METHOD FOR MANUFACTURING TRANSPOSITION COILS

1 . A method of manufacturing a transposition coil stack, the method comprising:

providing a conductor;

forming a first turn of the transposition coil stack, wherein forming the first turn comprises:

defining, by bending the conductor, a start of a loop,

winding a first straight portion of the conductor toward a first looping pin, wherein the first straight portion extends substantially along a first axis,

winding a first loop portion of the conductor around the first looping pin,

winding a second straight portion of the conductor toward a second looping pin located on an opposite side of the loop from the first looping pin,

winding a second loop portion of the conductor around the second looping pin, and

winding a third straight portion of the conductor toward the start of the loop, wherein the third straight portion extends substantially along the first axis.

2 . The method of claim 1 , further comprising forming a bend in the conductor.

3 . The method of claim 2 , wherein forming the bend comprises:

bending a first bend portion of the conductor on a conductor edge at an angle of approximately 45 degrees to the first axis, and

bending a second bend portion of the conductor on the conductor edge such that a portion of the conductor extends along a second axis parallel to the first axis.

4 . The method of claim 1 , further comprising forming a second turn, wherein forming the second turn comprises repeating the method of claim 1 .

5 . The method of claim 3 , further comprising:

bending a third bend portion of the conductor upwards along a y-axis, and

bending a fourth bend portion of the conductor downwards along the y-axis,

wherein a bottom of the conductor is in contact with a top of the conductor, and

wherein the third bend portion and the fourth bend portion extend along the first axis or the second axis.

6 . The method of claim 2 , wherein forming the bend comprises:

bending a first bend portion of the conductor on a conductor edge at an angle of approximately 45 degrees to a second axis, and

bending a second bend portion of the conductor on the conductor edge such that a portion of the conductor extends along the first axis and the first axis is parallel to the second axis.

7 . The method of claim 2 , wherein forming the bend comprises:

bending the conductor on a conductor edge in an S shape such that a first bend portion of the conductor extends across the first axis and a second bend portion of the conductor extends across a second axis.

8 . The method of claim 1 , further comprising repeating the method until a total of six turns have been created.

9 . The method of claim 8 , further comprising forming a plurality of subsequent turns.

10 . A method of manufacturing a transposition coil stack, the method comprising:

providing a conductor;

forming, by bending the conductor, a plurality of turns of the transposition coil stack;

calculating a volts per turn value;

determining, using the calculated volts per turn value, a thickness of turn insulation to be used in the transposition coil stack, and

applying the turn insulation to the transposition coil stack.

11 . A method of manufacturing a transposition coil, the method comprising:

providing a first conductor and a second conductor in at least two separate stacks, wherein the first conductor extends along a first axis and the second conductor extends along a second axis;

forming a double stack;

forming a bridge connection between the at least two separate stacks;

providing each of the two separate stacks with a dedicated main wall insulation that encircles exactly one of the at least two separate stacks; and

providing an outer main wall insulation that encircles the at least two separate stacks.

12 . The method of claim 11 , further comprising insulating the bridge connection.

13 . The method of claim 11 , wherein the bridge connection is a double series stack top to bottom side bridge design.

14 . The method of claim 13 , wherein forming the bridge connection comprises:

bending a first end portion of the second conductor on a conductor edge substantially 90 degrees away from the first conductor such that at least part of the first end portion extends along an axis orthogonal to the first axis,

bending a second end portion of the second conductor substantially 90 degrees downward along a y-axis such that the second end portion is in contact with the conductor edge, and

bending a bottom end portion such that the second end is bent at substantially 90 degrees toward the first conductor, wherein the bottom end portion is configured to pass across a first turn of the second conductor and the bottom end portion is in contact with a bottom of the second conductor.

15 . The method of claim 11 , further comprising winding the at least two separate stacks in opposite directions.

16 . The method of claim 11 , wherein forming the bridge connection includes connecting a top of one stack to a bottom of a separate stack.

17 . The method of claim 11 , further comprising forming a plurality of turns.

18 . The method of claim 17 , further comprising forming an odd number of turns.

19 . The method of claim 11 , wherein forming the bridge connection comprises:

extending a turn of the first conductor around the stack of the second conductor, and connecting the turn of the first conductor to a flipped-over stack of the second conductor.

20 . The method of claim 11 , wherein forming the bridge connection comprises:

extending a turn of the second conductor around a turn of the first conductor, and connecting the turn of the second conductor to a flipped-over turn of the first conductor.