Method of forming cascaded stator winding

1. A method of forming a cascaded stator winding comprising:

providing a stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof;

forming a plurality of A conductors;

forming a plurality of B conductors;

arranging the plurality of A and B conductors into a wire pack;

rolling the wire pack into a cylindrical shape having an outer dimension which allows it to be placed within the stator core;

placing the wire pack within the stator core; and

expanding the wire pack radially outward such that the slot segments of the wire pack are inserted within the core slots of the stator core.

2. The method of claim 1 wherein the arranging of the plurality of A and B conductors into a wire pack includes:

sequentially loading the plurality of A conductors into a magazine with each subsequent A conductor shifted one pitch in a first direction of the previous A conductor;

sequentially loading the plurality of B conductors into the magazine, having the at least half of the slot segments of the B conductors laying on top of the slot segments of the A conductors, with each subsequent B conductor shifted one pitch in a second direction of the previous B conductor, wherein the second direction is opposite of the first direction.

3. The method of claim 2 wherein the first B conductor is placed onto the magazine of A conductors such that one of the slot segments of the B conductor is shifted one pitch from one of the slot segments of the first A conductor.

4. The method of claim 2 wherein the forming of a plurality of A conductors includes:

forming a plurality of single continuous conductors such that each A conductor includes a plurality layers having a plurality of slot segments alternately connected at first and second ends by a plurality of end loop segments, wherein at least half of the end loop segments each include a first sloped portion and a second sloped portion that meet at an apex portion, wherein the slot segments of each layer are radially aligned with one another, the first sloped portion of the end loop segment is radially aligned with the slot segments, and the second sloped portion of the end loop segment is radially offset from the slot segments and the first sloped portion.

5. The method of claim 4 wherein the forming of a plurality of B conductors includes:

forming a plurality of single continuous conductors such that each B conductor includes a plurality of layers having a plurality of slot segments alternately connected at first and second ends by a plurality of end loop segments, wherein at least half of the end loop segments each include a first sloped portion and a second sloped portion that meet at an apex portion, wherein the slot segments of each layer are radially aligned with one another, the second sloped portion of the end loop segment is radially aligned with the slot segments, and the first sloped portion of the end loop segment is radially offset from the slot segments and the second sloped portion.

6. The method of claim 5 wherein the rolling of the wire pack into a cylindrical shape includes rolling the wire pack into a cylindrical shape such that the layers are radially aligned and that slot segments of a plurality of layers are positioned to be accepted within the same slots within the stator core, wherein the outer dimension of the wire pack allows the wire pack to be placed within the stator core.

7. The method of claim 6 wherein providing the stator core, just prior to insertion, having core slots with a circumferential width larger than the circumferential width of the slot segments at the inner diameter and further including a stator varnish process to bond the conductors to themselves and to the slot liners.

8. The method of claim 6 wherein the magazine is a circular magazine having a number of slots equal to at least the number of core slots times the number of layers divided by two.

9. The method of claim 6 wherein the magazine is a linear magazine having a number of slots equal to at least the number of core slots times the number of layers divided by two.

10. The method of claim 6 wherein the magazine has a number of slots equal to at least the number of core slots times the number of layers divided by two, plus the number of phases.

11. The method of claim 6 wherein the A conductors of a particular phase and the B conductors of the same particular phase are connected to one another, for each phase.

12. The method of claim 11 further including connecting the A conductors of a particular phase and the B conductors of the same particular phase in series to form a phase having a number of electrical turns equal to the number of the layers.

13. The method of claim 11 further including connecting the A conductors of a particular phase and the B conductors of the same particular phase in parallel to form a phase having a number of electrical turns equal to half of the number of the layers.

14. The method of claim 11 further including connecting neutral ends of the conductors into neutral bundles and connecting positive ends of the conductors to a rectifier to form a wye structure.

15. The method of claim 14 wherein arranging a wire pack results in a wire pack having at least six phases and further including connecting the neutral ends of every other one of the phases into at least one neutral bundle, and connecting the neutral ends of the other remaining half of the phases into at least a second neutral bundle thereby forming a multiple wye winding.

16. The method of claim 11 further including connecting positive ends of the conductors of one phase to neutral ends of conductors of another phase and then to a rectifier to form a delta structure.

17. The method of claim 16 wherein arranging a wire pack results in a wire pack having at least six phases and further including connecting the neutral ends of every other one of the phases to the positive ends of half the phases and connecting the neutral ends of the other remaining half of the phases to the positive ends of the other half the phases thereby forming a multiple delta winding.

18. A method of forming a cascaded stator winding comprising:

providing a stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, and having a circumferential width of the core slots at the inner diameter of the stator core;

providing a plurality of conductors having a circumferential width narrower than the circumferential width of the core slots just prior to insertion;

forming a plurality of six A conductors such that each A conductor includes a plurality layers having a plurality of slot segments alternately connected at first and second ends by a plurality of end loop segments, wherein at least half of the end loop segments each include a first sloped portion and a second sloped portion that meet at an apex portion, wherein the slot segments of each layer are radially aligned with one another, the first sloped portion of the end loop segment is radially aligned with the slot segments, and the second sloped portion of the end loop segment is radially offset from the slot segments and the first sloped portion,

forming a plurality of six B conductors such that each B conductor includes a plurality of layers having a plurality of slot segments alternately connected at first and second ends by a plurality of end loop segments, wherein at least half of the end loop segments each include a first sloped portion and a second sloped portion that meet at an apex portion, wherein the slot segments of each layer are radially aligned with one another, the second sloped portion of the end loop segment is radially aligned with the slot segments, and the first sloped portion of the end loop segment is radially offset from the slot segments and the second sloped portion,

sequentially loading a plurality of A conductors into the magazine with each subsequent A conductor shifted one pitch in a first direction of the previous A conductor and having at least half of the slot segments disposed in the outer portion of the magazine;

sequentially loading a plurality of B conductors into the magazine, with each subsequent B conductor shifted one pitch in a second direction of the previous B conductor, wherein the second direction is opposite of the first direction and having at least half of the slot segments disposed in the inner portion of the magazine;

rolling the wire pack into a cylindrical shape having a plurality of radial aligned layers and having an outer dimension which allows it to be placed within the stator core;

placing the wire pack within the stator core;

expanding the wire pack radially outward such that the slot segments of the wire pack are inserted within the core slots of the stator core;

bonding the conductors to themselves and to the slot liners;

connecting the leads of the A conductors of a particular phase and B conductors of the same particular phase, for each phase, thereby forming neutral ends and positive ends for each phase and a winding having a plurality of electrical turns.

19. The method of claim 18 further including connecting the neutral ends of half the phases into at least one neutral bundle, and connecting the neutral ends of the other half of the phases into at least a second neutral bundle thereby forming a multiple wye winding.

20. The method of claim 18 further including connecting the neutral ends of half the phases to the positive ends of half the phases and connecting the neutral ends of the other half the phases to the positive ends of the other half the phases thereby forming a multiple delta winding.