Systems and methods for manufacturing adaptive electric machines
AssigneeMatra Manufacturing & Services
InventorsBoris A. Maslov, Alexander Pyntikov
Life of this patent
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Abstract
A system and method for assembling machines using multiple, structurally equivalent components. The characteristics of each component are tested. The tested components are sorted into component classes using the test information. Individual components are selected from the classes and combined in a manner that, when combined, will provide desired price/performance characteristics in the machine. Machines with improved price/performance characteristics may be assembled without requiring change to the quality of the components, or the manner in which the components are manufactured.
Claims14
A method of assembling a plurality of machines, comprising:
- providing a plurality of structurally equivalent components,
- testing at least one characteristic of each of the plurality of components,
- sorting each of the tested components into at least one of a first component class and a second component class using information obtained in the testing step,
- providing components in the first component class for assembly of at least one machine in a first machine class, and
- providing components in the second component class for assembly of at least one machine in a second machine class.
An adaptive machine comprising a plurality of structurally equivalent components, each one of the plurality of components being selected from among at least two component classes, the first component class comprising components having a first characteristic, the second component class comprising components having a second characteristic, each one of the plurality of components being subjected to a test and, using information obtained in the test, being sorted into the first component class or the second component class.
A method for manufacturing an adaptive electric machine, comprising:
- fabricating a plurality of electromagnetic core elements,
- testing each of the electromagnetic core elements to identify electromagnetic core elements failing to meet quality control criteria,
- arranging the electromagnetic core elements that meet the quality control criteria into stator segments,
- windings each stator segment with wire,
- testing each of the stator segments to identify stator segments failing to meet quality control criteria,
- assembling a stator from the stator segments meeting quality control criteria,
- fabricating rotor magnet segments comprising either permanent magnet segments, electromagnet segments or combinations thereof,
- testing each of the rotor magnet segments to identify rotor magnet segments failing to meet quality control criteria,
- assembling a rotor having rotor magnet segments meeting the quality control criteria,
- inserting the stator into the rotor to form an electric machine,
- performing a quality control test on the electric machine and producing a quality control result, and
- grading the electric machine in accordance with the result of the quality control test.
A method of repairing or servicing a machine, comprising:
- testing a plurality of stator core segment in a defective adaptive electric machine,
- identifying a defective stator core segment, and
- replacing the defective stator core segment without replacing the entire stator.
A method for manufacturing a stator for an electric machine, comprising:
- fabricating an electromagnetic core elements,
- testing the electromagnetic core element to determine whether the electromagnetic core element fails to meet quality control criteria,
- winding the electromagnetic core element with wire to form a stator,
- testing the stator to determine whether the stator fails to meet quality control criteria and to provide a quality control result,
- grading the stator in accordance with the quality control result.
A method for manufacturing a rotor for an electric machine, comprising:
- fabricating a rotor magnet segment comprising either permanent magnet segments, electromagnetic segments or combinations thereof,
- testing the rotor magnet segment to identify rotor magnet segments failing to meet quality control criteria and to provide a quality control result,
- assembling a rotor having rotor magnet segments having like quality control results, and
- grading the rotor in accordance with the quality control result of the rotor magnet segments.
A method for manufacturing or servicing an adaptive electric machine, comprising:
- fabricating a plurality of stator core elements comprising electromagnetic circuits or permanent magnets, or both,
- testing each of the stator core elements to identify stator core elements failing to meet quality control criteria and having like quality control properties,
- arranging the stator core elements that have like quality control properties into a stator having segments.
A method for manufacturing or servicing an adaptive electric machine, comprising:
- fabricating a plurality magnetic segments comprising electromagnetic circuits or permanent magnets, or both,
- testing each of the magnetic segments to identify magnetic segments failing to meet quality control criteria and having like quality control properties,
- arranging magnetic segments that have like quality control properties into a rotor magnet assembly having segments.
Dependencies are inferred from the claim text.