Method for fabricating motors of different outputs using standardized parts

Abstract

A method for varying motor output using magnets of different fluxes includes manufacturing standardized parts, ascertaining desired motor output, selecting from a group of interchangeable magnets to provide the desired output, and assembling a motor with the selected magnets and standardized parts such that the desired output is provided. Additionally, a motor kit including a rotor configured to accommodate magnets of varying residual induction values and lengths, a stator configured to operate with the rotor, and a plurality of interchangeable magnets with different residual induction values and lengths.

What is claimed is:  
     
         1 . A method for fabricating a motor, said method comprising the steps of: 
 fabricating standardized motor parts;    ascertaining desired motor output;    selecting at least one magnet from a group of interchangeable magnets in accordance with desired motor outputs; and    assembling a motor with the selected magnet and standardized parts such that the desired output is substantially provided.    
     
     
         2 . A method in accordance with  claim 1  wherein said step of selecting further comprises the step of selecting one of a ferrite bonded magnet, a Neodymium bonded magnet and a Samarium Cobalt bonded magnet.  
     
     
         3 . A method in accordance with  claim 1  wherein said step of selecting further comprises the step of selecting from a group of interchangeable magnets with different residual induction levels and substantially similar thicknesses and lengths.  
     
     
         4 . A method in accordance with  claim 1  wherein said step of selecting further comprises the step of selecting from a group of interchangeable magnets with different residual induction levels and varying lengths.  
     
     
         5 . A method in accordance with  claim 1  wherein said step of selecting further comprises the step of selecting from a group of interchangeable ring magnets.  
     
     
         6 . A method in accordance with  claim 5  wherein said step of selecting further comprises the step of selecting from a group of interchangeable ring magnets comprising at least one crush rib.  
     
     
         7 . A method in accordance with  claim 1  wherein said step of selecting further comprises the step of selecting from a group of interchangeable magnets having substantially similar residual induction levels and different lengths.  
     
     
         8 . A motor kit comprising: 
 a rotor configured to accommodate magnets of varying residual induction values;    a stator configured to operate with said rotor; and    a plurality of interchangeable magnets.    
     
     
         9 . A motor kit in accordance with  claim 8  wherein said interchangeable magnets comprise a plurality of ring magnets.  
     
     
         10 . A motor kit in accordance with  claim 8  wherein said interchangeable magnets comprise magnets with different residual induction values and substantially similar width and height.  
     
     
         11 . A motor kit in accordance with  claim 8  wherein said interchangeable magnets comprise magnets having different residual induction values and different lengths.  
     
     
         12 . A motor kit in accordance with  claim 8  wherein said interchangeable magnets comprise magnets having substantially similar residual induction values and different lengths.  
     
     
         13 . A motor kit in accordance with  claim 8  wherein said interchangeable magnets comprise magnets having different residual induction values and substantially similar lengths.  
     
     
         14 . A motor kit in accordance with  claim 8  wherein said interchangeable magnets comprise at least one of a ferrite bonded magnet, a Neodymium bonded magnet and a Samarium Cobalt bonded magnet.  
     
     
         15 . A motor kit in accordance with  claim 8  wherein said rotor and said stator are configured to produce a motor with an inside out “outer rotor” motor construction.  
     
     
         16 . A method for fabricating a motor product line, said method comprising the steps of: 
 fabricating a first motor including an output and at least a first magnet; and    fabricating a second motor from parts interchangeable with the first motor, the second motor including an output different than the output of the first motor, the parts include a motor housing including a stator and a rotor assembly including a rotor core and a rotor shaft.    
     
     
         17 . A method for fabricating a motor product line in accordance with  claim 16  wherein said step of fabricating a second motor further comprises the step of fabricating a second motor such that the second motor includes at least a second magnet having a residual induction value different than a residual induction value of the at least one first magnet.  
     
     
         18 . A method for fabricating a motor product line in accordance with  claim 16  wherein the at least one first magnet comprises a first ring magnet, said step of fabricating a second motor further comprises the step of fabricating a second motor such that the second motor includes a second ring magnet having a residual induction value different than a residual induction value of the first ring magnet.  
     
     
         19 . A method for fabricating a motor product line in accordance with  claim 16  wherein said step of fabricating a second motor further comprises the step of fabricating a second motor such that the second motor includes a ring magnet comprising at least one crush rib.  
     
     
         20 . A method for fabricating a motor product line in accordance with  claim 16  wherein said step of fabricating a second motor further comprises the step of fabricating a second motor such that the second motor includes at least one second magnet having a thickness and length substantially similar to the at least one first magnet.  
     
     
         21 . A method for fabricating a motor product line in accordance with  claim 16  wherein said step of fabricating a second motor further comprises the step of fabricating a second motor from parts interchangeable with the first motor, the parts include a motor housing including a shell and a stator, the stator including a stator core, the stator core including a plurality of windings, a rotor including a rotor core rotatably mounted in the housing, and two endshields attached to ends of the housing shell, the endshields supporting at least one bearing.  
     
     
         22 . A method for fabricating a motor product line in accordance with  claim 16  wherein said step of fabricating a second motor further comprises the step of fabricating a second motor entirely from parts interchangeable with the first motor.  
     
     
         23 . A method for fabricating a motor product line in accordance with  claim 16  wherein said step of fabricating a second motor further comprises the step of fabricating a second motor such that the second motor includes at least one second magnet having a length different from the at least one first magnet.  
     
     
         24 . A method for fabricating a motor product line in accordance with  claim 16  wherein the first motor and the second motor are inside out “outer rotor” motors.