally at midpoints of said spaces; (g) moving two ends of said first bundle in said first direction under said second through nth bundles toward a next adjacent space n+1 adjacent to said second through nth adjacent spaces, inserting said two ends into said next adjacent space n+1 and tensioning said two ends to form a loop between said first space and said n+1 space; (h) repeating step (g) for each successive second through nth bundle by moving two ends of said second through nth bundles successively in said first direction toward next adjacent spaces, inserting said two ends in said respective next adjacent spaces and tensioning said two ends to form loops; (i) repeating steps (g) and (h) until said first through nth bundles have been inserted into final ones of said spaces around said circumference of said cylinder; (j) terminating the ends of said first through nth bundles after said first through nth bundles have been inserted into said final ones of said spaces; (k) removing said blades from said slots in said cylinder; (l) separating said first through nth bundles from said cylinder, whereby the wire bundles braided as in steps (c)-(k) form a distributed winding configuration being in the shape of a substantially cylindrical shell including a plurality of spaced apart elongated winding segments wherein adjacent ones of said winding segments are connected to one another, said winding segments having a plurality of elongated open spaces interdigitated therebetween; (m) thereafter inserting said plurality of flux carrying members into said plurality of open spaces in a relationship such that at least one flux carrying member is in one said open space to provide a winding/flux carrying member assembly, said plurality of flux carrying members being formed in a substantially elongated shape and said plurality of open spaces being formed in a substantially elongated shape; and (n) providing a non-electrically conductive bonding material around said winding/flux carrying member assembly to provide a substantially rigid structure. 18. A method of producing an armature for an electromagnetic transducer, said method comprising: (a) preparing a plurality of preformed discrete elongated high-permeability flux carrying members; (b) preparing n wire bundles, where in is at least two for a two-phase winding and at least three for a three phase winding, each said wire bundle having a predetermined length, each one of said wire bundles being formed of a plurality of substantially parallel wires; (c) winding said n wire bundles to provide a distributed winding configuration having a plurality of elongated open spaces; and (d) inserting said plurality of flux carrying members into said plurality of open spaces in a relationship such that at least one flux carrying member is in one open space to provide a winding/flux carrying member assembly. 19. A method of producing an armature for an electromagnetic transducer, said method comprising: (a) preparing a plurality of preformed, discrete elongated high-permeability flux carrying members by producing a multiplicity of insulated fine iron powder particles and pressing a predetermined amount of said insulated fine iron particles together to yield said plurality of said flux carrying members; (b) preparing n (n>0) wire bundles each having a predetermined length, each one of said wire bundles being formed of a plurality of parallel wires; (c) providing a winding mandrel comprising a cylinder having a plurality of slots on its surface oriented parallel to a longitudinal axis of said cylinder, said slots being uniformly spaced around a circumference of said cylinder; (d) providing a plurality of removable blades each having one end positioned in one of said plurality of slots and another end oriented to project from said surface of said cylinder, said blades having a thickness and width generally as said flux carrying members, adjacent ones of said blades forming a space therebetween; (e) inserting a first bundle of said n wire bundles into a first space between adjacent ones of said blades such that a linear center point of said first bundle is generally positioned at a midpoint of said first space; (f) inserting second through nth ones of said n wire bundles successively into said second through nth adjacent spaces between adjacent ones of said blades in a first direction around said circumference of said cylinder such that said second through nth bundles have respective linear center points positioned respectively generally at midpoints of said spaces; (g) moving two ends of said first bundle in said first direction under said second through nth bundles toward a next adjacent space n+1 adjacent to said second through nth adjacent spaces, inserting said two ends into said next adjacent space n+1 and tensioning said two ends to form a loop between said first space and said n+1 space; (h) repeating step (g) for each successive second through nth bundle by moving two ends of said second through nth bundles successively in said first direction toward next adjacent spaces, inserting said two ends in said respective next adjacent spaces and tensioning said two ends to form loops; (i) repeating steps (g) and (h) until said first through nth bundles have been inserted into final ones of said spaces around said circumference of said cylinder; (j) terminating the ends of said first through nth bundles after said first through nth bundles have been inserted into said final ones of said spaces; (k) forming said first through nth bundles, whereby the wire bundles braided as in steps (c)-(i) form a distributed winding configuration being in the shape of a substantially cylindrical shell including a plurality of space apart elongated winding segments wherein adjacent ones of said winding segments are connected to one another, said winding segments having a plurality of elongated open spaces interdigitated therebetween; (l) removing said blades from said slots in said cylinder and inserting said plurality of flux carrying members into said plurality of open spaces in a relationship such that at least one flux carrying member is in one said open space to provide a winding/flux carrying member assembly, said plurality of flux carrying members being formed in a substantially elongated shape and said plurality of open spaces being formed in a substantially elongated shape; and (m) thereafter providing a non-electrically conductive bonding material around said winding/flux carrying member assembly to provide a substantially rigid structure. 20. The method as in claim 19 wherein in step (k) forming said wire bundles further comprises heating said bundles.
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