Process for Assembly of Motor-Generators

A process for assembly of a brushless motor-generator comprising:

• assembling a rotor formed from two spaced apart rotor portions having magnetic poles that drive magnetic flux circumferentially through said rotor portions and back and forth across an armature airgap formed between said rotor portions;
• forming an air core armature by coating a substantially nonmagnetic armature form with a tacky adhesive layer, and winding armature windings into a winding pattern on to said substantially nonmagnetic form using wire comprised of multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their length when located inside said armature airgap;
• said windings being applied to said substantially nonmagnetic armature form by a parallel kinematic robot that moves in said winding pattern, dispenses said wire and sequentially applies pressure to sections of said wire against said tacky adhesive layer, wherein tack of said tacky adhesive layer holds said wire to said substantially nonmagnetic armature form while during the winding process, in said winding pattern later required for magnetic torque generation;
• and
• inserting said air core armature into said armature airgap and mounting said air core armature to a stator of said motor-generator for production of magnetically induced torque between said rotor and said stator.

A process for assembly of a brushless motor-generator comprising:

• assembling a rotor of a motor-generator;
• forming an air core armature by coating a stator portion with a tacky adhesive layer, and winding armature windings into a winding pattern using wire comprised of multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their length when located inside said armature airgap,
• said winding comprising sequentially applying pressure to sections of said wire against said tacky adhesive layer, wherein tack of said tacky adhesive layer holds said windings to said stator portion while during the winding process, in said winding pattern later required for magnetic torque generation;
• and
• assembling said stator portion with said rotor for production of magnetically induced torque between said rotor and said stator.