Method of manufacturing a laminated assembly

Claim 1

A method of manufacturing an assembly for a dynamoelectric machine including a core formed of a plurality of laminations of ferro-magnetic material and having a plurality of teeth with edges of the extremities of the teeth defining a bore, the method including: axially aligning the magnetizable laminations in stacked relation and forming the assembly with edges of the lamination teeth defining circumferentially spaced apart bore surfaces of the core; positioning a member formed of a material selected to have a coefficient of thermal expansion different than the coefficient of thermal expansion of the material forming selected portions of the assembly, in close proximity to such selected portions of the assembly while the member and the selected portions of the assembly are in a first thermal state; initially transferring heat relative to the member and the assembly, to cause a first dimensional change in the member and assembly, and to force the selected portions to conform to the configuration of the portion of the member proximate thereto; subsequently transferring heat relative to the member and assembly to cause a second dimensional change in the member and material forming selected portions of the assembly thereby to return the member to the first thermal state and preselected physical configuration thereof, and to establish the preselected dimensional relationships between selected surface portions of the assembly; and separating the member and assembly the assembly including a winding having at least one group of end turns, the member including a portion for disposition proximate to the at least one group of end turns; and wherein initially and subsequently transferring heat to the member and assembly cause the portion of the member to shape the at least one group of end turns into conformity with the surface configuration of such portion.

Claim 2

A method of manufacturing an assembly for a dynamoelectric machine including a core formed of a plurality of laminations of ferro-magnetic material and having a plurality of teeth with edges of the extremities of the teeth defining a bore, the method including: axially aligning the magnetizable laminations in stacked relation and forming the assembly with edges of the lamination teeth defining circumferentially spaced apart bore surfaces of the core; positioning a member formed of a material selected to have a coefficient of thermal expansion different than the coefficient of thermal expansion of the material forming selected portions of the assembly, in close proximity to such selected portions of the assembly while the member and the selected portions of the assembly are in a first thermal state; initially transferring heat relative to the member and the assembly, to cause a first dimensional change in the member and assembly, and to force the selected portions to conform to the configuration of the portion of the member proximate thereto; subsequently transferring heat relative to the member and assembly to cause a second dimensional change in the member and material forming selected portions of the assembly thereby to return the member to the first thermal state and preselected physical configuration thereof, and to establish the preselected dimensional relationships between selected surface portions of the assembly; and separating the member and assembly the assembly including a winding having at least one group of end turns, the member including a portion for disposition proximate to the at least one group of end turns; and wherein initially and subsequently transferring heat to the member and assembly cause the portion of the member to shape the at least one group of end turns into conformity with the surface configuration of such portion.

Claim 4

A method of manufacturing an assembly comprised of a plurality of component members including a plurality of laminations each having a central bore and a plurality of teeth defining winding accommodating openings therebetween and wherein the laminations are arranged in a stack to form a magnetic core having a central bore and a plurality of teeth, the method including establishing preselected dimensional relationships between selected surface portions of the assembly with such portions defined by a material having a predetermined first coefficient of thermal expansion, the method comprising the steps: positioning dimension relationship establishing means, formed of a material selected to have a coefficient of thermal expansion different that the first coefficient of thermal expansion and having a predetermined physical configuration while in a first thermal state, in close proximity to the selected surface portions of the assembly while the material defining the selected surface portions and the relationship establishing means are in a first thermal state, the relationship establishing means including at least one metallic member having a plurality of extensions arranged for disposition between adjacent teeth of the core; heating the metallic member and magnetic core thereby to expand the metallic member and magnetic core, with the member expanding into compressive engagement with at least some of the surfaCes of the magnetic core and forcing at least the selected surface portions of the assembly to conform to the configuration of the portion of the relationship establishing means proximate thereto; subsequently cooling the member and magnetic core thereby to cause a second dimensional change in the material defining the selected surface portions of the assembly and in the relationship establishing means, to return the relationship establishing means to the first thermal state and preselected physical configuration thereof, and to establish the preselected dimensional relationships between selected surface portions of the assembly; and separating the relationship establishing means and assembly by removing the member from the magnetic core; the step of positioning including placing the extensions between adjacent teeth of the magnetic core; and the step of heating the metallic member and core including heating the extensions and thereby expanding the extensions into compressive engagement with at least portions of at least some of the core teeth.

