Needle windings for high density copper filled inner teeth electric motor stators and methods therefor

Abstract

A segmented stator for an electric motor comprising: a plurality of teeth segments arranged in a circular configuration, each of the plurality of teeth segments having a body portion and a front surface extending inwardly from the body portion, the segmented stator also comprising an electrical wire wound around the body portion, the distance between adjacent front surfaces being less than a width of the electrical wire, and the electrical wire wound around the body portion substantially filling the space between adjacent teeth segments.

Description

background

[0001] [Technical field] The exemplary and non-limiting embodiments relate generally to electric motors, and more particularly, to an apparatus and method for winding a coil on a stator of an electric motor.

[0002] [Brief Description of the Prior Art] Coils used in electric motors are typically placed in slots formed between the radially inwardly projecting teeth of a stator by winding copper wire directly around the structure forming the stator teeth. In one method of winding wire to form the coils, the wire is fed from a spindle or winding tool directly onto the teeth structure. The winding operation is accomplished by directing the wire to the desired location on the teeth as it is fed from the winding tool. The winding tool is supported within the stator and configured for reciprocating and rotating motion relative to the teeth. The reciprocating and radial motion achieved while feeding the wire through the winding tool allows the wire to be positioned within the slots formed by the stator teeth. Abstract

[0003] The following summary is illustrative only and is not intended to limit the scope of the claims.

[0004] According to one aspect, an apparatus for joining a plurality of stator segments to form a stator for an electric motor includes: A winding housing; a plurality of stator segments coupled to the winding housing; The stator segments are movable on the winding housings in a radial direction relative to an axis between an inner position and an outer position. a winding tool removably positioned within the winding housing and rotatable about the axis, the winding tool being positionable between a first position out of the winding housing and a second position within the winding housing, the winding tool being configured to controllably wind wire onto the stator segments when in the second position within the winding housing, with the stator segments in the outer position, when the winding tool is in the first position and after the wire has been wound, the stator segments in the inner position to form a wound segmented stator.

[0005] In another aspect, an apparatus for forming a segmented stator for an electric motor includes: a winding receiving portion having a base and a plurality of holders, the plurality of holders being removably arranged on the base in a circular pattern and each of the holders being movable radially outward and radially inward; a teeth segment attachable to the holder; a winding tool having a needle and movable from a first position outside the winding housing to a second position inside the winding housing, the winding tool configured to receive an electrical wire from an upstream electrical wire source and feed the electrical wire through the needle; When the holder is moved radially outward, the winding tool can be moved from the first position to the second position, the needles can be inserted between the teeth segments, and the winding tool can be moved in at least two directions to wind wire on the teeth segments to form coils around the teeth segments. When the winding tool is movable from the second position to the first position, the holder can be retracted radially inward, the teeth segments are connected by the formed coils, and a segmented stator is formed.

[0006] In another aspect, a method for forming a segmented stator includes: Fixing the plurality of teeth segments to the winding receiving portion at radially expanding positions; placing a winding tool within the winding housing; operating the winding tool to wind wire around the teeth segments to form a coil; removing the winding tool from the winding housing; moving the teeth segments radially inward; final wiring the teeth segments that have been moved radially inward to form a segmented stator; Includes.

[0007] In another aspect, a segmented stator is a plurality of teeth segments arranged in a circular configuration, each having a body portion and a front surface extending inwardly from the body portion; an electric wire wound around the body portion; A distance between adjacent said front faces is less than a width of said wire, and said wire wound around said body portion substantially fills a space between adjacent said tooth segments. [Brief description of the drawings]

[0008] The above aspects and other features are described below with reference to the accompanying drawings.

[0009] [Figure 1] FIG. 2 is a schematic diagram of the windings of the integrated electric motor laminations forming the stator.

[0010] [Diagram 2] FIG. 2 is an enlarged schematic diagram of the winding portion of FIG.

[0011] [Diagram 3]FIG. 2 is a schematic diagram of an example of an embodiment of a segmented winding on multiple tooth segments to form a segmented stator.

[0012] [Figure 4] FIG. 4 is an enlarged schematic diagram of the segmented winding of FIG.

[0013] [Diagram 5] FIG. 2 is a perspective view of a teeth segment for a segmented winding 200 forming a segmented stator.

[0014] [Figure 6] 1 is a perspective view of a winding housing for a segmented winding, with the teeth segments shown in the "open" position.

