US4349957A — Method of making a bobbin wound stepping motor

Claim 1

Independent Claim 217 words

The method of assembling the stator of a motor having at least two annular units each including an annular coil and a toroidal core structure containing said coil, each said core structure including first and second pole parts each having an annular pole portion and said pole parts having respective sequences of poles upstanding from respective circular margins of said annular pole portions and regularly distributed in alternation but spaced apart arcuately in cylindrical array, the poles of said first annular unit being offset arcuately from the poles of said second annular unit, each pole having an air-gap-bounding surface spaced by an air gap from the rotor of the motor, including the steps of assembling one pole part of each of two toroidal core structures with their annular pole portions in slideable abutment with each other in approximate concentricity and with the poles thereof extending in opposite directions and establishing said arcuately offset relationship between said sequences of poles, adjusting said sequences of poles into concentricity by engaging said air-gap-bounding surfaces of the poles radially with a common radially adjustable concentricity establishing device that presses radially in all directions against said air-gap-bounding surfaces, and securing the pole pieces to each other in axial abutment while the pole parts are in their arcuate and concentric relationship thus established.

Claim 2

Independent Claim 217 words

The method of assembling the stator of a motor having at least two annular units each including an annular coil and a toroidal core structure containing said coil, each said core structure including first and second pole parts each having an annular pole portion and said pole parts having respective sequences of poles upstanding from respective circular margins of said annular pole portions and regularly distributed in alternation but spaced apart arcuately in cylindrical array, the poles of said first annular unit being offset arcuately from the poles of said second annular unit, each pole having an air-gap-bounding surface spaced by an air gap from the rotor of the motor, including the steps of assembling one pole part of each of two toroidal core structures with their annular pole portions in slideable abutment with each other in approximate concentricity and with the poles thereof extending in opposite directions and establishing said arcuately offset relationship between said sequences of poles, adjusting said sequences of poles into concentricity by engaging said air-gap-bounding surfaces of the poles radially with a common radially adjustable concentricity establishing device that presses radially in all directions against said air-gap-bounding surfaces, and securing the pole pieces to each other in axial abutment while the pole parts are in their arcuate and concentric relationship thus established.

Claim 3

Dependent Claim 36 words

The method of claim 1 wherein said circular margins along which said upstanding poles are distributed are inner margins of said annular pole portions, and wherein said concentrically establishing device presses radially outward in all directions.

Claim 4

Dependent Claim 262 words

The method of claim 1, the motor having at least first and second annular units each including an annular coil and a toroidal core structure containing said coil, each said core structure including a companion pair of pole parts each having an annular pole portion and said pole parts having respective sequences of poles upstanding from respective circular margins of said annular pole portions and regularly distributed in alternation but spaced apart arcuately in cylindrical array, each said pole having an air-gap-bounding surface separated by an air gap from the rotor of the motor, the companion pole parts of each said toroidal core structure having portions abutting each other axially, said method including performing the following steps (1) and (2) in succession after the steps of claim 1: (1) assembling the pole parts of the first toroidal pole structure in slideable axial abutting relationship to each other with the coil interposed between the companion pole parts thereof and with the poles of the companion pole parts interleaved and in approximate concentricity, establishing a desired arcuate relationship between the poles of said pole parts of the first annular unit, adjusting the air-gap-bounding surfaces of said interleaved poles into concentricity by engaging them with a radially adjustable concentricity establishing device that presses radially in all directions against the air-gap-bounding surfaces of the poles, and securing said companion pole part together while holding the companion pole parts in axial abutment and in their arcuate and concentric relationship thus established, and (2) the steps in the foregoing process (1) with respect to said second annular unit.

Claim 5

Dependent Claim 45 words

The method of assembling the stator of a motor as set forth in claim 3 wherein said circular margins along which the upstanding poles are distributed are inner margins of the related annular pole portions and wherein each said concentricity establishing device presses radially outward.

Claim 6

Dependent Claim 34 words

The method as in claim 1 wherein a fixture is brought into cooperation with a reference formation of each of said pole parts for establishing said arcuately offset relationship between said sequences of poles.

Claim 7

Dependent Claim 52 words

The method as in claim 1 wherein each of said assembled pole parts has a radial slot in the annular pole portion thereof and wherein a common locating element is positioned in the slots of both of the assembled pole parts for establishing said arcuately offset relationship between said assembled pole parts.

