Embodiments of the currently claimed disclosure are directed to methods for inserting an undulated coil assembly in the slots of a hollow core of a dynamoelectric machine. In some embodiments, the method can include positioning at least a first coil portion of the coil assembly around a support member, aligning a guide device with respect to end faces and the slots of the core, feeding the first coil portion from the drum support member along the guide device to insert adjacent superimposed linear portions (LI) of the coil assembly in the slots, engaging the superimposed linear portions (LI) along at least one guide surface during the feeding, and relatively moving the core with respect to the guide assembly device to position the slots for receiving the superimposed linear portions (LI).

A coil insertion device includes: a pair of delivery jigs respectively formed with slits into which a pair of side portions of a coil that are parallel with each other can be inserted; and a side portion inserting mechanism configured to push out the side portions inserted into the slits from the slits to insert the side portions into slots of a stator core, the slots facing the slits, the side portion inserting mechanism has: pushing blocks inserted into the slits; and a pushing block moving mechanism configured to move the pushing blocks in a depth direction of the slits.

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 (A1) 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 method and apparatus for inserting an undulated coil assembly (90) in the hollow core (101) of a dynamoelectric machine, the coil having a planar configuration with adjacent superimposed linear portions (LI) extending parallel to each other and a plurality of turn portions (T) connecting the linear portions (LI), comprising positioning at least a first coil portion (90′) of the coil assembly around a support member (200); aligning a guide assembly (302,303,304) with respect to the end faces and the slots (102) of the core (101); engaging the superimposed linear portions (LI) along guide surfaces that form a passage (301) during the feeding along the guide assembly (302,303,304); feeding the first coil portion (90) from the support member (200) along the guide assembly (302,303,304) to change orientation of adjacent superimposed linear portions (LI) being fed and to insert the adjacent superimposed linear portions being fed in the slots (102); relatively moving the core (101) with respect to the guide assembly (302,303,304) to position the slots (102) for receiving the superimposed linear portions (LI). A hollow core of a dynamoelectric machine wound with an undulated coil assembly comprising superimposed linear portions positioned at different pitch distances (PT1,PT2) in two adjacent slots (102).

A coil insertion guide device includes a positioning jig that positions a stator core; and a guide member that is provided in the positioning jig so as to be able to contact an end face of the stator core in an axial direction. A coil inserted into the slots along the radial direction of the stator core is guided by the guide members. The guide member includes a guide groove. The guide groove includes, on a side close to the end face of the stator core, a cuff support groove that houses and supports a cuff of one of the insulating members that protrudes from the end face of the stator core, and on a side far from the end face, a coil guide groove that protrudes toward an inside of the slot more than the cuff support groove and contacts the coil to guide movement of the coil.

Toroidal transformers are currently used only in low-voltage applications. There is no published experience for toroidal transformer design at distribution-level voltages. Toroidal transformers are provided with electrostatic shielding to make possible high voltage applications and withstand the impulse test.

A magnetic core (50) has a core shaft part which is inserted into a bobbin part, and configures a magnetic path of magnetic flux formed by a coil (40); the magnetic core (50) is configured by combining a pair of magnetic components (51, 52); the magnetic components (51, 52) have core ends formed so as to cross a core shaft part; the base part (20) has a fitting part which fits with at least one of the pair of core ends, when the core shaft part is inserted into the bobbin part; and the coil component (100) is characterized in that the pair of magnetic components (51, 52) and the bobbin base (10) are fixed to each other, while being bound by a sheet-like fixation member (70) which extends over the core end and the base part having been fitted to each other.

A resolver has a lead wire that can be slack even in a structure in which it is impossible to maintain the distance between an end of wound wire and a terminal pin without using a special jig. A lead wire of a stator coil 500 is entwined on a plurality of terminal pins 603 in a slack condition, and the entwined parts are fixed by soldering or welding. Terminal base 600 is then moved to a stator core 200 side, and the lead wire is made slack by contacting the lower surface of a terminal base body 601 to the upper surface of the stator core 200. Next, end part of the pins 306 of a primary insulator 300 are melted so as to fix the terminal base 600.

First and second divisional cores each including right and left leg portions and a yoke interconnecting those together are formed by molding respective yoke-side core members in a resin. Cylindrical core mounting portions extending from the outer circumference of the surface of the yoke-side core member are formed integrally with the respective right and left leg portions of the first divisional core. I-shaped leg-portion-side core members and spacers are attached in the cylindrical core mounting portion formed in each of the right and left leg portions. The surface of the yoke-side core member molded in the resin and the surface of the leg-portion-side core member are disposed so as to have a spacer therebetween. The two divisional cores are joined together by butting respective leg portions of the two divisional cores with each other to form an annular mold core, and a coil is wound around the mold core.

An electric machine is selectively operated as a transformer for AC voltage operation or as a throttle system for DC voltage operation. A transformer core has two limbs. An additional winding with a first additional partial winding is wound around a first limb and a second additional winding is wound around the second limb. A higher-voltage winding with a first higher-voltage partial winding is wound around the first additional partial winding and a second higher-voltage partial winding is wound around the second additional partial winding. A first traction winding is wound around the first higher-voltage partial winding and a second traction winding is wound around the second higher-voltage partial winding. A first DC voltage winding may be wound around the first traction winding and a second DC voltage winding may be wound around the second traction winding.