Patent ID: 7810225

Claim:
A method of making a wound field for a brushless direct current motor, direct current generator, alternating current motor or alternating current generator, said method comprising the steps of: (a) providing a base mold having an engagement face and at least one movable end turn form on the engagement face; (b) determining a number of distinct phases; (c) winding at least one strand of conductive material per distinct phase around at least one movable end turn forming tool; (d) creating a coil of conductive material from the at least one strand of conductive material; (e) forming the coil into a shape that indicates the number of poles required; (f) placing the coil onto an insertion instrument; (g) repeating steps (b) through (f) as needed to create a coil for each distinct phase; (h) inserting the insertion instrument and each coil into a stator core; (i) sizing an inside diameter of the coil(s) with the insertion instrument; (j) removing the insertion instrument from the stator core; and (k) installing the stator core into one of a brushless direct current motor, direct current generator, alternating current motor or alternating current generator.