[0015] [Figure 7] FIG. 7 is a perspective view of the winding housing of FIG. 6, but with the teeth segments shown in the "closed" position.

[0016] [Figure 8] 1 is a perspective view of a winding housing, depicting one teeth segment in an "open" position and one teeth segment in a "closed" position.

[0017] [Figure 9] 4 illustrates an exemplary process flow for a method of forming an exemplary segmented stator.

[0018] [Figure 10] FIG. 4 is a schematic diagram comparing the stator of FIG. 1 with the segmented stator of FIG. 3 to illustrate the difference in wiring density. Detailed explanation

[0019] 1 and 2, a winding for a conventional integrated electric motor lamination is generally designated 100, hereafter referred to as winding 100. Winding 100 is implemented using a winding housing 110 that is supported so that it can be rotated (by the motor). Winding housing 110 includes an outer ring 120. Outer ring 120 has twelve teeth 130 each extending inwardly. There is a gap between each of the teeth 130. Winding housing 110 is formed as a stack of pressed metal sheets. A winding spindle or winding tool 140 is disposed within outer ring 120 so as to pass through winding housing 110. Winding tool 140 is supported on a shaft having a wire guide. The wire guide guides wire 150 into winding tool 140 and feeds wire 150 through needles 160. The winding tool 140 is driven by a drive mechanism disposed below the winding housing 110 to perform reciprocating and oscillating (or rotating) motions. The reciprocating and oscillating (or rotating) motions of the winding tool 140 enable the winding of the electric wire 150 to form coils around each of the teeth 130. The continuously wound electric wire 150 and teeth 130 thus form the stator 170.

[0020] Referring to FIG. 2, during operation, the needle 160 extends into the gap between each of the teeth 130 and winds the wire 150 around each of the teeth 130, thereby forming a coil. The size of the physical gap between each of the teeth 130 is typically determined by a combination of the electrical design capabilities of the finished electric motor, the maximum winding size / width, the needle design, and the clearance for the needle 160 between adjacent needles 130 that have coils wound on them. The needle design is related to the width vs. strength required to wind the wire without breaking it or allowing the wire to sag across the gap. For example, when winding a coil around teeth 130 that are fixed in place, the width of the needle is limited by the amount of space between each of the teeth 130. A thin needle (such as needle 160) may sag and not allow an effective winding pattern of the wire to be formed. It may also break, which may completely halt the winding process. As shown, even though the wire 150 is tightly wound on each tooth 130, a significant amount of space or gap remains between the front faces of the teeth 130 as the needles 160 retract. This large gap between the front faces of adjacent teeth 130, because the teeth 130 must accommodate the needles 160, can reduce the smoothness of the motor's operation, which can result in increased cogging. Additionally, the unfilled space between the coils can result in less wire 150, which can reduce the power output of the motor.

[0021] 3 and 4, an embodiment of a segmented laminated stator and custom winding is shown generally at 200 and is referred to as "segmented winding 200." The exemplary segmented winding 200 is implemented using a winding housing 210. The winding housing 210 is supported so that it can be rotated using a motor.

[0022] The winding housing 210 supports a number of teeth segments 230. Each teeth segment 230 is formed from a number of stamped metal sheets. Each teeth segment 230 is wound with wire 250 and then assembled to form an exemplary segmented stator 270 (see FIG. 10).

[0023] To form the segmented winding 200, the winding tool 240 is positioned to extend upward through the winding housing 210. The winding tool 240 is supported on a shaft having a wire guide. The wire guide receives the wire 250 from an upstream source, guides the wire 250 to 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 located below the winding housing 210, and reciprocates and oscillates (rotates) about the shaft. The reciprocating and oscillating (rotating) motion of the winding tool moves the needle 260 to wind the wire 250 around each of the teeth segments 230 as they move outward and away from each other (see FIG. 6). The winding of the wire 250 forms a coil. The continuous coil of wire 250 and the teeth segments 230 form a segmented stator 270. As shown, the needles 260 are thicker than the needles 160 of FIG. 2. Also, because there is more space between the teeth segments 230 during the winding operation, the needles 260 can be more easily accommodated in the segmented winding 200. This makes the finished stator stronger and allows more wire 250 to be wound between adjacent teeth segments 230 (the spaces between the teeth segments 230 are more tightly packed). A programmable controller 290 including a processor and at least one memory for storing software may be used to control the wire winding operation.

