Abstract: Disclosed herein is a method for forming a rotor or stator core. The method includes the steps of: providing a plurality of key punches disposed about an inner diameter area of a sheet of electrical steel and circumferentially spaced from one another and activating a first key punch of the plurality of key punches to cut the electrical steel sheet to remove a portion to form a first key disposed at a first key rotational angle from the line of orientation from a plurality of key rotational angles.

Abstract: In a method to manufacture an improved exciter for a generator, the exciter comprising an exciter rotor, and an exciter stator, a coil of full hard cold rolled electrical steel is provided, the steel comprising at least silicon in a weight percent greater than 0.60%. Without a prior annealing of the full hard cold rolled steel coil, the coil is slit to create at least one strip. The at least one strip is stamped to create a plurality of rotor laminations and a plurality of stator laminations from the same strip. The rotor laminations are separated from the stator laminations and the set of rotor laminations and the set of stator laminations are created. Only the set of exciter rotor laminations are annealed. The annealed set of exciter rotor laminations are assembled to create the exciter rotor and the set of not annealed exciter stator laminations are assembled to create the exciter stator.

Abstract: In a method to manufacture an improved exciter for a generator, the exciter comprising an exciter rotor, and an exciter stator, a coil of full hard cold rolled electrical steel is provided, the steel comprising at least silicon in a weight percent greater than 0.60%. Without a prior annealing of the full hard cold rolled steel coil, the coil is slit to create at least one strip. The at least one strip is stamped to create a plurality of rotor laminations and a plurality of stator laminations from the same strip. The rotor laminations are separated from the stator laminations and the set of rotor laminations and the set of stator laminations are created. Only the set of exciter rotor laminations are annealed. The annealed set of exciter rotor laminations are assembled to create the exciter rotor and the set of not annealed exciter stator laminations are assembled to create the exciter stator.

Abstract: In a method for forming at least one of a circular rotor or stator lamination, at least one or two electrical strips of lamination material are provided. At least one or two of the strips are cut into segments. At least three of the segments are connected together to form a polygon having all equal sides.

Abstract: In an automotive plug ignition coil core system and method, a first core is formed of stacked laminations each of which comprises a segmented lamination strip folded around to create an enclosed loop shape. Each strip has four segments and a hinge web is provided between first and second, second and third, and third and fourth segments. A grain direction of electrical steel runs lengthwise in each of the segments. A second core inside of the closed loop first core is formed of a plurality of stacked laminations, each lamination having a grain direction of electrical steel running lengthwise.

Abstract: In a method for manufacturing a helically wound alternator core, stamping an electrical steel strip to create a lamination strip having a back-iron and projecting teeth. The lamination strip is helically wound by bending to form the helically wound alternator core. The core is then welded. Thereafter the helically wound welded alternator core is annealed.

Abstract: A method is provided for producing a magnetic core. A semi-processed cold rolled electrical steel is provided comprising .005 ? Tin ? .09% .0 < Carbon ? 0.050% .10 ? Manganese ? 1.00% .005 ? Phosphorus ? .120% .0 < Sulfur ? .010% .50 ? Silicon ? 2.50% .01 ? Aluminum ? 1.60% .0 ? Antimony < .02% Iron—at least substantial portion of balance. The semi-processed electrical steel is stamped to create stamped parts. The stamped parts are assembled and annealed after the stamping to form the magnetic core.

Abstract: In a spark plug ignition assembly for a spark plug, an ignition coil assembly has a steel laminated core, said core having a first core portion and a second core portion, and a primary winding around the first core portion and a secondary winding around the primary winding. A spark plug connecting member is provided for connecting the coil assembly to the spark plug. At least one of the first and second core portions has a slot therein with a magnet located in the slot.

Abstract: In a spark plug ignition assembly for a spark plug, an ignition coil assembly has a steel laminated core, said core having a first core portion and a second core portion, and a primary winding around the first core portion and a secondary winding around the primary winding. A spark plug connecting member is provided for connecting the coil assembly to the spark plug. At least one of the first and second core portions has a slot therein with a magnet located in the slot.

Abstract: In a method for manufacturing a helically wound alternator core, stamping an electrical steel strip to create a lamination strip having a back-iron and projecting teeth. The lamination strip is helically wound by bending to form the helically wound alternator core. The core is then welded. Thereafter the helically wound welded alternator core is annealed.

Abstract: In a lamination core, a punched material strip is wound to provide layers of the core. The material strip comprises a plurality of semi-circle individual strip segments linked by hinge-like carrying webs between adjacent split lines at adjacent ends of the respective adjacent strip segments. Each strip segment has a plurality of teeth defining slots. A segment arc angle of the segment is not equally divisible into 360° and a slot arc angle of the slots is equally divisible into the segment arc angle, so that mated lines of one winding defined by respective adjacent split lines of adjacent are laterally offset with respect to mated lines defined by respective adjacent split lines of an adjacent winding.

