Method for fabricating brushless motor windings

A method of assembling windings for a brushless motor, the method comprising the steps of:

• positioning lower winding sections around a central longitudinal axis in a cylindrical shape having a plurality of annularly spaced positions such that the lower winding sections form an “n” shape around every other position starting with a first position;
• positioning upper winding sections around the longitudinal axis such that the upper winding sections form an “n” shape around every other position starting with a second position adjacent the first position, the upper winding sections being stacked on top of the lower winding sections;
• and
• connecting the lower sections to the upper sections so as to form three flat wire windings in a Y configuration.

A method of assembling windings for a brushless motor, the method comprising the steps of:

• positioning a plurality of first layer winding sections around a central longitudinal axis in a cylindrical shape having a plurality of annularly spaced positions such that the first layer winding sections for an “n” shape around every other position starting with a first position;
• positioning a plurality of second layer winding sections around the longitudinal axis such that the second layer winding sections form an “n” shape around every other position starting with a second position adjacent the first position, the second layer winding sections being stacked on top of the first layer winding sections;
• connecting the first layer winding sections to the second layer winding sections so as to form first, second, and third flat wire windings of a Delta configuration;
• positioning a plurality of third layer winding sections around the longitudinal axis such that the third layer winding sections form a “u” shape around every other position starting with the second position, the third layer winding sections being stacked on top of the second layer winding sections;
• positioning a plurality of fourth layer winding sections around the longitudinal axis such that the fourth layer winding sections form a “u” shape around every other position starting with the first position, the fourth layer winding sections being stacked on top of the third layer winding sections;
• and
• connecting the fourth layer winding sections to the third layer winding sections so as to form fourth, fifth, and sixth windings of the Delta configuration.

A method of assembling windings for a linear brushless motor, the method comprising the steps of:

• placing a first winding along a linear path having a plurality of annularly spaced positions such that the first winding forms an “n” shape around every third position starting with a first position;
• placing a second winding along the linear path such that the second winding forms an “n” shape around every third position starting with a second position adjacent the first position, the second winding being stacked on top of the first winding;
• and
• placing a third winding around the linear path such that the third winding forms an “n” shape around every third position starting with a third position adjacent the second position, the third winding being stacked on top of the second winding.