[0024] Although twelve teeth segments 230 are shown configured to form segmented stator 270, any number of teeth segments 230 may be assembled in accordance with the disclosed embodiments. As seen in Figure 4, the rear end of each teeth segment 230 has a protrusion 423 on one side and a groove 424 on the other side. Then, as the teeth segments 230 are retracted together from an outer position to an inner position on winding housing 210, the protrusions 423 engage with the corresponding grooves 424 and are assembled into a ring.

[0025] 5, an embodiment of a teeth segment 230 supported by a holder 300 is shown. The holder 300 includes a clamp 310 or clamp portion. The clamp 310 is configured to hold, clamp, or otherwise support the teeth segments 230. Each teeth segment 230 is formed as a stamped metal lamination. Clamping may be by a screw 235 or other suitable mechanism. The holder 300 includes an adjustment portion 340. A slot 350 is provided within the adjustment portion 340. The slot 350 is configured to allow the holder 300 to receive a locking pin 450, allowing the holder 300 to slide for positional adjustment relative to the winding housing 210, and to be fixed relative to the winding housing 210. A guide peg 422 extends from a bottom surface of the holder 300. The guide pegs 422 are configured to slide into and engage angled channels 470 (as shown in FIG. 8) to effectively open and close the holder 300 over the winding housing 210 .

[0026] 6 and 7, the winding housing 210 is shown in more detail. As shown in FIG. 6, the winding housing 210 has a number of holders 300. The holders 300 are arranged to be radially movable on a base 420 that is rotatable about an axis A. The base 420 is supported on a support table 430. As shown in FIG. 6, the winding housing 210 is in an "open" or "wound" state, and a winding tool 440 is shown in the center. The winding tool 440 may be a winding gun available from WGE Equipment Solutions, Inc. (Fort Wayne, Indiana). Each of the holders 300 is arranged to be radially outwardly movable on the base 420 to provide maximum space between the individual teeth segments 230, thereby allowing maximum filling of the wires 250 on each teeth segment 230. The wires 250 may be copper, although other materials may be suitable. Each holder 300 is secured on the base 420 by a locking pin 450. The lock pin 450 passes through the slot 350 and is received in the base 420.

[0027] 7, the winding housing 210 is in a "closed state" on the base 420. As shown, the teeth segments 230 are not wired. Prior to being placed in the closed position (e.g., to perform final wiring if a wiring process has already been performed), the winding tool 240 is removed from the winding housing 210.

[0028] Referring to FIG. 8, the winding housing 210 is shown with two holders placed on the base 420. The first holder 300a is in an open position and the second holder 300b is in a closed position. The base 420 has recesses 410 extending radially from the center of the base 420 to the outer edge. In this example, there are 12 recesses 410, each of which accommodates a holder 300. When the holders 300 are placed in the recesses 410 on the base 420, the guide pegs 422 protruding from the bottom of each holder 300 extend through the slots 465 in the base 420 and sit in the diagonal 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. When the knob handle 455 is turned, for example, clockwise, the base remains in a fixed position while the rotating ring 480 rotates in a first direction. Then, due to the angled channel 470 of the rotating ring 480, the guide pegs 422 extending from the bottom of each holder 300 are moved radially inward, "closing" the holder 300 on the base 420. The locking pin 450 can then be turned to lock the holder 300 in place. Turning the knob handle 455, for example counterclockwise, rotates the rotating ring 480 in a second direction opposite to the first direction, moving the guide pegs 422 radially outward, "opening" the holder 300. All the holders 300 move together or synchronously to open and close. In FIG. 8, the holder 300a is in an open position and the holder 300b is in a closed position, but this is depicted as such only for the purpose of illustrating the limits of the movement of the holders 300.

[0029] Referring to FIG. 9, an example flow diagram of a method for winding a laminated stator tooth is generally shown at 900, hereafter referred to as "method 900." In method 900, a plurality of teeth segments are clamped or otherwise secured to respective holders, as shown at step 910. Each tooth segment may be comprised of a plurality of stamped metal laminations that are stacked to form the teeth segment. At step 920, each holder is slidably positioned in a circular winding housing for radial movement. Each holder is moved radially outward. At step 930, a winding tool is positioned within the winding housing and between the holders. At step 940, wire is wound from the winding housing onto each tooth segment. Once the teeth segments are positioned radially outward, a wound, expanded stator component is formed. At step 950, the winding tool is removed from the winding housing. At step 960, the holder is moved radially inward to bring the wound teeth segments into a contracted state. At step 970, final wiring is applied to the contracted wound tooth segments to form a segmented stator. The segmented stator, which is a collection of individual tooth segments with their windings, may be somewhat flexible. Final wiring may be performed, for example, after removing the flexible segmented stator from its winding housing, placing the segmented stator on a holder or the like, and squeezing the flexible stator components together. Either before or after final wiring, the wired tooth segments may be attached to a printed circuit board and epoxied or otherwise secured into a rigid shape.

