Abstract: There is disclosed a transformer, comprising a triangular wound core; a low voltage LV winding; and at least one high voltage HV foil disc winding and a method for manufacturing a transformer coil, comprising providing a high voltage HV inner mold assembly; and winding at least one HV foil disc winding on the HV inner mold assembly. There is also disclosed a mold for manufacturing a transformer coil, comprising side gears respectively arranged at top and bottom positions of a triangular wound core; a high voltage HV inner mold assembly connected to the side gears; and a HV outer mold assembly connected to the side gears, wherein the HV outer mold assembly has a top opening across a length thereof.

Abstract: A method of manufacturing a motor for a power tool includes providing an armature configured to be coupled to a shaft. The armature includes a yoke and a first tooth and a second tooth that extend radially outward from the yoke to define a slot between the first tooth and the second tooth. Each of the first tooth and the second tooth include an inner end adjacent the yoke and an outer end opposite the inner end. The method further includes coupling a first wire guide member to the outer end of the first tooth, coupling a second wire guide member to the outer end of the second tooth, winding wire into the slot, after winding wire into the slot, compressing the wire radially into the slot, uncoupling the first wire guide member from the first tooth, and uncoupling the second wire guide member from the second tooth.

Abstract: A modular “quick-form” tooling system and stator bar form set-up method is provided for reconfigurably mounting various stator bar bending/forming tool modules that are used to produce custom bends and curvatures in a length of stator bar stock. At least one stator bar support structure is provided having a support surface formed with an array of tool location alignment holes that allow a variety of different bend-forming tooling modules to be positioned relative to each other in a manner that will define the shape of a generator stator bar during a bending/forming process.

Abstract: A winding machine includes flyers 5 rotated around a flyer rotation axis AXf orthogonal to the axis AXs of a rotor 2 constituting a work while at the same time winding wires 6 on core 23 of rotor 2. Rotor 2 is set in the winding machine in such a position that the center position of core 23 in the direction along rotor axis AXs and flyer rotation axis AXf are displaced from each other.

Abstract: A coil forming apparatus for forming a continuous-pole coil having a plurality of single-pole coils includes a winding jig rotatable around a center swing axis. The winding jig includes: a holder rotatable around a center axis of rotation different from center swing axis; and a plurality of coil bobbins arranged around said holder and mounted for reciprocal movement between advanced and retracted positions relative to the holder. Each individual coil bobbin has a winding axes which can be aligned with the center swing axis by turning the winding jig around the center axis of rotation. The single-pole coils having little twist can be stably formed for any coil bobbin to thereby form the continuous-pole coil.

Abstract: A coil-winding method comprises: winding first coil clockwise around first, counterclockwise around second, and clockwise around third swath along mandrel, hooks grouped into swaths; winding second coil clockwise around between first arid second hooks of first to between first and second hooks of second swath, counterclockwise around from between first and second hooks of second to between first and second hooks of third swath, clockwise around between first and second hooks of third to between first and second hooks of first swath; winding third coil clockwise around between second and third hooks of first to between second and third hooks of second swath, counterclockwise around from between second and third hooks of second to between second and third hooks of third swath, clockwise around between second and third hooks of third to between second and third hooks of first swath; and releasing wound coils.

Abstract: In an electric motor, magnets (4) have two pairs of poles, the number of teeth (9) is 18, and the number of segments (14) of a commutator is 18. Winding wires (12, 25) for forming an armature coil (7) are formed by a first conductive wire (110) or a second conductive wire (120). The winding wire (25) has a first coil winding wire (7A) and a second coil winding wire (7B). The coil winding wires are each wound around four teeth (9) adjacent to each other. An end (31) of the second coil winding wire is connected to a segment (14) adjacent to a segment arranged at a position which is point symmetric with respect to a segment to which an end (30) of the first coil winding wire is connected. According to the invention, in the electric motor capable of changing the rotational speed of the armature by switching application of an electric current among three brushes, vibration and operating noise can be reduced, and mounting of the connecting wires and the winding wires can be facilitated.