Provided is a coil insertion device for inserting a wound coil into slots formed in a stator core and opening to a through-hole of the stator core, by placing the coil in the through-hole, and by expanding the coil to move the coil from inside toward outside with respect to the stator core. The coil insertion device includes a coil expander having a plurality of piece members arranged in an annular shape. The plurality of piece members are movable between a first position where the plurality of piece members are reduced in diameter so as to be insertable inside the wound coil, and a second position where the plurality of piece members are expanded in diameter from the first position to press the wound coil from inside toward outside, thereby inserting the wound coil into the slots at once.

Methods and apparatuses for forming a woven coil assembly (100), the coil assembly having adjacent superimposed linear portions (LI-L6, AL7-ALI2) extending parallel to each other in a first area (Al) of the coil assembly, and adjacent superimposed linear portions (L7-L12, AL13-AL18) extending parallel to each other in a second area (A2) of the coil assembly, wherein a plurality of head portions (T) connect the linear portions of the first area (AI) to the linear portions of the second area (A2).

A coil forming apparatus includes: a coil winding jig including a plurality of comb-shaped grooves; a coil conveying mechanism that pivotally conveys the belt-shaped coil along at least a portion of the outer periphery of the coil winding jig; and guide members guide the belt-shaped coil in an arc shape along an outer periphery of the coil winding jig while being in contact with the side ends, and allow the plurality of straight portions to be inserted into a respective one of the plurality of comb-shaped grooves in a second half portion of the belt-shaped coil upon pivot conveyance. The guide members include a reforming portion in a first half portion of the belt-shaped coil upon pivot conveyance, and the reforming portion deforms and reforms the belt-shaped coil in an arc shape in a state sandwiching the side ends of the belt-shaped coil.

A ferroresonant transformer assembly comprising, a core, a main shunt, first, second, and third windings, first and second tap connectors, and a selection connector. The first windings configured to be operatively connected to a primary power source. The first tap connector operatively connected to a first intermediate point defined by the third windings. The second tap connector operatively connected to a second intermediate point defined by the third windings. The selection connector operatively connected to the at least one load. Based on voltage requirements of the at least one load, the selection connector is operatively selectively connected to a selected tap connector selected from the first and second tap connectors.

A method of manufacturing an armature coil includes steps of arranging a plurality of coil conductors of the armature coil between an end metal die and a back portion metal die on a lower metal die; pressing, with the upper metal die in a pressing direction, the plurality of the coil conductors arranged between the end metal die and the back portion metal die on the lower metal die; and removing coil conductors that become formed in a convex shape and a concave shape from the lower metal die. The upper metal die may be provided with an inclined portion on a lower metal die side of the upper metal die, and the upper metal die may be configured to be pressed such that a space is formed by the dies, the space having a width that gets gradually narrower.

A method of manufacturing a coil includes forming a wound body by winding a coil wire in multiple layers, and forming a coil by pressing the wound body using a die surrounding the wound body and compressively deforming the wound body. The wound body has a contour of a rectangular or substantially rectangular shape in cross section, and includes coil wire portions located in the cross section of the coil wire, the coil wire portions being aligned along each side of the rectangular or substantially rectangular shape. The coil has a contour of a fan shape or approximate fan shape in the cross section, where the coil wire portions are aligned in a direction along an arc and a radial direction of the fan shape or approximate fan shape.

A current transformer assembly for harvesting power from a primary conductor, such as a power line, for operating electronics, where the assembly is secured to the conductor while the conductor is connected. The assembly includes a current transformer having a transformer structure with a central opening that accepts the primary conductor and a spindle member for accepting a current transformer magnetic tape operating as the core of the current transformer. The assembly also includes a tape carrier secured to the structure on which the transformer tape is wound, and a winding device operable to unwind the transformer tape from the tape carrier and wind the tape onto the spindle member.

A method of forming electronic substrates and assemblies is provided. The method includes depositing a material. The material is deposited as a powder or slurry. The method includes sintering the material, and retrieving an article, including a solid electronic substrate. Also provided are electronic substrates formed by additive manufacturing, and methods of deploying the same.

An electronic component comprises: a magnetic core having a flat base and a core, the flat base having a top, a bottom, and first and second opposite sides, the core is on the top; a winding having an edgewise coil including a wound flat wire and the core, the winding having two non-wound flat wires extending therefrom; and a magnetic exterior body covering the core and the edgewise coil. The two non-wound flat wires extend along the top, the first side, the bottom and then the second side, and the two non-wound flat wires are non-adhesively positioned around the flat base. The two non-wound flat wires on the bottom are externally exposed electrodes. The second side inclines towards the core. The two ends of the two non-wound flat wires are embedded into the magnetic exterior body to fix the two non-wound flat wires to the magnetic exterior body.

A method of inserting a winding into a stator having skewed slots formed on an inside diameter of a stator lamination includes forming a conductor having a plurality of slot segments, loading the conductor into a plurality of skewed slot elements of a linear cartridge having a first end, a second end, and a linear axis connecting the first end and the second end, the plurality of skewed slot elements being angled relative to the linear axis, transferring the conductor from the linear cartridge to a plurality of skewed slot members formed in an outside diameter of a rotary cartridge, inserting the rotary cartridge into the inside diameter of the stator lamination, and shifting the conductor from the rotary cartridge into the skewed slots of the stator.