[0030] 10, a comparison of stator 170 and segmented stator 270 is shown at 1000. It can be seen that in stator 170, the open spaces 990 between adjacent teeth 130 are not utilized for wiring to accommodate needles 160, whereas in segmented stator 270, formed using a segmented winding process, the open spaces between adjacent tooth segments 230 are filled with wire 250, forming a high density winding structure.

[0031] In the segmented stator 270, when the teeth segments 230 are assembled and mounted within the outer ring 295, the spacing between the front faces 296 of the teeth segments 230 is less than the width of the wire 250. Thus, the segmented stator 270 has a smaller gap between the front faces of adjacent teeth segments 230 and a denser copper fill in the body portion 297 than the stator 170. Although less power may be generated due to the smaller gap, this reduction in power is made up for by the denser copper fill in the body portion 297. In the segmented stator 270, the placement of the individual stator segments does not compromise the performance of the completed electric motor because the individual teeth segments 230 may be placed in a larger diameter winding housing compared to a conventional winding housing. This removes the physical design constraints of needle windings and allows for maximum copper fill between adjacent teeth in the stator 270 to substantially fill the space. By the space is substantially filled, it is meant that the space is not configured to receive additional wire 250. The combination of closely spaced (smaller than the width of wire 250) teeth segments and large copper filling provides a motor that operates at a higher power output with less cogging. Such a motor runs smoother than a motor that has a stator with wider spacing between teeth and less copper wire wound. Furthermore, the winding of a particular diameter or gauge of wire is not limited to the design width of the needle or teeth gap. Additionally, the needle width is not limited to a compromise design combination of one-piece design selection of tooth gap and wire gauge.

[0032] The features described herein may be provided in an apparatus. The features described herein may be provided in an assembly method for assembling an apparatus. The features described herein may be provided in a method of using an apparatus having the above-mentioned features. The features described herein may be provided in control software embodied in a memory and operable with a processor and capable of controlling the operation of the apparatus as described above.

[0033] According to an exemplary embodiment, an apparatus for connecting a plurality of stator segments to form a stator for an electric motor includes: A winding housing; a plurality of stator segments coupled to the winding housing; The stator segments are movable on the winding housings in a radial direction relative to an axis between an inner position and an outer position. a winding tool removably positioned within the winding housing and rotatable about the axis, the winding tool being positionable between a first position out of the winding housing and a second position within the winding housing, the winding tool being configured to controllably wind wire onto the stator segments when in the second position within the winding housing, with the stator segments in the outer position, when the winding tool is in the first position and after the wire has been wound, the stator segments in the inner position to form a wound segmented stator.

[0034] Each of the stator segments may be removably coupled to a holder radially movable between the inner position and the outer position. All of the holders may be synchronously movable between the inner position and the outer position. The winding tool may have needles, the winding tool configured to receive an electric wire from a wire source and feed the electric wire through the needles to wind the electric wire on the stator segments. The winding tool may include a controller comprising at least one processor and at least one non-volatile memory, where the non-volatile memory stores instructions that, when executed by the at least one processor, cause the winding tool to move in at least two directions to feed the electric wire through the needles to wind the electric wire on the stator segments.

[0035] In another exemplary embodiment, an apparatus for forming a segmented stator for an electric motor includes: a winding receiving portion having a base and a plurality of holders, the plurality of holders being removably arranged on the base in a circular pattern and each of the holders being movable radially outward and radially inward; a teeth segment attachable to the holder; a winding tool having a needle and movable from a first position outside the winding housing to a second position inside the winding housing, the winding tool configured to receive an electrical wire from an upstream electrical wire source and feed the electrical wire through the needle; When the holder is moved radially outward, the winding tool can be moved from the first position to the second position, the needles can be inserted between the teeth segments, and the winding tool can be moved in at least two directions to wind wire on the teeth segments to form coils around the teeth segments. When the winding tool is movable from the second position to the first position, the holder can be retracted radially inward, the teeth segments are connected by the formed coils, and a segmented stator is formed.

