A coil is configured with stacked n turns (where n is an integer of 2 or more) of spirally wound conductive wire having a rectangular cross-section. A k-th turn (where k is an integer and 1≤k≤n) of the coil has at least a straight portion and a corner portion extending from an end part of the straight portion. On an outer peripheral surface of the corner portion, there are formed at least a first bent portion bent toward an inner peripheral side and a second bent portion bent toward the outer peripheral side, and curvature C1 of the first bent portion is different from curvature C2 of second bent portion.

A coil is configured with stacked n turns (where n is an integer of 2 or more) of spirally wound conductive wire having a rectangular cross-section. A k-th turn (where k is an integer and 1≤k≤n) of the coil has at least a straight portion and a corner portion extending from an end part of the straight portion. On an outer peripheral surface of the corner portion, there are formed at least a first bent portion bent toward an inner peripheral side and a second bent portion bent toward the outer peripheral side, and curvature C1 of the first bent portion is different from curvature C2 of second bent portion.

Systems and methods for manufacturing stators for electric submersible pumps, where a stator core having an inner portion and an outer portion is formed. The inner portion has a plurality of teeth and outward-facing slots. Magnet wire coils are formed on the inner portion by holding the inner portion in a stationary position and using a linearly movable robotic arm to position the magnet wire in each slot while preventing the wire from sliding axially with respect to the stator and adjacent turns of the coil. After forming the magnet wire coils on the inner portion of the stator core, the outer portion of the stator core is press-fit onto the inner portion to close the slots. The magnet wire can thereby be positioned to maximize the fill factor of each slot and increase power density for a given temperature rise.

A stator includes a yoke extending in a circumferential direction about an axis line, a tooth extending from the yoke in a first direction toward the axis line, and a coil wound around and fixed to the tooth. The yoke has an inner wall surface facing the axis line. The tooth has a root part connected to the yoke. The inner wall surface of the yoke is a flat surface extending from an end of the root part of the tooth in the circumferential direction to an inner circumferential side relative to a plane passing through the end and perpendicular to the first direction.

A stator includes a yoke extending in a circumferential direction about an axis line, a tooth extending from the yoke in a first direction toward the axis line, and a coil wound around and fixed to the tooth. The yoke has an inner wall surface facing the axis line. The tooth has a root part connected to the yoke. The inner wall surface of the yoke is a flat surface extending from an end of the root part of the tooth in the circumferential direction to an inner circumferential side relative to a plane passing through the end and perpendicular to the first direction.

A rotor of an electric motor includes a rotor package with a plurality of radially directed rotor teeth and a commutator with a number of commutator bars which is twice as large as the number of rotor teeth. Diametrically opposed commutator bars are respectively connected to a contact bridge. A rotor winding includes a plurality of coils wound on the rotor teeth. Each coil has first and second coil ends and the first and second coil ends of each coil are connected directly to commutator bars that are not adjacent to each other. A method for manufacturing a rotor and an electric motor, are also provided.

An electromagnetic pole for a rotary electric machine with an axis of rotation is disclosed. The electromagnetic pole has a tooth comprising a tooth core of magnetic material. The tooth core is a laminated tooth core comprising a plurality of steel plates stacked in the direction of the axis of rotation. The electromagnetic pole also has a coil with a wire wound around the tooth core and at least one outer layer of the wire and one under layer of the wire. First portions of the wire of the outer layer are secured with second portions of the wire of the under layer by an adhesive material covering at least partially one of the first portions of the wire. A rotor comprising such electromagnetic poles, an electric machine comprising such a rotor, and a method for producing such an electromagnetic pole are also disclosed.

Apparatus (1) and method for winding coils (B) of a wire conductor (W) around respective radial poles (10c) of a core (10) of a dynamo electric machine component. The apparatus (1) comprises a wire dispenser arm (11) which rotates about a radial pole (10c) at a time to dispense the wire conductor (W) forming the turns (S). A first wire guide (32) is, furthermore, provided positioned at a first axial end (A) from the radial pole (10c) being wound and moved along a moving direction (132a, 132b) parallel to the radial direction (110c) of the radial pole (10c) to form a respective coil (B). A second and a third wire guide (36, 37) are, furthermore, provided positioned respectively, in a first and in a second slot (10a, 10b) adjacent to the radial pole (10c) being wound at opposite sides. The second and the third wire guides (36, 37) are positioned with respect to the first wire guide (32) in such a way to form at least a respective passageway (38a, 38b, 38′a, 38′b) for the wire conductor W. The apparatus (1) comprises, furthermore, at least a first and a second guide portion (35a, 35b, 35′a, 35′b) coplanar to each other in order to close, at least partially, the, or each, passageway (38a, 38b, 38′a, 38′b) during winding of the radial pole (10c).

Apparatus (1) and method for winding coils (B) of a wire conductor (W) around respective radial poles (10c) of a core (10) of a dynamo electric machine component. The apparatus (1) comprises a wire dispenser arm (11) which rotates about a radial pole (10c) at a time to dispense the wire conductor (W) forming the turns (S). A first wire guide (32) is, furthermore, provided positioned at a first axial end (A) from the radial pole (10c) being wound and moved along a moving direction (132a, 132b) parallel to the radial direction (110c) of the radial pole (10c) to form a respective coil (B). A second and a third wire guide (36, 37) are, furthermore, provided positioned respectively, in a first and in a second slot (10a, 10b) adjacent to the radial pole (10c) being wound at opposite sides. The second and the third wire guides (36, 37) are positioned with respect to the first wire guide (32) in such a way to form at least a respective passageway (38a, 38b, 38′a, 38′b) for the wire conductor W. The apparatus (1) comprises, furthermore, at least a first and a second guide portion (35a, 35b, 35′a, 35′b) coplanar to each other in order to close, at least partially, the, or each, passageway (38a, 38b, 38′a, 38′b) during winding of the radial pole (10c).

A brushless direct current motor, a stator part and its winding method are provided. The stator part includes a stator core and stator windings wound around stator poles. The stator poles and the stator windings are arranged in a one-to-one correspondence with each other. The stator windings are formed by winding a single conductive wire uninterruptedly on the stator poles. Two ends of the conductive wire are connected.