Claim 8

Dependent Claim 52 words

The method as in claim 2 wherein each of said assembled pole parts has a radial slot in the annular pole portion thereof and wherein a common locating element is positioned in the slots of both of the assembled pole parts for establishing said arcuately offset relationship between said assembled pole parts.

Claim 9

Dependent Claim 71 words

The method as in claim 3 wherein, as to each said annular unit of the motor, a first one of said companion pole parts has an annular wall that abuts the annular pole portion of a second of the companion pole parts, and wherein said cylindrical wall and the annular pole portion of said second pole part establish said slidable axially abutting relationship when the companion pole parts are initially assembled.

Claim 10

Dependent Claim 71 words

The method as in claim 4 wherein, as to each said annular unit of the motor, a first one of said companion pole parts has an annular wall that abuts the annular pole portion of a second of the companion pole parts, and wherein said cylindrical wall and the annular pole portion of said second pole part establish said slidable axially abutting relationship when the companion pole parts are initially assembled.

Claim 11

Independent Claim 209 words

The method of assembling the stator of a motor having at least one annular unit including an annular coil and a toroidal core structure containing said coil, said core structure including first and second companion pole parts each having an annular pole portion and said pole parts having respective sequences of poles upstanding from respective circular margins of the annular pole portions and regularly distributed in alternation but spaced apart arcuately in cylindrical array, each pole having an air-gap-bounding surface spaced by an air gap from the rotor of the motor, said companion pole parts having portions abutting each other axially, including the steps of assembling the pole parts of said toroidal pole structure in slidable axially abutting relationship to each other with the coil interposed between the companion pole pieces and with the poles of said pole parts interleaved in a cylindrical array and in approximate concentricity, establishing a desired arcuate relationship between the poles of said pole parts, adjusting the air-gap-bounding surfaces of said interleaved poles into concentricity by engaging them with a common radially adjustable concentricity establishing device that presses radially in all directions against said air-gap-bounding surfaces, and securing the pole parts together in axial abutment and in their arcuate and concentric relationship thus established.

Claim 12

Independent Claim 209 words

The method of assembling the stator of a motor having at least one annular unit including an annular coil and a toroidal core structure containing said coil, said core structure including first and second companion pole parts each having an annular pole portion and said pole parts having respective sequences of poles upstanding from respective circular margins of the annular pole portions and regularly distributed in alternation but spaced apart arcuately in cylindrical array, each pole having an air-gap-bounding surface spaced by an air gap from the rotor of the motor, said companion pole parts having portions abutting each other axially, including the steps of assembling the pole parts of said toroidal pole structure in slidable axially abutting relationship to each other with the coil interposed between the companion pole pieces and with the poles of said pole parts interleaved in a cylindrical array and in approximate concentricity, establishing a desired arcuate relationship between the poles of said pole parts, adjusting the air-gap-bounding surfaces of said interleaved poles into concentricity by engaging them with a common radially adjustable concentricity establishing device that presses radially in all directions against said air-gap-bounding surfaces, and securing the pole parts together in axial abutment and in their arcuate and concentric relationship thus established.

Claim 13

Dependent Claim 36 words

The method of claim 10 wherein said circular margins along which said upstanding poles are distributed are inner margins of said annular pole portions, and wherein said concentricity establishing device presses radially outward in all directions.

Claim 14

Dependent Claim 27 words

The method as in claim 10 wherein locating elements are brought into cooperation with locating formations of said pole parts, respectively, for establishing said desired arcuate relationship.

Claim 15

Dependent Claim 51 words

The method as in claim 10 wherein each of said pole parts of each said toroidal pole structure has a radial opening in the annular pole portion thereof and wherein locating portions of a fixture are positioned in said openings for establishing said desired arcuate relationship between the assembled pole parts.

Claim 16

Dependent Claim 51 words

The method as in claim 11 wherein each of said pole parts of each said toroidal pole structure has a radial opening in the annular pole portion thereof and wherein locating portions of a fixture are positioned in said openings for establishing said desired arcuate relationship between the assembled pole parts.

Claim 17

Dependent Claim 71 words

The method as in claim 10 wherein, as to each said annular unit of the motor, a first one of said companion pole parts has an annular wall that abuts the annular pole portion of a second of the companion pole parts, and wherein said cylindrical wall and the annular pole portion of said second pole part establish said slidable axially abutting relationship when the companion pole parts are initially assembled.