[0036] The holder may be radially slidable and outwardly movable within a recess on a surface of the base. The apparatus may further include a rotating ring. The rotating ring is disposed on a first surface of the winding housing. The first surface is opposite a second surface on which the holder is disposed in the winding housing. The holder is moved radially outward or inward by rotation of the rotating ring. The holder may have guide pegs protruding from an underside thereof. Rotation of the rotating ring causes sliding of the guide pegs in an oblique channel of the base as the holder is moved radially outward or inward. The rotating ring may be movable relative to the base using a knob handle. The holder may be fixedly positionable on the base using a locking pin. The teeth segments may include a plurality of laminations of metal pressings. The teeth segments may be interconnected at the rear ends of the teeth segments using a projection and groove structure. The apparatus may further include a controller coupled to the winding tool. However, the controller has at least one processor and at least one non-volatile memory, and the non-volatile memory stores instructions that, when executed by the at least one processor, controllably cause the winding of electric wire around the tooth segments.

[0037] In another exemplary embodiment, a method for forming a segmented stator includes: Fixing the plurality of teeth segments to the winding receiving portion at radially expanding positions; placing a winding tool within the winding housing; operating the winding tool to wind wire around the teeth segments to form a coil; removing the winding tool from the winding housing; moving the teeth segments radially inward; final wiring the teeth segments that have been moved radially inward to form a segmented stator; Includes.

[0038] Fixing the teeth segments in a winding housing may include fixing each of the teeth segments to a respective holder and fixing the holder to a base. Operating the winding tool to wind wire around the teeth segments to form a coil may include using a controller comprising at least one processor and at least one non-volatile memory, the non-volatile memory storing instructions that, when executed by the at least one processor, controllably move the winding tool in at least two directions to wind wire around the teeth segments. Prior to retracting the teeth segments and performing final wiring, the retracted teeth segments are removed from the winding housing and placed on a holder and pressed together. After performing final wiring, the teeth segments may be set into a rigid shape. Fixing the teeth segments in a rigid shape may include epoxying the teeth segments together.

[0039] In another exemplary embodiment, a segmented stator for an electric motor comprises: a plurality of teeth segments arranged in a circular configuration, each having a body portion and a front surface extending inwardly from the body portion; an electric wire wound around the body portion; A distance between adjacent said front faces is less than a width of said wire, and said wire wound around said body portion substantially fills a space between adjacent said tooth segments.

[0040] The distance between the adjacent front faces may reduce the amount of cogging of a motor incorporating the segmented stator. The amount of wire wound around the body portion may increase the power of a motor incorporating the segmented stator. The wire may be copper wire. The segmented stator may further comprise a removable ring. An inner surface of the link has the plurality of teeth segments attached thereto. The removable ring, the plurality of teeth segments, and the wire may be secured to a rigid structure using epoxy.

[0041] It should also be understood that the above description is merely illustrative. Various variations and modifications may occur to those skilled in the art. For example, the features recited in the various dependent claims may be combined with each other in any suitable combination. In addition, features from the various embodiments described above may be selectively combined to form new embodiments. This application is therefore intended to embrace all such variations, modifications and variations that fall within the scope of the appended claims.

Claims

1. 1. An apparatus for connecting a plurality of stator segments to form a stator for an electric motor, comprising: A winding housing; a plurality of stator segments coupled to the winding housing; the stator segments are movable on the winding housings in a radial direction relative to an axis between an inner position and an outer position, the apparatus further comprising: a winding tool removably positioned within the winding housing and rotatable about the axis, the winding tool being positionable between a first position out of the winding housing and a second position within the winding housing; the winding tool is configured, when positioned in the second position within the winding housing, to controllably wind an electric wire onto the stator segments when the stator segments are in the outer position; When the winding tool is in the first position and after the wire has been wound, the stator segments assume the inner position to form a wound segmented stator; Device.

2. The apparatus of claim 1 , wherein each of the stator segments is removably coupled to a holder that is radially movable between the inner position and the outer position.

3. The apparatus of claim 2 , wherein all of said holders are synchronously movable between said inner position and said outer position.

4. The apparatus of claim 1 , wherein the winding tool has a needle, the winding tool configured to receive an electrical wire from a wire supply and feed the electrical wire through the needle to wind the electrical wire around the stator segment.

5. 5. The apparatus of claim 4, wherein the winding tool comprises a controller comprising at least one processor and at least one non-volatile memory that stores instructions that, when executed by the at least one processor, cause the winding tool to move in at least two directions to feed wire through the needles and wind the wire on the stator segments.

