One-piece field core shell

Method for forming a one-piece field core shell having an inner and an outer annular ring, and a mounting flange, which comprising the steps of:

• placing an annular disc sheet metal workpiece in a flow-forming machine and supporting said workpiece with a headstock mandrel and a mounting flange forming mandrel;
• pressing a shaping roller against a side of said annular disc and spinning said annular disc;
• moving the shaping roller progressively radially inward against the side of said spinning disc and displacing a portion of metal while thinning part of the disc, forming said mounting flange;
• removing said disc with said mounting flange formed and inverting said disc by 180 degrees from its formed position;
• placing said disc with said mounting flange formed, in said flow-forming machine and supporting said workpiece with a mounting flange mandrel and an inner annular ring forming mandrel;
• pressing a shaping roller against a side of and spinning said annular disc with the mounting flange formed;
• moving the shaping roller progressively radially inward against the side of the rotating disc with the mounting flange formed and displacing a portion of metal while thinning part of the disc forming said inner annular ring;
• removing said disc with said mounting flange formed and inverting said disc by 180 degrees from its formed position;
• placing said disc with said mounting flange and inner annular ring formed, in said flow-forming machine and supporting said workpiece with a mounting flange mandrel and an outer annular ring forming mandrel;
• moving an outer annular ring forming tool radially inward against the side of the rotating disc with the mounting flange formed and the inner annular ring formed and displacing a portion of said metal forming said outer annular ring;
• and
• forming a bore and a hole to feed wire leads.

Method for forming a one-piece field core shell having an inner and an outer annular ring, and a mounting flange, which comprises:

• placing an annular disc sheet metal workpiece in a flow-forming machine and supporting said workpiece with a headstock mandrel and an inner annular ring forming mandrel;
• pressing a shaping roller against a side of said annular disc and spinning said annular disc;
• moving the shaping roller progressively radially inward against the side of said spinning disc and displacing a portion of metal while thinning part of the disc, forming said inner annular ring;
• removing said disc with said inner annular ring formed and inverting said disc by 180 degrees from its formed position;
• placing said disc with said inner annular ring formed, in said flow-forming machine and supporting said workpiece with a inner annular ring mandrel and an outer annular ring forming mandrel;
• moving an outer annular ring forming tool radially inward against the side of the rotating disc with the inner annular ring formed and displacing a portion of said metal forming a radially extending surface of the outer annular ring;
• forming a mounting flange;
• and
• forming a bore and a hole to feed wire leads.

Method for forming a one-piece field core shell having an inner and an outer annular ring, and a mounting flange, which comprises:

• placing an annular disc sheet metal with a hole in its center workpiece in a flow-forming machine and supporting said workpiece with a headstock mandrel and a mounting flange forming mandrel;
• forming a mounting flange;
• pressing a shaping roller against a side of said annular disc and spinning said annular disc;
• moving the shaping roller progressively radially inward against the side of said spinning disc and displacing a portion of metal while thinning part of the disc, forming said inner annular ring;
• removing said disc with said mounting flange and inner annular ring formed and inverting said disc by 180 degrees from its formed position;
• placing said disc with said inner annular ring formed and mounting flange formed in said flow-forming machine and supporting said workpiece with a inner annular ring mandrel and an outer annular ring forming mandrel;
• moving an outer annular ring forming tool radially inward against the side of the rotating disc with the inner annular ring formed and displacing a portion of said metal forming said outer annular ring;
• and
• forming a bore and a hole to feed wire leads.

A field core shell which comprises:

• a spin-roll formed outer annular ring integral to and encircling a center axis of the disc and extending from the bottom external surface in a direction that is perpendicular to the bottom surface of the disc and parallel to the center axis of the disc;
• a spin-roll formed inner annular ring integral to and encircling a center axis of the disc, said inner annular axis spaced radially inward from said outer annular ring and extending from the bottom external surface in a direction that is perpendicular to the bottom surface of the disc and parallel to the center axis of the disc;
• and
• a spin-roll formed mounting flange integral to the disc and having a bore extending from the mounting flange to the bottom external surface of the disc.

A field core assembly comprising:

• a wire winding pod having a top and bottom surface comprising an outer annular ring integral to and encircling a center axis of the wire winding pod and extending in a direction perpendicular to the bottom of the wire winding pod and parallel to the center axis of the wire winding pod, an inner annular ring integral to and encircling a center axis of the wire winding pod, said inner annular axis spaced radially inward from said outer annular ring and extending in a direction perpendicular to the bottom of the wire winding pod and parallel to the center axis of the wire winding pod;
• a mounting flange that encircles a center axis of the wire winding pod and extends in a direction perpendicular to the top surface of the wire winding pod and parallel to the center axis of the wire winding pod, the wire winding pod having a bore extending from the mounting flange to the bottom of the wire winding pod and a hole in the top surface of the wire winding pod to feed wire winding leads;
• wire windings located inside the wire winding pod having wire leads feed through the hole in the top surface of the wire winding pod;
• and
• an electrical connector attached to the top surface of the wire winding pod for connecting said field core assembly to an external source.