Needle winding for high density copper filled internal tooth electric motor stator and method thereof
By adopting a segmented stator device in the electric motor, using multiple tooth segments and rotatable winding tools, the problem of poor coil winding in the prior art is solved, and higher power density and stability are achieved.
Patent Information
- Application Number
- CN202380040033.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-03-30
- Filing Date
- 2023-03-30
- Publication Date
- 2024-12-20
AI Technical Summary
When the coil is wound in existing electric motors, the width of the needle is limited by the tooth gap, resulting in poor winding effect of wires and may break, affecting the stability and power of the motor.
Using a segmented stator device, by setting a movable multiple tooth segments and a rotatable winding tool in the winding nest, the needle is used to wrap the wires in a larger space between the tooth segments, forming a denser coil to fill the tooth segments. space between.
The stability and power density of the electric motor are improved, the cogging effect is reduced, and the robustness of the finished stator and the wire filling density are enhanced.
Smart Images
Figure CN119174097A_ABST
Abstract
Description
Technical Field
[0001] The exemplary and non-limiting embodiments relate generally to electric motors and, more particularly, to an apparatus and method for winding coils on a stator of an electric motor. Background Art
[0002] The coils used in electric motors are typically placed in slots formed between radially inwardly extending teeth of the stator by winding copper wire directly onto structures forming the stator teeth. In one method of winding the wire to form the coils, the wire is fed directly onto and around the tooth structures from a spindle or winding tool. The winding operation is performed by directing the wire to the desired position on the teeth as the wire is fed from the winding tool, which is supported within the stator and configured for reciprocating rotational motion relative to the teeth of the stator. The reciprocating radial motion performed while feeding the wire through the winding tool facilitates placement of the wire within the slots formed by the teeth of the stator. Summary of the invention
[0003] The following summary is by way of example only. This summary is not intended to limit the scope of the claims.
[0004] According to one aspect, an apparatus for connecting a plurality of stator segments to form a stator for an electric motor includes: a winding nest; a plurality of stator segments coupled to the winding nest, the stator segments being movable in a radial direction relative to an axis on the winding nest, the stator segments being movable between an inwardly retracted position and an outwardly extended position; and a winding tool removably positionable in the winding nest and rotatable about the axis, the winding tool being positionable between a first position outside the winding nest and a second position in the winding nest. The winding tool, when positioned in the second position in the winding nest, is configured to controllably wind wire around the plurality of stator segments when the stator segments are positioned in the outwardly extended position. When the winding tool is positioned in the first position and after winding the wire, the stator segments are positioned in an inwardly retracted position to form a wound segmented stator.
[0005] According to another aspect, an apparatus for forming a segmented stator for an electric motor includes: a winding nest including a base and a plurality of retainers removably arranged on the base in a circular pattern, the retainers being positioned to be extendable in a radially outward direction and retractable in a radially inward direction; a plurality of tooth segments attachable to the retainers; and a winding tool having a needle and movable from a first position outside the winding nest to a second position in the winding nest, the winding tool being configured to receive wire from an upstream wire source and feed the wire through the needle. When the retainer is extended in a radially outward direction, the winding tool is movable from the first position to the second position so that the needle is extendable between the tooth segments and the winding tool is movable in at least two directions to wind the wire around the tooth segments to form a coil around the tooth segments. When the winding tool is movable from the second position to the first position, the retainer is retractable in a radially inward direction and the tooth segments are connected through the formed coil to form the segmented stator.
[0006] According to another aspect, a method of forming a segmented stator for an electric motor includes: securing a plurality of tooth segments to a winding nest, the tooth segments being secured to the winding nest in a radially expanded position; positioning a winding tool in the winding nest; operating the winding tool to wind wires around the tooth segments to form coils; removing the winding tool from the winding nest; folding the tooth segments inwardly in a radial direction; and performing final wiring on the folded tooth segments to form a segmented stator.
