Stacking Method For Electric Machines

6:

• A method for manufacturing a precision chassis assembly for the stator assembly and the rotor assembly of an electric machine module comprising the four steps of:
• a) Incorporate a manufacturing jig comprising at least one keying object selected from a group consisting of key protrusion objects and key insertion objects:
• Wherein said keying object of said manufacturing jig is precisely complementary to the arrangements, positions, shapes, sizes, and surface configuration of said keying object of said chassis assembly to be manufactured;
• b) Incorporate the complement of said keying object of said manufacturing jig into the raw components of said chassis assembly of said electric machine module to be manufactured further selected from a group consisting of rotor assembly and stator assembly:
• Wherein said incorporation only include said raw components which mate to said keying object of said manufacturing jig;
• c) Install said raw components with said complement of said keying objects onto said keying object of said manufacturing jig:
• Wherein said raw components are precisely position and held in the foot print of said chassis assembly to be manufactured by said manufacturing jig;
• d) Attach said raw components installed on said keying object of said manufacturing jig with raw structural components for completing said chassis assembly to be manufactured:
• Wherein said raw structural components are selected from a group consisting of precision and non-precision raw materials;
• Whereby said remaining raw structural components together with said installed raw components form said chassis assembly are precisely aligned with said manufacturing jig.

7:

• The combination defined in claim 6, wherein said manufacturing jig is integral with the manufacturing tool of the electromagnetic core further selected from a group consisting of rotor and stator core electromagnetic core of said electric machine module:
• Wherein said electromagnetic core is first manufactured with said manufacturing tool;
• Wherein the air-gap surface of said electromagnetic core is pre-aligned to the precision surface of said manufacturing tool and said integral manufacturing jig;
• Wherein said electromagnetic core is included with said raw components;
• Whereby said chassis assembly becomes a precision structural frame of said rotor and stator electromagnetic core of said electric machine module.