US 12,170,466 B1
Concentrated motor winding configuration and method of manufacturing
Tausif Husain, Maple Valley, WA (US); Rick Roller, Seattle, WA (US); and Sung Ho An, Seattle, WA (US)
Assigned to Amazon Technologies, Inc., Seattle, WA (US)
Filed by Amazon Technologies, Inc., Seattle, WA (US)
Filed on Jun. 7, 2022, as Appl. No. 17/834,196.
Int. Cl. H02K 15/04 (2006.01); H02K 15/06 (2006.01)
CPC H02K 15/0428 (2013.01) [H02K 15/06 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method to form a concentrated motor winding, comprising:
bending a plurality of wires into a U-shape, the U-shape including a substantially straight central portion and two substantially straight end portions, respective ones of the two substantially straight end portions extending from respective ends of the substantially straight central portion, wherein each of the plurality of wires has a same U-shape and a same length;
forming a twist along the substantially straight central portion of individual wires of the plurality of wires;
subsequent to bending the plurality of wires into the U-shape, inserting the plurality of wires laterally onto a stator pole from only a same side of the stator pole, wherein no wires are inserted laterally from an opposite side of the stator pole;
inserting two straight wires at opposite sides of the plurality of wires along the stator pole, the opposite sides including a top of a stack of the plurality of wires closer to a first end of the stator pole and a bottom of the stack of the plurality of wires closer to a second opposite end of the stator pole;
bending respective ends of the substantially straight end portions of the plurality of wires and respective ends of the two straight wires around the stator pole;
welding respective pairs of the respective ends of the substantially straight end portions of the plurality of wires and the respective ends of the two straight wires that are bent around the stator pole; and
wherein the concentrated motor winding provides a winding density greater than or equal to 70%.