Abstract: In a method for manufacturing pencil cores a continuous strip of electrical steel is provided. The continuous strip is cut to create a plurality of starting strips as laminations each having a length longer than a desired length of the pencil cores and at least one of the strips having a strip width at least equal to or larger than a desired diameter of a cross-section of the pencil cores. The starting strips are provided with a bonding layer. The starting strips are stacked and then heated and cured to create a bonded stack. The bonded stack is machined to a substantially circular cross-section. Without a de-burring or de-smearing operation after the machining, the machined bonded stack is cut to create a plurality of pencil cores of the desired length. The pencil cores created by the method are substantially round, and have no welds at end faces.

Abstract: In a method for manufacturing a lamination for a motor or generator where a plurality of the laminations are used to form a core of the motor or generator, a material strip of electrical steel is provided having a width substantially corresponding to half of an outer diameter of the lamination to be created. Slant cuts are made along the material strip to form trapezoids of substantially a same area. Two of the trapezoids are joined together along a side edge of each to form a hexagon. The lamination is then stamped from the hexagon.

Abstract: In a system for processing metal, a furnace is provided which receives the metal being processed. At least one heating burner is provided in the furnace together with at least one atmosphere burner of substantially a same construction as the heating burner. An exhaust of the atmosphere burner at least partially provides an atmosphere within the furnace for the metal processing. An exhaust of the heating burner is separate from the exhaust of the atmosphere burner. A fuel feed for the atmosphere burner and a fuel feed for the heating burner are each separately controllable.

Abstract: In a system for producing a helical stator, a stator core strip is provided having a base portion with spaced tangs extending from the base portion. The strip is driven in a feed direction toward a bending region. At the bending region the strip is bent with an outside pressure member positioned to apply pressure at an outside edge of the strip base portion and with an inside pressure wheel having a plurality of teeth. A backstop surface of the teeth contact an inside edge of the base portion between adjacent tangs to support the base portion as the strip is bent by the outside pressure member. A winding arbor receives the bent strip to collect multiple turns of the bent strip to form the helical stator.

Abstract: In a system for processing metal, a furnace is provided which receives the metal being processed. At least one heating burner is provided in the furnace together with at least one atmosphere burner of substantially a same construction as the heating burner. An exhaust of the atmosphere burner at least partially provides an atmosphere within the furnace for the metal processing. An exhaust of the heating burner is separate from the exhaust of the atmosphere burner. A fuel feed for the atmosphere burner and a fuel feed for the heating burner are each separately controllable.

Abstract: In a method or system for producing a helical stator, a stator core strip is provided having a base portion with spaced tangs extending from the base portion. The strip is driven in a feed direction toward a bending region. At the bending region the strip is bent with an outside pressure member positioned to apply pressure at an outside edge of the strip base portion and with an inside pressure wheel having a plurality of teeth. A backstop surface of the teeth contact an inside edge of the base portion between adjacent tangs to support the base portion as the strip is bent by the outside pressure member. A winding arbor receives the bent strip to collect multiple turns of the bent strip to form the helical stator.

Abstract: In a method and system for an improved annealing furnace cooling and purging, atmosphere injection jets are provided in close proximity to a bottom of a tray carrying a lamination product in a cooling section. Atmospheric extraction tubes are also provided extracting atmosphere which is delivered to a high temperature variable speed fan which then outputs at a pressure side atmosphere to tubes having the injection jets. The system may be retrofit into an existing annealing furnace already having water cooled finned tubes and a recirculation fan in the cooling section. Cooling water tubes and a recirculating fan may also be provided in a purge vestibule located after an output from the cooling section for additional cooling.

Abstract: In an improved annealing furnace for laminations having a purge vestibule and an oxidation section, atmosphere injection tubes with atmosphere injection jets are provided in the oxidation section at a conveyor directly beneath trays conveying the laminations. Atmosphere extraction tubes are also provided along with a fan which draws atmosphere from the extraction tubes and provides a pressure output to the atmosphere injection tubes. The speed of the fan may be variable.

Abstract: For manufacturing a straight strip lamination, a die is provided having at least a main slot punch and a part feature punch. The strip is fed into the die station with a constant slot step distance progression with the slot punch activated to create a plurality of slots. When a part feature is to be punched, the slot punch is deactivated, the part feature punch is activated, and the strip is fed with a new step distance, which is different than the slot distance.