Claim 5

A method of manufacturing an assembly comprised of a plurality of component members including a plurality of laminations each having a central bore and a plurality of teeth defining winding accommodating openings therebetween and wherein the laminations are arranged in a stack to form a magnetic core having a central bore and a plurality of teeth, the method including establishing preselected dimensional relationships between selected surface portions of the assembly with such portions defined by a material having a predetermined first coefficient of thermal expansion, the method comprising the steps: positioning dimension relationship establishing means, formed of a material selected to have a coefficient of thermal expansion different that the first coefficient of thermal expansion and having a predetermined physical configuration while in a first thermal state, in close proximity to the selected surface portions of the assembly while the material defining the selected surface portions and the relationship establishing means are in a first thermal state, the relationship establishing means including at least one metallic member having a plurality of extensions arranged for disposition between adjacent teeth of the core; heating the metallic member and magnetic core thereby to expand the metallic member and magnetic core, with the member expanding into compressive engagement with at least some of the surfaCes of the magnetic core and forcing at least the selected surface portions of the assembly to conform to the configuration of the portion of the relationship establishing means proximate thereto; subsequently cooling the member and magnetic core thereby to cause a second dimensional change in the material defining the selected surface portions of the assembly and in the relationship establishing means, to return the relationship establishing means to the first thermal state and preselected physical configuration thereof, and to establish the preselected dimensional relationships between selected surface portions of the assembly; and separating the relationship establishing means and assembly by removing the member from the magnetic core; the step of positioning including placing the extensions between adjacent teeth of the magnetic core; and the step of heating the metallic member and core including heating the extensions and thereby expanding the extensions into compressive engagement with at least portions of at least some of the core teeth.

Claim 6

A method of manufacturing an assembly of component members for a dynamoelectric machine including a core formed of a plurality of magnetizable laminations having circumferentially spaced apart bore defining teeth, and including at least one winding supported on the core, the method including establishing preselected dimensional relationships between selected surface portions of the assembly, the method comprising: applying unhardened material that will adhere to at least a selected portion of at least one of the component members, positioning dimensional relationship establishing means having a predetermined size and shape in close proximity to the selected surface portions of the assembly; heating the establishing means, assembly, and unhardened material to a temperature in a predetermined temperature range; effecting a dimensional change in the dimensional relationship establishing means whereby such means and selected surface portions move into compressive engagement thereby to force the selected surface portions to conform to a configuration determined by such means; hardening the unhardened material while heating the assembly, and thereby causing the material to adhere at least to the selected portion of the at least one of the component members; and cooling the assembly to an initial thermal state.

Claim 7

A method of manufacturing an assembly of component members for a dynamoelectric machine including a core formed of a plurality of magnetizable laminations having circumferentially spaced apart bore defining teeth, and including at least one winding supported on the core, the method including establishing preselected dimensional relationships between selected surface portions of the assembly, the method comprising: applying unhardened material that will adhere to at least a selected portion of at least one of the component members, positioning dimensional relationship establishing means having a predetermined size and shape in close proximity to the selected surface portions of the assembly; heating the establishing means, assembly, and unhardened material to a temperature in a predetermined temperature range; effecting a dimensional change in the dimensional relationship establishing means whereby such means and selected surface portions move into compressive engagement thereby to force the selected surface portions to conform to a configuration determined by such means; hardening the unhardened material while heating the assembly, and thereby causing the material to adhere at least to the selected portion of the at least one of the component members; and cooling the assembly to an initial thermal state.

Claim 10

A method of manufacturing a dynamoelectric machine assembly comprising a plurality of component members including a stack of magnetizable laminations and establishing preselected dimensional relationships between selected surface portions of the assembly, the method comprising: applying unhardened adhesive material to at least selected ones of the component members; positioning dimensional relationship establishing means having a preselected physical configuration in close proximity to the selected surface portions; effecting a first dimensional change in such means by heating the means to cause thermal expansion thereof and forcing the selected surface portions to conform to the configuration of the portion of the means proximate thereto; hardening the adhesive material while heating the means thereby to bond the adhesbie material to selected ones of the component members; effecting a secoNd dimensional change in the means; and separating the means and assembly.

Claim 11

A method of manufacturing a dynamoelectric machine assembly comprising a plurality of component members including a stack of magnetizable laminations and establishing preselected dimensional relationships between selected surface portions of the assembly, the method comprising: applying unhardened adhesive material to at least selected ones of the component members; positioning dimensional relationship establishing means having a preselected physical configuration in close proximity to the selected surface portions; effecting a first dimensional change in such means by heating the means to cause thermal expansion thereof and forcing the selected surface portions to conform to the configuration of the portion of the means proximate thereto; hardening the adhesive material while heating the means thereby to bond the adhesbie material to selected ones of the component members; effecting a secoNd dimensional change in the means; and separating the means and assembly.

