Brushless Motor Coil Assembly with Press-Inserted Terminals

The patent merges multiple separate wire processing operations into a single continuous wire that forms both coils. The wire is wound to form a first coil, then extended to form a second coil, eliminating the need for separate cutting and soldering operations at each terminal. This reduces the number of terminal processed portions from multiple separate connections to a single continuous wire structure, thereby reducing complexity while maintaining connection reliability through the continuous wire path.

The patent applies preliminary action by pre-forming the wire into a continuous structure that includes both coils before assembly. The wire is wound to form the first coil and then extended to form the second coil in a single continuous operation, so that when the stator core is assembled, the electrical connections are already established. This eliminates the need for time-consuming cutting and soldering operations during final assembly, significantly reducing manufacturing time and improving ease of manufacture.

The patent extracts and eliminates the unnecessary wire cutting and soldering operations from the manufacturing process. By using a single continuous wire to form both coils, the patent removes the need for multiple terminal processing steps, thereby reducing manufacturing cost. The continuous wire structure achieves complete coil connections without requiring additional materials or processes for joining separate wire segments, thus reducing both labor and material costs.