An electromechanical rotary actuator includes a stator having teeth extending inwardly from an inner wall surface, wherein free ends of each tooth form an aperture dimensioned for receiving a rotor, the free ends forming a gap therebetween. A segmented set of electrical coils extends around each tooth, wherein each coil of the segmented set has a thickness sufficient for passing through the gap between the first and second teeth. Electrically insulating tabs extend into an opening around each tooth carrying the segmented set of coils. The tabs maintain each of the coils within the segmented set in a spaced relation to the stator. When fabricating the actuator, each of the coils are fabricated and individually placed around a tooth with each coil having a thickness and breadth for optimally packing the stator.

A rotating electric machine includes: a stator core having a plurality of slots aligned along a circumferential direction; a stator having a stator coil with an enamel coating inserted into the slots of the stator core; and a rotor rotatably arranged over the stator core through a given gap. The stator coil includes: main coils of a plurality of phases in which a plurality of segment coils each having a rectangular cross-section wire formed into a substantially U-shaped wire in advance is connected to each other; a first sub-coil having a lead wire led from the slots and attached with an AC terminal, and connected to one end of the respective main coils; and a second sub-coil having a neutral wire led from the slots, and connected to the other end of the respective main coils. The lead wire and the neutral wire are each formed of a wire with a bend structure having a plurality of straights and bends.

A method of manufacturing an assembled conductor includes: arranging a plurality of peripheral wires having anisotropic cross-sectional shapes around a central wire; bundling the central wire and the peripheral wires that have been arranged, to form a conducting wire bundle; and rolling the conducting wire bundle to form the assembled conductor. The arranging includes a bending process for bending the plurality of peripheral wires in directions along imaginary lines that extend radially relative to an axis of the central wire on an imaginary plane intersecting the axis of the central wire.

A motor for a surgical instrument includes a rotor and a stator. The rotor includes a shaft and a magnet. The stator includes (i) a cavity in which the rotor is disposed, and (ii) a coil assembly. The coil assembly includes multiple phase sets. The phase sets include multiple sets of wires. Each of the phase sets includes multiple coils and corresponds to a respective one of the sets of wires. The coils in each of the phase sets are at respective positions about the rotor. One of the sets of wires includes at least three wires. The stator causes the rotor to axially rotate a surgical tool of the surgical instrument based on current received at the sets of wires.

A method for producing a coil includes winding a wire in order to produce a wound coil, and stretching the wound coil from an initial state into a stretched state with an increased spread. The method includes providing the wound coil, in the stretched state, with a coating, and transferring the wound coil from the stretched state back into a state of smaller spread.

A process for assembling a brushless motor-generator includes assembling a rotor formed from two spaced apart rotor portions having magnetic poles that drive magnetic flux circumferentially through the rotor portions and back and forth across an armature airgap formed between the rotor portions. An air core armature is formed by coating a substantially nonmagnetic armature form with a tacky adhesive layer, and winding armature windings into a winding pattern onto the substantially nonmagnetic form using wire made of multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their length when located inside the armature airgap, wherein the strands of said wire are diametrically held together by an outer serve. The winding of the armature form includes sequentially applying pressure to sections of said wire against the tacky adhesive layer.

To prevent breakage of the segment of an enameled wire that extends between a pin and a winding groove on an insulating stator base, a tension servo of an automatic wire-winding machine in controlled to first wind the enameled wire tightly around the pin of the insulating stator base and then to loosely wind the enameled wire around the pin to form at least one loose winding with a gap between the enameled wire and the pin. The enameled wire is then drawn into the winding groove of the stator base and tightly wound around the stator core within the winding groove. Optionally at least one first loose winding with a gap between the enameled wire and a bottom of the winding groove may initially be formed before tightly winding additional windings within the winding groove.

First and second winding bodies are each configured so as to have a helical shape by winding a conductor wire for m turns, where m is a natural number that is greater than or equal to two, an armature winding is configured by mounting two-lane winding bodies into respective pairs of slots, two-lane winding bodies being configured by assembling the first and second winding bodies, the coil ends include a top portion that displaces in a radial direction at a central portion, and the radial displacement at the top portion is ad, where a is a natural number that is greater than or equal to 2 and less than or equal to 2(m1), and d is a radial thickness of the rectilinear portions, 4m of the rectilinear portions being housed inside the slots so as to line up in single columns.

In a rotary electric machine according to the present invention, an armature winding includes a plurality of distributed winding bodies that are each produced by winding a single conductor wire that is insulated, that is jointless and continuous, and that has a constant cross-sectional area perpendicular to a longitudinal direction, the conductor wires include first through third coil end portions that link first through fourth rectilinear portions and first through fourth rectilinear portions, and are formed such that radial widths w of the first through fourth rectilinear portions are wider than radial widths w of the first through third coil end portions.

A stator for an electric motor includes: a stator core that includes a plurality of teeth on which insulating portions are provided; and a coil formed by winding a wire around each of the teeth. A lead-in opening and a lead-out opening are formed in insulating portions provided on an outside diameter side of the stator core. The lead-in opening leads in a crossover wire of the coil routed to an outer peripheral side of the insulating portions to the side of the teeth. The lead-out opening leads out the crossover wire of the coil from the side of the teeth to the outer peripheral side of the insulating portions. The length from an axial end portion of the stator core on an insulating portion side to the lead-in opening is different from the length from the axial end portion to the lead-out opening.