Controlled adjustable manufacturing method for variable laminations used

Abstract

A controlled adjustable method for forming and stacking laminations that are used in an electro-magnetic device such as a motor or transformer is disclosed. The method steps provide the incremental forming of a predetermined number of laminations from magnetically conductive material with each lamination having at least one coil winding segment of predetermined incrementally varying width. Each coil winding segment is formed by the movement of variable electrically adjustable mechanical forming elements such as punching or stamping dies or laser devices relative to magnetically conductive material. Following formation of the laminations with the aforementioned coil winding segments of predetermined incrementally varying width, the laminations, with the formed coil winding segments, are stacked to provide a combined generally circular outer winding area about which a predetermined length of conductive wire can be positioned, either directly around the winding area by the placement of a bobbin wound with the electrically conductive wire, or the wire can be wound about a split bobbin that is first assembled over the winding area for subsequent winding with the electrically conductive wire. In moving the forming elements relative to the magnetically conductive material, the forming elements can be moved in any direction in any predetermined linear and/or curvilinear path, depending on the laminations produced. As a result, a variety of different types of electro-magnetic induction devices having a reduced amount of material can be produced.