Claim 18

Independent Claim 65 words

The method as in any one of claims 1, 10, 2-4, 7, or 9-14 wherein said pole parts have resistance welding projections where they are in abutment initially and wherein securing the parts to each other is effected by resistance welding, and wherein said common concentricity establishing device has a pole-engaging surface of electrical insulation for avoiding welding-current paths between said poles through said device.

Claim 19

Independent Claim 66 words

The method as in claims 15, 8 or 9 wherein each of said pole parts of each said toroidal pole structure has a radial slot in the annular pole portion thereof and wherein locating portions of a fixture are positioned in said slots for establishing said desired arcuate relationship between the assembled pole parts, and wherein the abutting pole parts are secured together by resistance welding.

Claim 20

Independent Claim 216 words

The method of assembling the stator of a motor having at least one annular unit including an annular coil and a toroidal core structure containing said coil, said core structure including first and second annular pole parts each having an annular pole portion and respective sequences of poles upstanding from a circular margin of the annular pole portion and regularly distributed arcuately in cylindrical array, each pole having an air-gap-bounding surface spaced by an air gap from the rotor of the motor, said toroidal core structure and any additional core structures of the motor having adjacent annular core parts in succession along the axis of the motor, said method including the steps of assembling adjacent annular core parts of said motor to each other with the poles thereof in approximate concentricity and establishing a desired arcuate relationship between the poles of the adjacent pole parts of the motor by arcuate locating means which is spaced from said upstanding poles and which accommodates radial shift of said adjacent pole parts in relation to each other, adjusting the air-gap-bounding surfaces of said interleaved poles into concentricity by engaging them with a common radially adjustable concentricity establishing device that presses radially in all directions, and securing the adjacent pole parts together in their arcuate and concentric relationship thus established.

Claim 21

Independent Claim 216 words

The method of assembling the stator of a motor having at least one annular unit including an annular coil and a toroidal core structure containing said coil, said core structure including first and second annular pole parts each having an annular pole portion and respective sequences of poles upstanding from a circular margin of the annular pole portion and regularly distributed arcuately in cylindrical array, each pole having an air-gap-bounding surface spaced by an air gap from the rotor of the motor, said toroidal core structure and any additional core structures of the motor having adjacent annular core parts in succession along the axis of the motor, said method including the steps of assembling adjacent annular core parts of said motor to each other with the poles thereof in approximate concentricity and establishing a desired arcuate relationship between the poles of the adjacent pole parts of the motor by arcuate locating means which is spaced from said upstanding poles and which accommodates radial shift of said adjacent pole parts in relation to each other, adjusting the air-gap-bounding surfaces of said interleaved poles into concentricity by engaging them with a common radially adjustable concentricity establishing device that presses radially in all directions, and securing the adjacent pole parts together in their arcuate and concentric relationship thus established.

Claim 22

Dependent Claim 42 words

The method as in claim 18 wherein said circular margins along which said upstanding poles are distributed are inner margins of the annular pole portions of said adjacent pole parts, and wherein said concentricity establishing device presses radially outward in all directions.

Claim 23

Independent Claim 40 words

The method as in either of claims 18 or 19 wherein said arcuate locating means comprises a formation of each of said adjacent pole parts spaced from said upstanding poles thereof and portions of a fixture cooperating with said formations.

Claim 24

Independent Claim 51 words

The method as in either of claims 18 or 19 wherein said adjacent pole parts comprise a said toroidal core structure, and wherein the arcuate locating means comprises an opening in each of said adjacent pole parts spaced from said upstanding poles and parts of a fixture received in said openings.

Claim 25

Dependent Claim 54 words

The method as in claim 18 or 19 wherein the motor has at least two of said annular units, and wherein the aforesaid process of assembling, arcuately relating, concentrically adjusting and uniting an adjacent pair of pole pieces is performed successively as to each of the successive pairs of pole pieces of the motor.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1985-09-20	1986-03-22	1986-09-21	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1989-09-20	1990-03-22	1990-09-21	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1993-09-20	1994-03-22	1994-09-21	$7700.00	Window Closed / Lapsed

Method of making a bobbin wound stepping motor

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