Airex Corporation

James Sedgewick

David J Carroll

Michael Drew

Richard D Sedgewick

The present invention provides a rotational magnetic gimbal with an integral magnetic bearing. Brushless DC motor technology provides electromagnetic suspension, using a single electromagnetic actuator to perform both the radial bearing and rotary torque (motoring) functions. An integrated motor and magnetic bearing consistent with the invention comprises a rotor comprising a plurality of permanent magnets and a stator comprising a plurality of independently controlled coil segments magnetically coupled to the permanent magnets. Embodiments may further comprise first and second radial position sensors, the first radial position sensor disposed in or adjacent to a clearance gap between the rotor and the stator for sensing the position of the rotor with respect to the stator along a first axis, and a second radial position sensor disposed in or adjacent to the clearance gap between the rotor and the stator for sensing the position of the rotor with respect to the stator along a second axis. In method form, a method for providing integral electromagnetic motor and bearing functions comprises sensing a first radial position of a rotor, the rotor comprising a plurality of permanent magnets, with respect to a stator along a first axis, the stator comprising a plurality of independently controlled coil segments magnetically coupled to the permanent magnets; and sensing a second radial position of the rotor with respect to the stator along a second axis; and delivering current to at least one coil segment, the amount of current based on at least one sensed position.

Integrated magnetic bearing

A coil winding system and process is provided that includes a coil winding fixture and a coil press fixture. The coil winding fixture includes a pair of winding arms each having a set of in-line winding pins. The sets of in-line pins are arranged parallel to one another in one axis, and form an angle to another axis. Magnetic wire is machine wound into the slots between the pins to form coil phases, and, advantageously the individual coils can be wound together to minimize spatial tolerance build-up between phases. Likewise the slots are arranged parallel and adjacent one another to ensure that each winding is parallel to the next to maximize efficiency of the coils. The press fixture includes a forming press and a saddle to form the wound coils into a predetermined shape using heat and pressure applied to the press fixture.

Method and apparatus for winding and forming motor coil assemblies

The present invention provides a linear motor assembly that uses keying technique to provide a uniform mechanical interface for linear motor coils to the mount or mounting bracket. This permits a molded coil assembly to be built as a subassembly, so that later insertion into brackets of varying configurations is possible. The keying technique locks the coil to the mount or mounting bracket, and accommodates many different bracket configurations without modification to the coil assembly. The coil is keyed to the bracket and may be attached with an adhesive such as an epoxy bond or thermal grease to improve the thermal dissipation from the motor to the mounting surface. This subassembly can be pre-manufactured and transformed to an application-specific assembly with relative ease in a short period of time. Bracket or mounting options may include various cooling features such as water or air-cooling. The subassembly can also be integrated directly to a linear system comprised, for example, of bearings or encoders. This eliminates the need for a separate mounting bracket, and improves heat dissipation.

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York, ME, United States of America

James Sedgewick