[0007] According to another aspect, a segmented stator for an electric motor includes: a plurality of tooth segments arranged in a circular configuration, the tooth segments having a body portion and a front surface extending inwardly from the body portion; and a wire wound on the body portion. A distance between adjacently positioned front surfaces of the tooth segments is less than a width of the wire. The wire wound on the body portion substantially fills a space between adjacently positioned tooth segments. BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The above aspects and other features are explained in the following description in conjunction with the accompanying drawings, in which:
[0009] Figure 1 is a schematic diagram of windings stacked in layers for forming a stator of a one-piece electric motor;
[0010] Figure 2 yes Figure 1 A close-up diagram of the windings;
[0011] Figure 3 is a schematic diagram of an example embodiment of a segmented winding for forming a plurality of tooth segments of a segmented stator;
[0012] Figure 4 yes Figure 3 A close-up diagram of the segmented winding;
[0013] Figure 5 is a perspective view of a tooth segment for forming a segmented winding of a segmented stator;
[0014] Figure 6 is a perspective view of a winding nest for segmented windings with the tooth segments in the "open" position;
[0015] Figure 7 yes Figure 6 A perspective view of a winding nest with the tooth segments in the "closed" position;
[0016] Figure 8 is a perspective view of a winding nest showing one tooth segment in an "open" position and one tooth segment in a "closed" position;
[0017] Fig. 9 is a flow chart showing example steps in a method of forming an example segmented stator; and
[0018] Fig.10 It is a comparison Figure 1 The stator and Figure 3 Schematic diagram of a segmented stator to illustrate the difference in wiring density. DETAILED DESCRIPTION
[0019] refer to Figure 1 and Figure 2 , a conventional winding of a one-piece electric motor laminate stack is generally shown at 100 and is hereinafter referred to as "winding 100". Winding 100 is performed using a winding nest 110 that is supported for rotatable movement using a motor. The winding nest 110 includes an outer ring 120 having a plurality of twelve inwardly extending teeth 130 with gaps between each tooth 130 and formed as a stack of stamped metal sheets. A winding shaft or winding tool 140 is positioned in the outer ring 120 to extend upward through the winding nest 110. The winding tool 140 is supported on a shaft having a wire guide that guides a wire 150 into the winding tool 140 and feeds the wire 150 through a needle 160. The winding tool 140 is driven by a drive mechanism positioned below the winding nest 110 to perform a reciprocating oscillating or rotating motion. The reciprocating oscillating or rotating motion of the winding tool 140 facilitates wrapping or winding of the wire 150 to form a coil around each tooth 130 , with the continuously wound wire 150 and teeth 130 forming the stator 170 .
[0020] refer to Figure 2During operation, the needle 160 extends into the gap between each tooth 130 to wrap or wind the wire 150 around each tooth 130 to form a coil. The size of the physical gap between each tooth 130 is typically a compromise decision based on the electrical design performance of the finished electric motor, the maximum magnet winding wire size / gauge, the needle design (the width and strength required for the winding force without damaging the wire or causing the wire to bend beyond the gap), and the gap for the needle 160 between the teeth 130 of adjacent wound coils. For example, when winding the coil onto the teeth 130 that are fixed in place, the width of the needle is limited to the amount of space between each tooth 130. Thinner needles (such as needle 160) may bend, which may result in a less effective winding pattern for the wire, and / or they may break, thereby completely interrupting the winding operation. As shown, even if the wire 150 is tightly wound around each tooth 130, a large amount of space or gap remains between the front surfaces of the teeth 130 when the needle 160 is retracted. Having such a large gap between the front surfaces of adjacent teeth 130 (since the teeth 130 must accommodate the pins 160) may impair the smoothness of the motor operation, resulting in a large amount of cogging. In addition, since there are fewer wires 150, the unfilled space between the coils may affect the power of the motor.
[0021] Reference now Figure 3 and Figure 4 , an example embodiment of a segmented stator lamination and custom winding is generally shown at 200 and is hereinafter referred to as "segmented winding 200." The example segmented winding 200 is made using a winding nest 210 that is supported for rotatable movement using a motor.