Claim 12

A method of manufacturing a dynamo-electric machine assembly comprising a plurality of component members and establishing preselected dimensional relationships between selected surface portions of the assembly with such portions defined by a material having a predetermined first coefficient of thermal expansion, the method comprising: applying unhardened heat hardenable adhesive material to at least selected ones of the component members; positioning dimensional relationship establishing means formed of a material selected to having a coefficient of thermal expansion different than the first coefficient of thermal expansion and having a preselected physical configuration in close proximity to the selected surface portions; effecting a first dimensional change in the relationship establishing means and forcing the selected surface portions to conform to the configuration of the portion of said means proximate thereto; hardening the adhesive material; effecting a second dimensional change in said means; and separating said means and assembly; the step of effecting a dimensional change including transferring heat to the relationship establishing means and to the material defining the selected surface portions, thereby to cause the first dimensional change, harden the adhesive material, and bond the adhesive material to at least the selected ones of the component members.

Claim 13

A method of manufacturing a dynamo-electric machine assembly comprising a plurality of component members and establishing preselected dimensional relationships between selected surface portions of the assembly with such portions defined by a material having a predetermined first coefficient of thermal expansion, the method comprising: applying unhardened heat hardenable adhesive material to at least selected ones of the component members; positioning dimensional relationship establishing means formed of a material selected to having a coefficient of thermal expansion different than the first coefficient of thermal expansion and having a preselected physical configuration in close proximity to the selected surface portions; effecting a first dimensional change in the relationship establishing means and forcing the selected surface portions to conform to the configuration of the portion of said means proximate thereto; hardening the adhesive material; effecting a second dimensional change in said means; and separating said means and assembly; the step of effecting a dimensional change including transferring heat to the relationship establishing means and to the material defining the selected surface portions, thereby to cause the first dimensional change, harden the adhesive material, and bond the adhesive material to at least the selected ones of the component members.

Claim 15

A method for use in the manufacture of a dynamoelectric machine stator assembly having a desired bore configuration, the assembly at least including a ferro-magnetic core having a bore, and organic insulating material; the method comprising: positioning dimensional relationship establishing means in the bore of the core while the core is at an initial ambient temperature, the dimensional relationship establishing means having a size and shape to fit in the bore of the core while such means is at a temperature that at least approximates the initial ambient temperature and the dimensional relationship establishing means being formed of a material having a coefficient of thermal expansion greater than that of the core; heating the dimensional relationship establishing means, the core, and the insulating material to an elevated temperature predetermined to be both sufficiently low to be non-destructive of the insulating material and sufficiently high to cause the dimensional relationship establishing means to compressively engage the core defining portions of the core and to force movement of at least some surface portions of the bore relative to other surface portions of the bore, so that the bore of the core will conform to the shape of the dimensional relationship establishing means without destruction of the insulating material; and thereafter cooling the dimensional relationship establishing means, core, and insulating material to a final ambient temperature; to thereby establish a uniformly concentric bore configuration without destruction of the insulating material in the assembly.

Claim 16

A method for use in the manufacture of a dynamoelectric machine stator assembly having a desired bore configuration, the assembly at least including a ferro-magnetic core having a bore, and organic insulating material; the method comprising: positioning dimensional relationship establishing means in the bore of the core while the core is at an initial ambient temperature, the dimensional relationship establishing means having a size and shape to fit in the bore of the core while such means is at a temperature that at least approximates the initial ambient temperature and the dimensional relationship establishing means being formed of a material having a coefficient of thermal expansion greater than that of the core; heating the dimensional relationship establishing means, the core, and the insulating material to an elevated temperature predetermined to be both sufficiently low to be non-destructive of the insulating material and sufficiently high to cause the dimensional relationship establishing means to compressively engage the core defining portions of the core and to force movement of at least some surface portions of the bore relative to other surface portions of the bore, so that the bore of the core will conform to the shape of the dimensional relationship establishing means without destruction of the insulating material; and thereafter cooling the dimensional relationship establishing means, core, and insulating material to a final ambient temperature; to thereby establish a uniformly concentric bore configuration without destruction of the insulating material in the assembly.