Modular electromagnetic machines and methods of use and manufacture thereof

Abstract

An electromagnetic machine includes a housing, an axle coupled to the housing in a rotatable fashion, a stator assembly disposed generally within the housing, the stator assembly including a stator plate and a stator bearing coupled to the axle such that the stator assembly is rotatable about the axle, a rotor assembly fixed to the axle and disposed generally within the housing and including a rotor housing that defines a circumferentially extending channel that is sized to receive a portion of the stator assembly therein; and a locking mechanism configured to selectively prevent and permit rotation of the stator assembly about the axle via the stator bearing. The housing can include an access window defined therein such that the stator assembly is accessible through the access window.

1 - 104 . (canceled) 
     
     
         105 . A method of servicing an electromagnetic machine having a plurality of coil modules, the method comprising:
 electrically disconnecting an existing coil module from an existing portion of a circuit board of the electromagnetic machine;   removing the existing coil module from the electromagnetic machine through an access window defined in a housing of the electromagnetic machine; and   inserting a new coil module into the electromagnetic machine through the access window to replace the existing coil module.   
     
     
         106 . The method of  claim 105 , wherein the electromagnetic machine includes an access window cover that is configured to cover the access window, and wherein the method further comprises:
 prior to removing the existing coil module through the access window, removing the access window cover from the housing of the electromagnetic machine; and   after inserting the new coil module through the access window, reattaching the access window cover to the housing of the electromagnetic machine.   
     
     
         107 . The method of  claim 105 , wherein the housing of the electromagnetic machine includes a first wall and a second wall coupled together, and wherein the existing coil module is disposed within a hollow interior defined between the first wall and the second wall. 
     
     
         108 . The method of  claim 107 , wherein the existing coil module is replaced with the new coil module without decoupling the first wall and the second wall. 
     
     
         109 . The method of  claim 105 , further comprising, prior to removing the existing coil module through the access window, removing the existing portion of the circuit board from the electromagnetic machine through the access window. 
     
     
         110 . The method of  claim 109 , further comprising, after inserting the new coil module through the access window:
 inserting the existing portion of the circuit board back into the electromagnetic machine through the access window; and   electrically connecting the new coil module to the existing portion of the circuit board.   
     
     
         111 . The method of  claim 109 , further comprising, after inserting the new coil module through the access window:
 inserting a new portion of the circuit board into the electromagnetic machine through the access window to replace the existing portion of the circuit board; and   electrically connecting the new coil module to the new portion of the circuit board.   
     
     
         112 . The method of  claim 105 , wherein the electromagnetic machine includes an alignment plate disposed between the plurality of coil modules and the circuit board, the alignment plate being configured to aid in maintaining contact between the plurality of coil modules and the circuit board. 
     
     
         113 . The method of  claim 112 , further comprising, prior to removing the existing coil module through the access window, removing, at least a portion of the alignment plate from the electromagnetic machine through the access window, the removed portion of the alignment plate being disposed between the existing coil module and the existing portion of the circuit board. 
     
     
         114 . The method of  claim 113 , further comprising, after inserting the new coil module through the access window, inserting the removed portion of the alignment plate back into the electromagnetic machine through the access window. 
     
     
         115 . The method of  claim 113 , further comprising, after inserting the new coil module through the access window, inserting a new portion of the alignment plate into the electromagnetic machine through the access window to replace the removed portion of the alignment plate. 
     
     
         116 . The method of  claim 105 , wherein the plurality of coil modules is mounted on a rotatable stator assembly within the housing of the electromagnetic machine. 
     
     
         117 . The method of  claim 116 , further comprising:
 disengaging a locking mechanism of the electromagnetic machine to permit rotation of the stator assembly relative to the housing; and   rotating the stator assembly until the existing coil module and the existing portion of the circuit board are accessible through the access window.   
     
     
         118 . The method of  claim 117 , wherein the disengaging the locking mechanism includes removing one or more locking members from one or more respective apertures defined in the housing and one or more corresponding apertures defined in the stator assembly. 
     
     
         119 . The method of  claim 117 , further comprising reengaging the locking mechanism to prevent rotation of the stator assembly relative to the housing. 
     
     
         120 . A method of operating an electromagnetic machine having a plurality of coil modules and a circuit board electrically connecting the plurality of coil modules, the method comprising:
 electrically connecting the plurality of coil modules in a first wiring arrangement;   operating the electromagnetic machine during a first period of time while the plurality of coil modules is electrically connected in the first wiring arrangement;   modifying the circuit board to change the electrical connection of the plurality of coil modules from the first wiring arrangement to a second wiring arrangement; and   operating the electromagnetic machine during a second period of time while the plurality of coil modules is electrically connected in the second wiring arrangement.   
     
     
         121 . The method of  claim 120 , wherein the circuit board includes a plurality of portions, and wherein a respective portion of the plurality of coil modules is electrically connected to each portion of the circuit board, and wherein modifying the circuit board further comprises:
 electrically disconnecting the respective portion of the plurality of coil modules from at least one portion of the circuit board;   removing the at least one portion of the circuit board from the electromagnetic machine through an access window defined in a housing of the electromagnetic machine;   inserting at least one new portion of the circuit board into the electromagnetic machine through the access window to replace the removed at least one portion of the circuit board; and   electrically connecting the respective portion of the plurality of coil modules to the at least one new portion of the circuit board.   
     
     
         122 . The method of  claim 120 , wherein a housing of the electromagnetic machine includes a first wall and a second wall coupled together to form a hollow interior in which the circuit board is disposed, and wherein the circuit board is modified without decoupling the first wall and the second wall. 
     
     
         123 . The method of  claim 120 , wherein the first wiring arrangement is configured to provide three-phase power, and the second wiring arrangement is configured to provide single-phase power. 
     
     
         124 . The method of  claim 120 , wherein:
 the plurality of coil modules includes a first sub-set of one or more coil modules and a second sub-set of one or more coil modules;   when the plurality of coil modules is electrically connected in the first wiring arrangement, the first sub-set of coil modules is wired to provide an electrical power phase and the second sub-set of coil modules is disconnected; and   when the plurality of coil modules is electrically connected in the second wiring arrangement, the second sub-set of coil modules is wired to provide the electrical power phase and the first sub-set of coil modules is disconnected.