Electromechanical Limited Rotation Rotary Actuator and Method Employing Segmented Coils

A limited rotation rotary actuator comprising:

• a stator having first and second teeth extending inwardly from an inner wall surface thereof, wherein a free end of each tooth in combination forms an aperture dimensioned for receiving a rotor therein, and wherein the free end of the first tooth is in spaced relation to the free end of the second tooth to form a gap therebetween;
• and
• a segmented set of electrical coils extending around the first tooth,
• wherein each coil of the segmented set of electrical coils has a thickness sufficient for passing through the gap between the first and second teeth.

A method of fabricating a limited rotation rotary actuator, the method comprising:

• providing a stator having first and second teeth extending inwardly from an inner wall surface thereof, wherein a free end of each tooth forms an aperture dimensioned for receiving a rotor therein, and wherein the free end the first tooth is in spaced relation to the free end of the second tooth for forming a gap therebetween;
• forming a first coil having an opening therein for extending around the first tooth, wherein the coil has a thickness sufficient for passing through the gap;
• passing the first coil through the gap and positioning the first coil around the first tooth;
• forming a second coil having an opening therein for extending around the first tooth, wherein the second coil has a thickness sufficient for passing through the gap;
• passing the second coil through the gap and positioning the second coil around the first tooth;
• forming a third coil having an opening therein for extending around the second tooth, wherein the coil has a thickness sufficient for passing through the gap;
• passing the third coil through the gap and positioning the third coil around the second tooth;
• forming a fourth coil having an opening therein for extending around the second tooth, wherein the fourth coil has a thickness sufficient for passing through the gap;
• and
• passing the fourth coil through the gap and positioning the fourth coil around the second tooth.