An axial flux motor for an appliance includes a stator yoke. A plurality of stator teeth extend from the stator yoke in an axial direction and are positioned about a central rotational axis. Each stator tooth includes a plurality of laminations that extend in the axial direction and form a “T” shaped member. The plurality of stator teeth are overmolded with a polymeric material to define a plurality of axial stator poles. At least one winding extends around the plurality of axial stator poles. A ring-shaped rotor rotates about the central rotational axis of the stator yoke. The rotor is positioned proximate an axial end of the plurality of axial stator poles.

A method of assembling a coil on an irregular-shaped multi-part tooth of an electric machine may include inserting at least one wedge-portion of the multi-part tooth into an opening of the coil such that a broader end of the at least one wedge-portion extends out of the opening in the coil. The method may also include mounting the coil with the inserted at least one wedge-portion on a core tooth-portion of the multi-part tooth such that the broader end of the at least one wedge-portion remains extended out of the opening in the coil, exerting a force on the broader end of the at least one wedge-portion to tighten the coil on the multi-part tooth.

An apparatus for assembling a coil includes a blade inserted into a slot of a stator core in a state where insulating paper is inserted into the slot. In a method for assembling the coil, the insulating paper is inserted into the slot of the stator core, the blade is inserted into the slot into which the insulating paper is inserted, the coil is inserted into the slot into which the blade is inserted, the coil being inserted in a direction opposite to a direction in which the blade is inserted. When the coil is inserted into the slot, the blade is pulled out from the slot along with the insertion of the coil into the slot.

A stator assembly method of assembling a stator that includes a stator core that includes a slot that has an opening that opens on one side in a radial direction, a coil that includes a slot-housed portion housed in the slot, and insulation disposed between the slot and the slot-housed portion, the method including disposing the insulation in the slot; opening a portion of the insulation on the one side in the radial direction by inserting a first guide jig into the insulation, which is disposed in the slot, along a center axis direction of the stator core, after disposing the insulation; and inserting the slot-housed portion into the slot via the opening by moving the coil and the first guide jig together toward the other side in the radial direction with respect to the stator core, after opening the portion of the insulation.

An electric machine provided with a stator structure including internal and external layers of interleaved pre-wound coils made of rectangular wire coated with enamel insulation varnish is described herein. The two layers of pre-wound coils allow the use of slightly different size of pre-wound coils, which facilitates their insertion into the stator slots.

A wave winding coil (9) has a first linear part (11a), second linear part (11b), arm part (12) and turn part (13). A retaining apparatus (1) retains the first linear part (11a) along the axis line direction between middle pins (3b, 3b) of a middle body part (3), and retains the second linear part (11b) between upper pins (2b, 2b), middle pins (3b, 3b), and lower pins (4b, 4b), in a state where sections of both ends of the second linear part (11b) in the axis line direction deviate to each other in circumferential opposite sides of the wave winding coil (9) to the axis line direction of the wave winding coil (9) and in a state where a bent angle θb′ between the second linear part (11b) and the connecting part is smaller than a bent angle θa′ between the first linear part (11a) and the connecting part.

A stator includes: a stator core; three-phase coils attached to the stator core by distributed winding; and a lacing material. A first phase coil is a coil through which a largest current flows among the three-phase coils when a current flows through the three-phase coils from a source of electric power for magnetizing a magnetic material. The first phase coil has a first region, a second region, and a third region. The lacing material is wound on the first region more than at least one of the second region or the third region.

A method of manufacturing an armature coil includes the steps of: stacking multiple armature coils to generate a stack of armature coils in a stacking direction as a first step; securing first and second ends of the stack of armature coils with a pair of clamping dies, respectively, as a second step after completing the first step; and sandwiching and depressing the stack of armature coils with pressing die in a given direction intersecting the stacking direction as a third step after completing the second step. The pressing die includes a pair of sandwiching dies to sandwich and depress the stack of armature coils in the given direction. The pair of sandwiching dies has a narrower interval at a position closer to a first end of the stack than that at another position closer to a second end thereof.

A coil insertion method includes winding U-phase, V-phase, and W-phase coils; inserting the U-phase, V-phase, and W-phase coils into a transfer block, such that the U-phase, V-phase, and W-phase coils are held in a plurality of holding grooves of the transfer block so as to spirally overlap, the transfer block having a columnar shape, and the holding grooves being formed in radial fashion around the transfer block so as to open from a center part of the transfer block toward an outer periphery thereof; inserting the transfer block into an inner periphery of the stator core; and pushing a side part of the coils held in the holding grooves radially outward toward predetermined slots of the stator core so that the coils are inserted from the inner peripheral side of the stator core into the slots.

A method of fabricating a coil for mounting on a tooth of a stator or a rotor of an electric machine includes winding a wire about a mandrel to form a coil having a first shape corresponding to the shape of the mandrel. The method may also include removing the coil having the first shape from the mandrel, and applying a mechanical force on the coil to change the shape of the coil from the first shape to a second shape. The second shape may correspond to the shape of the tooth. The method may also include mounting the coil of the second shape on the tooth.