Patent ID: 7204011

Claim:
A method for manufacturing an adaptive electric machine, comprising: fabricating a plurality of electromagnetic core elements; testing each of the electromagnetic core elements to identify electromagnetic core elements failing to meet quality control. criteria; arranging the electromagnetic core elements that meet the quality control criteria into stator segments; winding each stator segment with wire; testing each of the stator segments to identify stator segments failing to meet quality control criteria; assembling a stator from the stator segments meeting quality control criteria; fabricating rotor magnet segments comprising either permanent magnet segments, electromagnet segments or combinations thereof; testing each of the rotor magnet segments to identify rotor magnet segments failing to meet quality control criteria; assembling a rotor having rotor magnet segments meeting the quality control criteria; inserting the stator into the rotor to form an electric machine; performing a quality control test on the electric machine and producing a quality control result; and grading the electric machine in accordance with the result of the quality control test.