[0022] The winding nest 210 supports a plurality of tooth segments 230, each of which is formed from a plurality of stamped metal sheets. Each of the tooth segments 230 is wound with wire 250 and then assembled to produce an example segmented stator 270 (eg, Fig.10 270 in FIG. 1 ).
[0023] In forming the segmented winding 200, a winding tool 240 is positioned to extend upward through the winding nest 210, the winding tool 240 is supported on a shaft having a wire guide that receives the wire 250 from an upstream source, guides the wire 250 into the winding tool 240, and feeds the wire 250 through a needle 260 (or other wire feeding mechanism) extending from the winding tool 240. The winding tool 240 is driven by a drive mechanism positioned below the winding nest 210 to perform reciprocating oscillating or rotating motion about the shaft. The reciprocating oscillating or rotating motion of the winding tool facilitates the movement of the needle 260 so as to wind the wire 250 around each tooth segment 230 when the tooth segments 230 are spaced apart in the extended position. The wire 250 is wrapped or wound to form a coil, and the continuously coiled wire 250 and tooth segments 230 form a segmented stator 270. As shown, the needle 260 is larger than the tooth segment 230. Figure 2 The needle 160 is thicker, and because the amount of space between the tooth segments 230 is increased during the winding operation, the needle 260 can be more easily accommodated in the segmented winding 200, which results in a stronger finished stator and allows more wires 250 to be disposed between adjacent tooth segments 230 (the space between the tooth segments 230 is more completely filled). A programmable controller 290 including a processor and at least one memory with software can be provided for controlling the winding operation.
[0024] Although twelve tooth segments 230 are shown arranged to form the segmented stator 270, any number of tooth segments 230 may be assembled with respect to the disclosed example embodiments. Figure 4 As shown, the rear end of each tooth segment 230 includes a protrusion 423 on one side and a groove 424 on the other side, so that when the tooth segments 230 are folded together from the extended position to the retracted position on the winding nest 210, the protrusion 423 engages with the corresponding groove 424 and can be assembled into a ring.
[0025] refer to Figure 5 , shows an example embodiment of a tooth segment 230 supported on a retainer 300. The retainer 300 includes a clamp 310 or clamping portion, which is configured to hold, clamp or otherwise support the tooth segments 230, each of which is formed as a stack of metal stamping laminations. The clamping effect can be achieved by screws 235 or any other suitable means. The retainer 300 also includes an adjustment portion 340, which has a slot 350 disposed therein, and the slot 350 is configured to allow the retainer 300 to receive a locking pin 450 and be slidably and adjustably positioned and secured to the winding nest 210. A guide pin 422 depends from the bottom of the retainer 300, and the guide pin 422 is configured to engage in the angled channel 470 and slide therein (such as Figure 8 As shown), in order to realize the opening and closing of the retainer 300 on the winding nest 210.
[0026] refer to Figure 6 and Figure 7 , the winding nest 210 is shown in more detail. Figure 6 As shown, the winding nest 210 includes a plurality of retainers 300, which are movably arranged in a radial direction on a base 420 rotatable around an axis A, and the base 420 is supported on a support table 430. Figure 6 As shown, the winding nest 210 is in an open or winding position, with the winding tool 440 shown in the center. The winding tool 440 can be a winding gun available from WGE Equipment Solutions (Fort Wayne, Indiana). Each retainer 300 is positioned to extend in a radial direction on the base 420 to provide a maximum amount of space between each individual tooth segment 230, thereby allowing maximum filling of the wire 250 on each tooth segment 230. The wire 250 can be copper, but other materials may also be suitable for the wire. Each retainer 300 is fixedly positioned on the base 420 via a locking pin 450, which extends through each corresponding slot 350 and is received in the base 420.
[0027] refer to Figure 7 , the winding nest 210 is in the "closed" position on the base 420. As shown, the tooth segment 230 is not wired. Before being placed in the closed position (for example, if the wiring process has been performed, the final wiring is performed), the winding tool 240 is removed from the winding nest 210.
