Manufacturing coils for an axial flux rotating electrical machine
AssigneeMaxxwell Motors, Inc.
InventorsMichael Cunnyngham, Maksym Pryimak
Life of this patent
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Abstract
Embodiments involve rotors for axial flux induction rotating electric machines that use a soft magnetic composite for the rotor core. A first embodiment is directed to a rotor for a rotating electrical machine that transmits magnetic flux parallel to a shaft of the rotor. The rotor includes a rotor winding and a plurality of cores. The rotor winding consists of a solid piece of conductive material that comprises a plurality of cavities. Each core is placed in a respective cavity and comprises a highly resistive isotropic ferromagnetic powder.
Claims12
A method of manufacturing a coil for a rotating electrical machine that transmits magnetic flux parallel to a shaft of the machine, the method comprising:
- (a) repeatedly bending a wire at substantially 180 degree angles to form the bent wire into a stack that extends in an axial direction such that a number of bends in the wire corresponds to a number of turns of a winding for a stator of the rotating electrical machine;
- and
- (b) pressing, along a transverse direction perpendicular to the axial direction, the stack of bent wire with a die having interlaced teeth alternating along the axial direction and having a shape configured to press adjacent layers of the stack of bent wire in opposite directions along the transverse direction to form the wire into the coil to fit over at least one tooth of the stator of the rotating electrical machine.
Dependencies are inferred from the claim text.