Abstract:
A method of forming a stator core assembly for an electric machine includes providing a stator core having a plurality of radially extending slots, forming a flat wire pack having a plurality of continuous electrical wires, shaping the flat wire pack into a substantially cylindrical shape, and engaging the substantially cylindrically shaped flat wire pack with the stator core such that the continuous electrical wires are interlaced within the slots of the stator core.
Abstract:
A stator core assembly having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots. A first electrical conductor and a second continuous electrical conductor are inserted within the winding slots circumferentially around the stator core. The conductors form a plurality of layers, each layer being defined as one substantially complete circumferential pass of the conductors around the stator core. Each of the conductors include a plurality of straight portions that lay within the winding slots, and a plurality of end loop portions that extend circumferentially to connect two of the straight portions. The length of the straight portions and end loop portions vary between the layers based upon the radial location of the particular layer within the stator core and a pre-determined axial height of the end loop portions.