Process for assembly of air core motor-generators

Abstract

A process for assembly of a brushless air core motor-generator includes assembling a rotor formed from two spaced apart rotor portions having magnetic poles that drive magnetic flux circumferentially through the rotor portions and back and forth across an armature airgap between the rotor portions. An air core armature is made by coating a nonmagnetic armature form with a tacky adhesive layer, and winding armature windings in a winding pattern onto the form with a winding head, using wire comprised of bundled multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their lengths where located inside the magnetic flux in the armature airgap. The armature windings are adhered to the nonmagnetic form simultaneously as the winding head traverses the winding pattern while applying pressure to the wire against the tacky adhesive, so tack of the tacky adhesive layer holds the wire to the armature form during the winding process, in the winding pattern later required for magnetic torque production. The air core armature is inserted into the armature airgap and mounted to a stator of the motor-generator for production of magnetically induced torque between the rotor and the stator.