[0028] refer to Figure 8, the winding nest 210 is shown with two retainers positioned on the base 420, the first retainer 300a is in an open position and the second retainer 300b is in a closed position. The base 420 includes recesses 410 (12 recesses 410, each recess 410 correspondingly accommodating a corresponding retainer 300) extending radially from the center of the base 420 to the outer edge. When the retainers 300 are positioned in the recesses 410 on the base 420, the guide pins 422 hanging down from the bottom of each retainer 300 extend through the slots 465 in the base 420 and are positioned in the corresponding angled channels 470 in the rotating ring 480 below the base 420. The knob handle 455 is used to rotate the rotating ring 480 below the base 420. For example, when the knob handle 455 is turned clockwise, the base remains in a fixed position while the rotating ring 480 rotates in a first direction, and the angled configuration of the channel 470 in the rotating ring 480 causes the guide pins 422 extending from the bottom of each retainer 300 to be driven radially inward to "close" the retainer 300 on the base 420. Then, the locking pin 450 can be turned to lock the retainer 300 in place. For example, turning the knob handle 455 counterclockwise causes the rotating ring 480 to rotate in a second direction opposite to the first direction, thereby causing the guide pins 422 to be driven radially outward to "open" the retainer 300. The retainers 300 all move in unison or synchronously to open or close. As shown, the retainer 300a is in an open position and the retainer 300b is in a closed position, which is only used to illustrate the travel limit of the retainer 300.
[0029] refer to Fig. 9, a flow chart illustrating an example method of winding a single layer of stator teeth is generally shown at 900 and is hereinafter referred to as "method 900". In method 900, as shown in step 910, a plurality of tooth segments are clamped or otherwise secured to respective retainers. Each tooth segment may include a plurality of stamped metal laminations stacked to form the tooth segment. At step 920, each retainer is slidably positioned on a circular winding nest so as to be extendable and retractable in a radial direction. The retainer extends in a radial direction. At step 930, a winding tool is positioned between the retainers in the winding nest. At step 940, when the tooth segments are positioned in an extended radial direction, wires are wound from the winding nest onto each tooth segment to form an expanded wired stator assembly. At step 950, the winding tool is removed from the winding nest. At step 960, the retainer is retracted in a radial direction to fold the wired tooth segments. At step 970, final wiring is performed on the folded wired tooth segments to form a segmented stator. The segmented stator, which is a collection of individual tooth segments bundled together with wires, may be somewhat flexible. For example, final wiring may be performed after removing the flexible segmented stator from the winding nest, placing the segmented stator on a holder or the like, and compressing the elements of the flexible stator together. Before or after final wiring, the wired tooth segments may be mounted to a printed circuit board and secured into a rigid form with epoxy or other means.
[0030] refer to Fig.10 , a comparison of stator 170 and segmented stator 270 is shown as 1000. As shown in stator 170, the gaps 990 between adjacent teeth 130 created by the accommodation of pins 160 are not used for wiring, while in segmented stator 270 formed using the segmented winding process, the gaps between adjacent tooth segments 230 have been filled with wires 250 to form a denser wiring arrangement.
[0031] In the segmented stator 270, when the tooth segments 230 are assembled and mounted within the outer ring 295, the front surfaces 296 are spaced apart from each other by a distance less than the width of the wire 250. Thus, the segmented stator 270 has a narrower gap between the front surfaces of adjacently positioned tooth segments 230 and a denser copper fill in the body portion 297 than the stator 170. The narrower gap may result in less power being produced, but any reduction in power can be recovered by the denser copper fill in the body portion 297. In the segmented stator 270, since the individual tooth segments 230 can be placed in a winding nest of a larger diameter than a conventional winding nest, the performance of the finished electric motor is not compromised by the placement of the individual segments of the stator. This eliminates the physical design constraints of needle winding and provides maximum copper fill between adjacently positioned teeth in the stator 270 to substantially fill the space. Substantially filling the space means that the space is not configured to accommodate additional wires 250. The maximum copper fill coupled with the closer spaced tooth segments (smaller than the width of the wire 250) compared to prior art motors provides a motor that operates at a lower amount of cogging but at a higher power, which runs more smoothly than a motor with stator teeth spaced farther apart and fewer copper wire wraps. Furthermore, the wrapping of a wire of a particular diameter or gauge is not limited to the design width or tooth gap of the needle. Furthermore, the needle width is not limited to a compromise design combination of a one-piece design selection of tooth gap and wire gauge.