6. 1. An apparatus for forming a segmented stator for an electric motor, comprising: a winding receiving portion having a base and a plurality of holders, the plurality of holders being removably arranged on the base in a circular pattern and each of the holders being movable radially outward and radially inward; A teeth segment attachable to the holder; a winding tool having a needle and movable from a first position outside the winding housing to a second position inside the winding housing, the winding tool configured to receive an electrical wire from an upstream electrical wire source and feed the electrical wire through the needle; Equipped with as the holder moves radially outward, the winding tool is movable from the first position to the second position, the needles can be inserted between the teeth segments, and the winding tool is movable in at least two directions to wind wire on the teeth segments to form coils around the teeth segments; When the winding tool is movable from the second position to the first position, the holder is allowed to be retracted radially inward, and the teeth segments are connected by the formed coil to form a segmented stator; Device.

7. The apparatus of claim 6 , wherein the holder is radially slidable and outwardly movable within a recess on a surface of the base.

8. a rotating ring disposed on a first surface of the winding housing; the first surface is a surface of the winding accommodating portion opposite to a second surface on which the holder is disposed, The holder is moved radially outward or radially inward by the rotation of the rotating ring.

7. The apparatus of claim 6.

9. 9. The apparatus of claim 8, wherein the holder has guide pegs protruding from an underside thereof, and wherein rotation of the rotatable ring causes the holder to move radially outward or inward, resulting in sliding of the guide pegs within angled channels in the base.

10. The device of claim 8 , wherein the rotatable ring is movable relative to the base using a knob handle.

11. The apparatus of claim 6 , wherein the holder is fixably positionable on the base using a locking pin.

12. The apparatus of claim 6 , wherein the teeth segment comprises a plurality of stamped metal laminations.

13. The apparatus of claim 6 , wherein the teeth segments are interconnected at their rear ends using a projection and groove configuration.

14. 7. The apparatus of claim 6, further comprising a controller coupled to the winding tool, the controller having at least one processor and at least one non-volatile memory, the non-volatile memory storing instructions that, when executed by the at least one processor, controllably cause winding of wire around the tooth segments.

15. 1. A method of forming a segmented stator for an electric motor, comprising the steps of: Fixing the plurality of teeth segments to the winding accommodating portion at radially expanding positions; placing a winding tool within the winding housing; operating the winding tool to wind wire around the teeth segments to form a coil; removing the winding tool from the winding housing; moving the teeth segments radially inward; final wiring the teeth segments that have been moved radially inward to form a segmented stator; A method comprising:

16. The method of claim 15 , wherein fixing the plurality of teeth segments to the winding housing comprises fixing each of the plurality of teeth segments to a respective holder and fixing the holder to a base.

17. 16. The method of claim 15, wherein operating the winding tool to wind wire around the tooth segments to form a coil includes using a controller having at least one processor and at least one non-volatile memory, wherein the non-volatile memory stores instructions that, when executed by the at least one processor, controllably move the winding tool in at least two directions to wind wire around the tooth segments.

18. 16. The method of claim 15, wherein the retracted teeth segments are removed from the winding housing and placed on a holder and pressed together prior to retracting the teeth segments inward and performing final wiring.

19. 20. The method of claim 18, wherein after final wiring, the plurality of teeth segments are set into a rigid shape.

20. The method of claim 19 , wherein fixing the plurality of teeth segments in a rigid shape comprises epoxiing the plurality of teeth segments together.

21. 1. A segmented stator for an electric motor, comprising: a plurality of teeth segments arranged in a circular configuration, each having a body portion and a front surface extending inwardly from the body portion; an electric wire wound around the body portion; having the distance between adjacent said front faces is less than a width of said wire; an electrical wire wound around the body portion substantially filling a space between adjacent teeth segments; Segmented stator.

22. 22. The segmented stator of claim 21, wherein the distance between adjacent front faces reduces an amount of cogging in a motor incorporating the segmented stator.

23. 22. The segmented stator of claim 21, wherein an amount of wire wound on the body portion increases the power of a motor in which the segmented stator is incorporated.

24. 22. The segmented stator of claim 21, wherein the electrical wires are copper wires.

25. 22. The segmented stator of claim 21, further comprising a removable ring, the inner surface of the link having the plurality of teeth segments attached thereto.

26. 26. The segmented stator of claim 25, wherein the removable ring, the plurality of teeth segments, and the electrical wires are secured to a rigid structure using an epoxy resin.

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