Abstract: Systems and methods for constructing a motor having a stator, and a plurality of rotor sections secured to a shaft which is positioned to rotate within a bore of the stator. Each rotor section has permanent magnets forming corresponding magnetic poles. Each rotor section has first and second inwardly facing keyways which are identically positioned in each rotor section and are configured to enable each rotor section to be alternately positioned in at least three distinct circumferential orientations with respect to a key of the shaft. A first subset of the rotor sections is secured to the shaft in a first one of the circumferential orientations, a second subset of the rotor sections is secured to the shaft in a second one of the circumferential orientations, and a third subset of the rotor sections is secured to the shaft in a third one of the circumferential orientations.

Abstract: A motor for an electrical submersible pump includes a stator and rotor, where the rotor is made up of adjacent columns of magnets affixed onto an annular core. End rings on opposite ends of the core provide axial backstops for magnet columns. Thin coaxial sleeves are shrunk fit over the magnets and end rings and that radially compress the magnets. Apertures in a column are formed radially through the core and receive fasteners for securing a guide bar to the core. The guide bar simulates an installed column of magnets to guide placement of adjacent columns of magnets as the guide bar width is substantially the same as a column of magnets, and aperture locations are strategically positioned so that when the guide bar is secured onto the core. After the guide bar is removed the one of the columns of magnets is then adhered to the core.

Abstract: Systems and methods for constructing a motor having a stator, and a plurality of rotor sections secured to a shaft which is positioned to rotate within a bore of the stator. Each rotor section has permanent magnets forming corresponding magnetic poles. Each rotor section has first and second inwardly facing keyways which are identically positioned in each rotor section and are configured to enable each rotor section to be alternately positioned in at least three distinct circumferential orientations with respect to a key of the shaft. A first subset of the rotor sections is secured to the shaft in a first one of the circumferential orientations, a second subset of the rotor sections is secured to the shaft in a second one of the circumferential orientations, and a third subset of the rotor sections is secured to the shaft in a third one of the circumferential orientations.

Abstract: A combined pump and motor has a stator mounted for non-rotation in a housing. The stator has windings that create an electromagnetic field in the stator cavity when powered. An upper diffuser and a lower diffuser are mounted for non-rotation in the stator cavity. Annular clearances exist between the upper diffuser and the inner diameter of the stator and between the lower diffuser and the inner diameter of the stator. An impeller between the lower diffuser and the upper diffuser has an array of magnets circumferentially mounted around the impeller that impart rotation to the impeller in response to the electromagnetic field in the stator cavity. The array of magnets has at least one end portion extending into one of the upper and lower diffuser annular clearances.

Abstract: A combined well pump and motor includes a housing having an axis, an upstream end and a downstream end. Diffusers are mounted for non-rotation in the housing, each of the diffusers having diffuser passages. An impeller is mounted between each of the diffusers for rotation relative to the impellers. Each of the impellers has impeller vanes defining impeller passages. The impeller has an exterior outer wall extending circumferentially around the impeller vanes, closing outer sides of each of the impeller passages. An array of magnets is mounted to each of the impellers. The magnets are spaced circumferentially apart from each other around the axis at a different radial distance from the axis than the impeller vanes. A stator is mounted in the housing. The stator has windings for interacting with the magnets to impart rotation to the impellers.

Abstract: A well fluid pump has a housing with a stator having a stack of discs through which windings extend. First and second stage modules in a bore of the stator have rotating impellers and non-rotating diffusers. Magnets mounted in each of the stage modules rotate the impellers in response to electromagnetic fields generated by the windings. Anti-rotation members join adjacent ones of the impellers together in each of the stage modules for rotation in unison. A bearing assembly between the first and second stage modules has a rotatable inner portion in engagement with the impellers in the first and second stage modules for causing them to rotate in unison. The bearing assembly has a non-rotating outer portion in engagement with the stator to prevent rotation.

Abstract: A combined pump and motor has a stator mounted for non-rotation in a housing. The stator has windings that create an electromagnetic field in the stator cavity when powered. An upper diffuser and a lower diffuser are mounted for non-rotation in the stator cavity. Annular clearances exist between the upper diffuser and the inner diameter of the stator and between the lower diffuser and the inner diameter of the stator. An impeller between the lower diffuser and the upper diffuser has an array of magnets circumferentially mounted around the impeller that impart rotation to the impeller in response to the electromagnetic field in the stator cavity. The array of magnets has at least one end portion extending into one of the upper and lower diffuser annular clearances.

Abstract: A combined well pump and motor includes a housing having an axis, an upstream end and a downstream end. Diffusers are mounted for non-rotation in the housing, each of the diffusers having diffuser passages. An impeller is mounted between each of the diffusers for rotation relative to the impellers. Each of the impellers has impeller vanes defining impeller passages. The impeller has an exterior outer wall extending circumferentially around the impeller vanes, closing outer sides of each of the impeller passages. An array of magnets is mounted to each of the impellers. The magnets are spaced circumferentially apart from each other around the axis at a different radial distance from the axis than the impeller vanes. A stator is mounted in the housing. The stator has windings for interacting with the magnets to impart rotation to the impellers.