[0032] Features described herein may be provided in an apparatus. Features described herein may be provided in an assembly method for assembling an apparatus. Features described herein may be provided in a method of using an apparatus having the above features. Features described herein may be provided in control software, embodied in a memory and capable of being used with a processor, or controlling an apparatus by movement as described above.
[0033] In one example embodiment, an apparatus for connecting a plurality of stator segments to form a stator for an electric motor includes: a winding nest; a plurality of stator segments coupled to the winding nest, the stator segments being movable in a radial direction relative to an axis on the winding nest, the stator segments being movable between an inwardly retracted position and an outwardly extended position; and a winding tool removably positionable in the winding nest and rotatable about the axis, the winding tool being positionable between a first position outside the winding nest and a second position in the winding nest. The winding tool, when positioned in the second position in the winding nest, is configured to controllably wind wire around the plurality of stator segments when the stator segments are positioned in the outwardly extended position. When the winding tool is positioned in the first position and after winding the wire, the stator segments are positioned in an inwardly retracted position to form a wound segmented stator.
[0034] The stator segments may be removably coupled to a retainer, the retainer being movable in a radial direction between an inwardly retracted position and an outwardly extended position. The retainer may be movable between the inwardly retracted position and the outwardly extended position in a synchronized motion. The winding tool may include a needle, the winding tool being configured to receive a wire from a wire source and to wind the wire around the stator segments as the wire is fed through the needle. The winding tool may include a controller having at least one processor and at least one non-transitory memory storing instructions that, when executed with the at least one processor, cause the winding tool to move in at least two directions to feed the wire through the needle and to wind the wire around the stator segments.
[0035] In another example embodiment, an apparatus for forming a segmented stator for an electric motor includes: a winding nest including a base and a plurality of retainers removably arranged on the base in a circular pattern, the retainers being positioned to be extendable in a radially outward direction and retractable in a radially inward direction; a plurality of tooth segments attachable to the retainers; and a winding tool having a needle and movable from a first position outside the winding nest to a second position in the winding nest, the winding tool being configured to receive wire from an upstream wire source and feed the wire through the needle. When the retainer is extended in a radially outward direction, the winding tool is movable from a first position to a second position such that the needle is extendable between the tooth segments, and the winding tool is movable in at least two directions to wind the wire around the tooth segments to form a coil around the tooth segments. When the winding tool is movable from the second position to the first position, the retainer is retractable in a radially inward direction and the tooth segments are connected through the formed coil to form the segmented stator.
[0036] The retainer can be slidably extendable in a recess in a radial direction on a surface of the base. The device can also include a rotating ring positioned on a first surface of the winding nest, the first surface being opposite to a second surface of the winding nest on which the retainer is positioned, wherein when the rotating ring rotates, the retainer is driven in a radially outward direction or a radially inward direction. The retainer can include a guide pin hanging from the lower side of the retainer, wherein when the rotating ring rotates, the retainer is driven in a radially outward direction or a radially inward direction to cause the guide pin to slide in an angled channel in the base. The rotating ring can be movable relative to the base using a knob handle. The retainer can be fixedly positionable on the base using a locking pin. The tooth segment can include a plurality of metal stamping stacks. The tooth segment can be interconnected using a protrusion and a groove arrangement at the rear end of the tooth segment. The device can also include a controller coupled to the winding tool, the controller including at least one processor and at least one non-transitory memory storing instructions, which can controllably perform the winding of the wire around the tooth segment when executed with at least one processor.
