Electrodynamic apparatus and method of manufacture

Abstract

Electrodynamic apparatus such as a motor, generator or alternator is configured having a stator core assembly formed of pressure shaped processed ferromagnetic particles which are pressure molded in the form of stator modules. These generally identical stator modules are paired with or without intermediate modules to provide the stator core structure for receiving field winding components. In one embodiment, two sets of the paired stator modules are combined in tandem to enhance operational functions without substantial diametric increases in the overall apparatus.

1 - 39 . (canceled)  
   
   
       40 . A method for manufacturing a stator assembly for a multiphase electrodynamic apparatus having an axis, comprising the steps of: 
 (a) providing a powdered metal pressing facility for producing by compressive molding a stator core module, said facility being configured to provide said stator core module as being formed of ferromagnetic particles which are generally mutually insulatively associated, and said stator core module comprising a back iron portion and a plurality of stator pole core members each formed integrally with said back iron portion said said back iron portion having a back iron widthwise extent and back iron length extending from a bottom surface to a top surface, said core members having a winding core portion with core widthwise extent and extending a core length between bottom and top winding core surfaces, and a flux interaction portion having an interaction widthwise extent, integrally formed with said winding core portion and extending an interaction length from a top surface to a bottom surface, said back iron widthwise extent and corresponding said back iron length, said winding core widthwise extent and corresponding said winding core length, and said interaction widthwise extent and corresponding said interaction length being selected to derive a said stator core module by said compressive molding wherein said particles of said stator core modules exhibit a density effective to achieve adequate operational permeability and avoidance of magnetic saturation under operating conditions;    (b) molding at least a first and a second stator core module in a said powdered metal pressing facility;    (c) symmetrically disposing said first and second stator core modules about said axis in a manner wherein said back iron portions are circumferentially aligned and said stator pole core members are axially aligned to an extent permitting stator pole winding to be applied over said axially aligned stator pole core members said winding core portion of said first and second stator core modules;    (d) fixing said stator pole core members of said first and second stator core modules in such axially aligned orientation; and    (e) providing a sequence of field windings each extending over and supported by the mutually outwardly disposed top surfaces of said winding core portions of said first and second stator core modules.    
   
   
       41 . The method of  claim 40  wherein: 
 said back iron widthwise extent and corresponding back iron length are selected in step (a) to respectively exhibit a ratio equal to or less than about 1 to 5.    
   
   
       42 . The method of  claim 40  wherein: 
 said winding core widthwise extent and corresponding winding core length are selected in step (a) to respectively exhibit a ratio equal to or less than about 1 to 5.    
   
   
       43 . The method of  claim 40  wherein: 
 said interaction widthwise extent and corresponding interaction length are selected in step (a) to respectively exhibit a ratio equal to or less than about 1 to 5.    
   
   
       44 . The method of  claim 40  wherein: 
 at least a third said stator core module is placed and aligned intermediate said first and second stator core modules; said field winding surmounting said winding core portions between said winding core portions of said first and second stator modules.    
   
   
       45 . The method of  claim 40  wherein: 
 said step (b) further comprises molding at least a third and a forth stator core module in a said powdered metal pressing facility;    said step (c) further comprises symmetrically disposing said first, second, third and fourth stator core modules about said axis in a manner wherein said back iron portions are circumferentially aligned and said third and fourth stator core modules' stator pole core members are axially aligned to an extent permitting stator pole winding to be applied over said axially aligned stator pole core members said winding core portion of said third and fourth stator core modules;    said step (d) further comprises fixing said stator pole core members of said third and fourth stator core modules in such axially aligned orientation; and    said step (e) further comprises providing a sequence of field windings each extending over and supported by the mutually outwardly disposed top surfaces of said winding core portions of said third and fourth stator core modules, said first and second stator core modules being connected in series or parallel electrical interconnection with said third and fourth stator core modules.    
   
   
       46 . A method of enclosing a stator core module assembly comprising of two or more stator core modules each formed of pressure shaped ferromagnetic particles which are generally mutually insulatively associated comprising the steps of: 
 (a) placing a rotor assembly central to said stator core modules;    (b) affixing a first motor end cap over one end of the shaft of said rotor assembly and adjacent with an end surface of said stator core module assembly;    (c) affixing a second motor end cap over the opposite end of said rotor shaft and adjacent with the other end of said stator core module assembly; and    (d) installing two or more fastening devices through said rotor assembly from said first motor end cap to said second motor end cap and tightening said fastening devices such that the components of said stator core module assembly are firmly held in place and aligned.    
   
   
       47 . The method of  claim 46  further comprising the step of: 
 (e) installing a sleeve over the outside surface of said stator core module assembly intermediate said first motor end cap and said second motor end cap, said sleeve aligning and enclosing said stator core module assembly.    
   
   
       48 . The method of  claim 46  wherein said step (d) further comprises installing said fastening devices as screws.  
   
   
       49 . The method of  claim 46  wherein said step (d) further comprises installing said fastening devices as fastening rods.