Manufacturing technology for continuous high-density coils for brushless motors

This paper reports on our development of a manufacturing technology for continuous high-density coils and terminal processing for high performance motor stators. We have developed a “series winding and collective forming method”. The coils are wound in series, and their slot insertion parts are collectively formed and clung. Four continuous and high-density coils with a slot-fill rate of 75% were prepared using the developed winding form and manufacturing facilities. Moreover, terminal insulation of the continuous coils was established with the developed wiring board. A 60% decrease in man-hours and 95% decrease in the cost of the board can be expected by using our technique rather than conventional printed circuit board manufacturing techniques.