[0037] In another example embodiment, a method of forming a segmented stator for an electric motor includes: securing a plurality of tooth segments to a winding nest, the tooth segments being secured to the winding nest in a radially expanded position; positioning a winding tool in the winding nest; operating the winding tool to wind wires around the tooth segments to form coils; removing the winding tool from the winding nest; folding the tooth segments inward in a radial direction; and performing final wiring on the folded tooth segments to form a segmented stator.
[0038] Securing the plurality of tooth segments to the winding nest may include securing the tooth segments to respective retainers and securing the retainers to a base. Operating a winding tool to wind the wire around the tooth segments to form the coils may include using a controller having at least one processor and at least one non-volatile memory storing instructions that, when executed using the at least one processor, controllably move the winding tool in at least two directions to wind the wire around the tooth segments. After folding the tooth segments and before performing final wiring, the folded tooth segments may be removed from the winding nest, placed on a retainer, and compressed together. After performing final wiring, the tooth segments may be secured into a rigid form. Securing the tooth segments into a rigid form may include epoxying the tooth segments together.
[0039] In another example embodiment, a segmented stator for an electric motor includes: a plurality of tooth segments arranged in a circular configuration, the tooth segments having a body portion and a front surface extending inwardly from the body portion; and a wire wrapped around the body portion. A distance between adjacently positioned front surfaces of the tooth segments is less than a width of the wire. The wire wrapped around the body portion substantially fills a space between adjacently positioned tooth segments.
[0040] The distance between adjacently positioned front surfaces can reduce the amount of tooth slots in a motor in which the segmented stator is incorporated. The amount of wire wrapped around the body portion can increase the amount of power in the motor in which the segmented stator is incorporated. The wire can be copper wire. The segmented stator can also include a removable ring, and the plurality of tooth segments can be clamped to the inner surface of the removable ring. The removable ring, the plurality of tooth segments and the wire can be fixed into a rigid structure using epoxy resin.
[0041] It should be understood that the above description is illustrative only. Those skilled in the art may design various alternatives and modifications. For example, the features described in the various dependent claims may be combined with each other in any suitable combination. In addition, the features of the above different embodiments may be selectively combined into new embodiments. Therefore, this specification is intended to cover all such alternatives, modifications and variations that fall within the scope of the appended claims.
Claims
1. An apparatus for connecting a plurality of stator segments to form a stator for an electric motor, the apparatus comprising: winding nest; a plurality of stator segments coupled to the winding nest, the stator segments being movable in a radial direction relative to an axis on the winding nest, the stator segments being movable between an inwardly retracted position and an outwardly extended position; as well as a winding tool removably positionable in the winding nest and rotatable about the axis, the winding tool positionable between a first position outside the winding nest and a second position in the winding nest; wherein the winding tool, when positioned in the second position in the winding nest, is configured to controllably wind wire around the plurality of stator segments when the stator segments are positioned in the outwardly extending position; and Wherein when the winding tool is positioned in the first position and after winding the wire, the stator segments are positioned in the inwardly retracted position to form a wound segmented stator. 2 . The apparatus of claim 1 , wherein the stator segments are removably coupled to a retainer, the retainer being movable in the radial direction between the inwardly retracted position and the outwardly extended position.
3. The device of claim 2, wherein the retainer is movable between the inwardly retracted position and the outwardly extended position in a synchronized motion. 4 . The apparatus of claim 1 , wherein the winding tool comprises a needle configured to receive the wire from a wire source and to wind the wire around the stator segment as the wire is fed through the needle.
5. The apparatus of claim 4, wherein the winding tool comprises a controller having at least one processor and at least one non-transitory memory storing instructions that, when executed using the at least one processor, cause the winding tool to move in at least two directions to feed the wire through the needle and to wind the wire around the stator segment.
