Abstract: Magnetic motor component sleeves (209) for motor components with the sleeves (209) having various helpful magnetic characteristics, such as high magnetic permeability; magnetic saturation; residual (or remanent) magnetization; anisotropic magnetic properties. Method for making a magnetic linear motor shaft (202), including thermal treatment to temporarily change the dimensions of various shaft components to allow tight assembly.

Abstract: An apparatus and method for identifying the position of a magnetic shaft are provided. N field sensors are adjacently positioned at fixed locations relative to the shaft's periodic field, corresponding to 180/N relative phase shifts. A table provides N>2 predetermined signal models and a pre-identified position associated with each. An interpolator compares a representation of the N measured sensor signals to at least two predetermined models to generate a correction signal that provides another pre-identified position. The correction signal depends on N sensors for every position of the shaft. The correction signal is used to incrementally choose said another pre-identified position from the table as an approximate position of the shaft in an iterative process to find the minimum correction signal and identify the position.

Abstract: A stator assembly for a linear motor includes a plurality of interleaved modular pieces. Prewound coils and spacer pieces are alternately provided along the length of the stator. The spacer pieces have a generally trapezoidal cross section, complementary to a trapezoidal cross section of the prewound coils. Rims may be provided at an inner region of the spacer pieces. At the outer edge of the spacer pieces is provided a wall which mates with the identical wall on an adjacent spacer piece. The spacer piece may have radial slots cut entirely and/or partially through the piece in order to reduce the current and eddy currents induced when the prewound coils are energized.

Abstract: A stator assembly has a pair of end holes leading to a hollow region which has a larger diameter than the end holes. The assembly is manufactured around an elongated pole having a diameter equal to the end holes, which is surrounded by a temporary sleeve whose thickness fills the gap between the pole and the inner wall of the hollow region. The pieces of the assembly are placed onto the pole such that the sleeve lies within the hollow region, to thereby align them correctly with one another. After the pieces are secured to each other, the pole is removed, leaving the sleeve within the hollow region, and then the sleeve is removed. The sleeve may be flexible in order to expedite its removal from the hollow, and also may be of a magnetic material that is kept in place by magnetic forces generated by the stator assembly or by the pole.