Disclosed are various embodiments for winding heavy gauge coils of electric machines having fractional concentrated windings including one of more of positioning the middle of a predetermined length of heavy gauge wire in contact with an inclined chamfer in a face of a center projection of a fixture tool, simultaneously bending both ends of the heavy gauge wire in a first direction using the center projection to compete the first turn of the coil, simultaneously bending both ends of the heavy gauge wire in a seconding direction using the center projection to complete a second turn of the coil; continuing to simultaneously bend the heavy gauge wire in the first direction and the seconding direction until the required number of even or odd turns are completed, removing one of the adjoining right-angle faces of the fixture tool; and sliding the coiled heavy gauge wire off of the center projection.

A 3D printed metal coil for an electrical machine. The 3D printed coil has a plurality of turns and is configured to fit within a slot in an electrical machine. A cross-sectional shape of successive turns of the plurality of turns varies such that a portion of each turn forms a part of an external surface of the metal coil, the external surface forming an interface with a side of the slot.

A winding electric wire enables a space factor to be increased and an eddy current to be suppressed, despite using an easy winding process. A winding electric wire is configured such that one enameled wire or a plurality of enameled wires bundled in parallel or in a litz form are braided so as to be formed into a belt-like rectangular or square wire shape having flat braided wires forming flatly-molded layers the number that is two or a multiple of two.

The invention relates to a coil former (1) for winding conductor wire (100) into coil windings (101), in particular for subsequent insertion in a stator carrier, said coil former having a coil former front (2) and a coil former rear (3), wherein the coil former front (2) and the coil former rear (3) span, by means of a peripheral surface (4), a spiral winding path (P) around a spiral axis (W) for the conductor wire (100), and wherein support elements (10, 11) are arranged along the winding path (P) and protrude beyond the peripheral surface (4) and laterally delimit the spiral winding path (P). The invention also relates to a winding device (50) having a coil former (1) of this kind and to a method for operating the winding device (50).

Methods of winding a serpentine pattern of a stator coil and structures made from the methods. In one embodiment, a method forms a serpentine winding from a bundle of wires with a first end and a second end, then joins a first group of in-hand conductors of the second end to a second group of in-hand conductors of the first end, the result of which electrically connects a first turn to a second turn. The successive turns of the coil are connected in the same manner. In one embodiment, a method forms a multiple phase serpentine winding, such as three-phases, with coplanar radial conductors. In one embodiment, a method includes a method of forming a serpentine winding on one or more layers of a printed circuit board (PCB). In one embodiment, a method uses plated slots adjacent one or more radial torque inducing conductors to electrically connect the radial conductors of one layer to one or more corresponding radially torque inducing conductor(s) on at least one other layer. In one embodiment, a method removes the electrically conductive material on at least one end of the plated slot in order to reduce looping electrical currents. In one embodiment, a method removes the electrically conductive material from each end of a plated slot so that a pair of radially torque inducing conductors are electrically connected in series.

A mother substrate that enables winding cores to be obtained in a manner in which the mother substrate is divided along x-direction division lines and y-direction division lines is prepared. Subsequently, x-direction division grooves are formed along the x-direction division lines on a first main surface of the mother substrate, y-direction division grooves are formed along the y-direction division lines on the first main surface, and shallow bottom surface exposure grooves, for exposing surfaces that are to be core portion bottom surfaces, are formed on the first main surface. The mother substrate is divided by performing a flattening process on a second main surface of the mother substrate that is opposite the first main surface until the second main surface reaches the x-direction division grooves and the y-direction division grooves to obtain the winding cores that are separated from each other.

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 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.

Disclosed herein are a motor and a method of manufacturing the motor. The motor includes a rotor, a stator including a plurality of coil bobbin unit groups, and a coil prepared on coil bobbin units by winding a wire sequentially on coil bobbin units of each coil bobbin unit group, cutting the wound wire at a cutting point, connecting one end of the cut wire to a neutral point port, and connecting the other end of the cut wire to a driving point port.

A method for producing a coil for electric apparatus of the present invention is the method for producing a coil for electric apparatus for cutting spirally a block-shaped workpiece formed with a cylindrical portion corresponding to the coil in a circumferential direction of the cylindrical portion, the spiral coil is formed by turning a cutting means while moving it relatively to the workpiece from a part corresponding to one end of the coil to a part corresponding the other end of the coil along a machining line spirally set in the circumferential direction of the cylindrical portion. According to the invention, since the coil is formed by cutting the continuous cutting machining plane without generating a step in design from the block-shaped workpiece formed with a cylindrical portion corresponding to the coil using a wire-tool etc., it is possible to constitute a high-quality coil.