6. An apparatus for forming a segmented stator for an electric motor, the apparatus comprising: Winding nest, including: a base; and a plurality of retainers removably arranged in a circular pattern on the base, the retainers being positioned to be extendable in a radially outward direction and retractable in a radially inward direction; a plurality of tooth segments attachable to the retainer; and a winding tool having a needle and movable from a first position outside the winding nest to a second position within the winding nest, the winding tool being configured to receive wire from an upstream wire source and feed the wire through the needle; wherein the winding tool is movable from the first position to the second position when the retainer is extended in the radially outward direction so that the needle can extend between the tooth segments, and the winding tool is movable in at least two directions to wind the wire around the tooth segments to form a coil around the tooth segments; Wherein when the winding tool is movable from the second position to the first position, the retainer is retractable in the radially inward direction and the tooth segments are connected via the formed coils to form the segmented stator.
7. The device of claim 6, wherein the retainer is slidably extendable in a recess in a radial direction on the surface of the base.
8. The device according to claim 6 further includes a rotating ring, which is positioned on a first surface of the winding nest, the first surface is opposite to a second surface of the winding nest, and the retainer is positioned on the second surface, wherein when the rotating ring rotates, the retainer is driven in the radial outward direction or the radial inward direction.
9. A device according to claim 8, wherein the retainer includes a guide pin hanging from the lower side of the retainer, and wherein when the rotating ring rotates, the retainer is driven in the radially outward direction or the radially inward direction to cause the guide pin to slide in the angled channel in the base.
10. The device of claim 8, wherein the rotating ring is movable relative to the base using a knob handle.
11. The device of claim 6, wherein the retainer is fixably positionable on the base using a locking pin.
12. The apparatus of claim 6, wherein the tooth segment comprises a stack of multiple metal stampings.
13. The device of claim 6, wherein the tooth segments are interconnected using a projection and groove arrangement at rear ends of the tooth segments.
14. The apparatus of claim 6, further comprising a controller coupled to the winding tool, the controller comprising at least one processor and at least one non-volatile memory storing instructions that, when executed using the at least one processor, controllably execute winding of the wire around the tooth segment.
15. A method of forming a segmented stator for an electric motor, the method comprising: securing a plurality of tooth segments to a winding nest, the tooth segments being secured to the winding nest in a radially expanded position; positioning a winding tool in the winding nest; operating the winding tool to wind the wire around the tooth segment to form a coil; removing the winding tool from the winding nest; folding the tooth segments inwardly in a radial direction; as well as Final wiring is performed on the folded tooth segments to form a segmented stator.
16. The method of claim 15, wherein securing the plurality of tooth segments to the winding nest comprises securing the tooth segments to respective retainers and securing the retainers to a base.
17. The method of claim 15, wherein operating the winding tool to wind the wire around the tooth segment to form the coil comprises: A controller is used having at least one processor and at least one non-transitory memory storing instructions that, when executed using the at least one processor, controllably move the winding tool in at least two directions to wind the wire around the tooth segment.
18. The method of claim 15, wherein after folding the tooth segments and before performing the final routing, the folded tooth segments are removed from the winding nest, placed on a holder, and compressed together.
19. The method of claim 18, wherein after performing the final routing, the tooth segments are fixed in a rigid form.
20. The method of claim 19, wherein securing the tooth segments in the rigid form comprises epoxying the tooth segments together.
21. A segmented stator for an electric motor, the segmented stator comprising: a plurality of tooth segments arranged in a circular configuration, the tooth segments having a body portion and a front surface extending inwardly from the body portion; as well as an electric wire wound around the body portion; wherein a distance between adjacently positioned front surfaces of the tooth segments is less than a width of the wire; and The wires wrapped around the body portion substantially fill the spaces between adjacently positioned tooth segments.
22. The segmented stator of claim 21, wherein the distance between the adjacently located front surfaces reduces the amount of cogging in a motor in which the segmented stator is incorporated.
23. The segmented stator of claim 21, wherein the amount of said wire wrapped around the body portion increases the amount of power in a motor in which said segmented stator is incorporated.
24. The segmented stator of claim 21, wherein the wires are copper wires.
25. The segmented stator of claim 21, further comprising a removable ring, the plurality of tooth segments being clampable to an inner surface of the removable ring.
26. The segmented stator of claim 21, wherein the removable ring, the plurality of tooth segments, and the wires are secured into a rigid structure using epoxy.