Patent ID: 7436098

Claim:
A method of making a stator assembly for an electrical machine, the method characterized in that it includes the steps of providing a stator having a first face and a second face, the first face adapted to be positioned adjacent a rotor assembly such that an annular rotor air gap separates the rotor assembly from the stator assembly, the second face having a first set of slots defined therein and adapted to receive electrical windings therein; inserting at least one electrical winding into the first set of slots; providing a back iron adapted to be mounted to the second face; mounting the back iron and stator to one another to provide a stator assembly; and then providing a second set of slots in the first face of the cylindrical stator, the second set of slots communicating with at least some of the first set of slots, the second set of slots having a circumferential width Gg, a radial height Hg and an axial length Lg, defining an area of the second slots as a function of Hg and Lg, said stator assembly allowing for a leakage magnetic flux to flow across said second slot and around the at least one winding when current flows in said winding, this leakage magnetic circuit having a given leakage inductance, said leakage magnetic flux inducing a counter-voltage in said winding of polarity in opposition to the main voltage that causes the primary current, further characterized in that the second slots are sized by selecting given values of circumferential width Gg or area of the slot so as to have an associated leakage inductance such that the flux across said slot and around the winding induces a counter-voltage of a given magnitude so as to limit a maximum output current in the at least one winding to a pre-selected value, the pre-selected value selected to be below a current at which the machine is thermally damaged by heat generated in the at least one winding.