Method for making an electric motor winding

A method of making a stator assembly for an electric motor, generator or alternator comprising:

• fabricating a wound field by:
• continuously winding an insulated conductor about a mandrel to obtain a coil having a first plurality of individual windings wound in a first direction about said mandrel, and a second plurality of windings wound in a second direction about said mandrel opposite the first direction thereabout;
• flattening said coil to obtain a substantially flat, two-layered web having a first end and a second end, wherein a peripheral section of one of said first plurality of windings overlies a corresponding diametrically-opposite peripheral section of one of said second plurality of windings;
• and joining
• the first end of said web to the second end thereof so that a peripheral section of another of said second plurality of windings overlies a corresponding diametrically-opposite peripheral section of another of said first plurality of windings;
• inserting said wound field into a magnetic return path;
• and
• inserting a sleeve member into said wound field, said sleeve member defining an interior space in which a rotor assembly may be constrained to rotate.

A method of making a multiphase wound field for an electric motor, generator or alternator comprising:

• (a) simultaneously winding at least two insulated conductors about a common axis at axially spaced intervals in a first winding direction to form a group of at least two adjacent coil units;
• (b) axially shifting the insulated conductors with respect to the coil units by a distance of approximately (n-1) times the axial width of a coil unit, with n being the number of conductors being wound;
• (c) simultaneously winding a second group of adjacent coil units as provided in step (a) in a second winding direction which is opposite the first winding direction, the second group of coil units being adjacent to the first group of coils;
• (d) compressing the adjacent coil groups into a substantially flat, two-layered web having a first axial end and a second axial end;
• and
• (e) rolling the flat web into a wound field by joining the first axial end to the second axial end.

A method of winding a coreless and slotless stator for an electric motor, generator or alternator comprising:

• (a) simultaneously winding two insulated conductors about a common axis in a first circumferential winding direction to form a first group of two discrete axially spaced coil units;
• (b) axially shifting each of the insulated conductors with respect to said first group of coil units to a position wherein said conductors are conditioned for the winding of a second group of discrete axially spaced coil units in axially spaced relation to said first group of coil units;
• (c) simultaneously winding said conductors in a second circumferential winding direction opposite the first circumferential winding direction to form the second group of coil units;
• (d) reconfiguring all of said coil units by concomitantly
• (1) radially compressing said coil units into a substantially flat, two-layered web, and
• (2) axially displacing one layer of said web relative to the other layer of said web a distance substantially equal to the axial dimension of one of said coil groups;
• and
• joining opposite ends of said web to form a cylindrical stator and thereby superimpose the portions of the coil unit at one end of said web and lying in the first layer thereof over the portions of the coil unit lying at the opposite end of said web and in the second layer thereof whereby current flows in the same direction in each of the conductors in the superimposed layers of each coil unit thereby to produce a compatible, mutually reinforcing electro-magnetic field.

A method of making a multiphase wound field for an electric motor, generator or alternator comprising:

• (a) simultaneously winding at least two insulated conductors about a common axis at axially spaced intervals in a first winding direction to form a first group of at least two adjacent coil units;
• (b) axially shifting the at least two insulated conductors by a predetermined distance relative to the first group of coil units;
• (c) simultaneously winding the at least two axially shifted conductors about the common axis at axially spaced intervals in a second winding direction opposite the first winding direction to form a second group of at least two adjacent coil units;
• (d) flattening the first and second groups of coil units to form a substantially flat, two-layered web having a first axial end and a second axial, wherein a peripheral section of each respective coil unit in said first group overlies a diametrically-opposite peripheral section of a corresponding coil unit in said second group;
• and
• (e) joining the first axial end of said flat, two-layered web to the second axial end of said flat, two-layered web.

A method of making a wound field for a multiphase electric motor, generator or alternator comprising the steps of:

• continuously winding at least two insulated conductors about an axis at axially-spaced intervals so as to obtain an even number of adjacent coil groups including a first coil group and a last coil group, each coil group including adjacent coil units, each coil unit of any one of said coil groups being wound from a different one of said insulated conductors, the coil units of each successive coil groups being wound in a direction opposite that of the preceding coil group;
• flattening the coil groups to obtain a substantially flat, two-layered web having a first axial end and a second axial end, such that a peripheral section of each coil unit in the first coil group overlies a corresponding diametrically-opposite peripheral section of each coil unit of a successive coil group also wound from the same one of said insulated conductors;
• and
• joining the first axial end of said web to the second axial end thereof, such that a peripheral section of each coil unit of the last coil group overlies corresponding diametrically-opposite peripheral section of the coil unit of the first coil group also wound from the same one of said insulated conductors.

A method of making a wound field for a multiphase electric motor, generator or alternator comprising the steps of:

• winding at least two insulated conductors about an axis at axially-spaced intervals in a first direction to form a first group of at least two adjacent coil units wound in said first direction, each of said coil units having a nominal axial width;
• axially shifting said insulated conductors with respect to the coil units of said first group by a distance related to the nominal axial width of the coil units;
• winding said insulated conductors about said axis at axially-spaced intervals in a second direction which is opposite the first direction to form a second group of at least two adjacent coil units wound in said second direction, said second group of coil units being adjacent to the first group of coil units;
• flattening the coil groups to obtain a substantially flat, two-layered web having a first axial end and a second axial end, such that a peripheral section of a first one of the coil units wound in the first direction overlies a corresponding diametrically-opposite peripheral section of a first one of the coil units wound in the second direction;
• and
• joining the first axial end of said web to the second axial end thereof, such that a peripheral section of a second one of the coil units wound in the second direction overlies a corresponding diametrically-opposite peripheral section of a second one of the coil units wound in the first direction.