In a first aspect, a method for removing an electromagnetic module from an electrical machine is provided. The electrical machine comprises a plurality of electromagnetic modules having an electromagnetic material. The electromagnetic modules comprise base and a support extending from the base and supporting the electromagnetic material. The base comprises a bottom surface and a first side surface. The first side surface comprises an axially extending groove defining a cooling channel with an axially extending groove of a first side surface of an adjacent electromagnetic module. The method comprises inserting a rod in a cooling channel formed by the groove of the electromagnetic module to be removed and a groove of an adjacent electromagnetic module; releasing the electromagnetic module to be removed from a structure of the electrical machine; and sliding the electromagnetic module to be removed along the rod.

A transportation tooling structure, a split electric motor module with the transportation tooling structure, and a transportation method are provided. The transportation tooling structure comprises: a split base plate, a stator support and a rotor support, wherein the lower end of the stator support is fixedly supported on the upper surface of the split base plate, and the upper end of the stator support is fixedly supported on the side of a split stator close to the split base plate; and the upper end of the rotor support is fixedly supported on the side of an end of a split rotor away from the split stator, and the lower end of the rotor support is fixedly supported on the side of the split stator away from the split base plate.

An electric motor including a motor rotor and a motor stator including a stator core including a plurality of stator teeth spaced along a circumferential direction of the stator core, a plurality of coil groups, wherein each of the plurality of coil groups includes a plurality of coils wound on a corresponding stator tooth, and an incoming line terminal and an outgoing terminal both comprising a same number of coil ends, and two motor lead groups, wherein a number of the plurality of motor leads of each of the two motor lead groups is equal to a number of the plurality of coil groups, and wherein each of the plurality of motor leads is connected to one incoming line terminal or one outgoing line terminal of one corresponding coil group of the plurality of coil groups.

The reliability of a rotating electrical machine is improved. A method for manufacturing a stator used in a rotating electrical machine includes: a first step of arranging a first segment coil and a second segment coil to face each other; a second step of processing the first segment coil to generate a bridge part that comes into contact with the second segment coil; and a third step of joining the bridge part and the second segment coil by laser welding.

The invention relates to a device for cutting to length conductor pieces, in particular hairpins, received in a stator core, including a receptacle for the stator core together with the conductor pieces received therein, the free ends of which protrude out of the stator core when in the received state, in particular in the direction of gravity, and a cutting unit which comprises cutting portions that are designed and arranged such that they can be moved toward one another in order to act in a cutting manner from two opposing sides on at least one conductor piece to be cut to length, and the longitudinal axis thereof, during a cutting process.

A stator with closed slots with continuous winding is described, comprising: a first, internal stator part comprising longitudinal teeth, spaced by a space configured to make the lower part of the closed slots of the stator; a second, external annular stator part, comprising seats complementary with the teeth and configured to be meshed with the first stator part in order to form the closed slots and the stator; a continuous winding comprising a strap, which comprises first sectors mutually connected by second sectors alternate thereto, the strap being configured to be wound on the first, internal stator part, by placing the first sectors into the spaces included between the teeth; a process for making such stator is further described.

A process is described, for making a continuous winding for a stator of an electric machine comprising the following steps: bending on a plane of a strip to make a strap in a single piece, which comprises first sectors to be inserted inside closed slots of a stator and connected by second bending sectors which remain outside the slots; providing a first, internal stator part comprising a plurality of longitudinal teeth, spaced by a space which makes the lower part of the slots; making the winding on the first stator part, by placing the first sectors of strap in the spaces included between the teeth; and connecting the two free ends of every strap; a continuous winding made with such process is further described.

To provide an on-vehicle brushless motor device capable of being downsized with respect to an axial direction of a rotor and a method of manufacturing the same. The on-vehicle brushless motor device 1 includes a brushless motor 10 and an electronic substrate 30. The brushless motor 10 includes a rotor 12 and a stator 16 including a plurality of coils 18 arranged around the rotor 12. The electronic substrate 30 is arranged on a side opposite to an output side of the brushless motor 10 along a plane P intersecting an axial direction X. The on-vehicle brushless motor device 1 further includes a soldering portion 40 that connects a coil wire 20 of the coil 18 and the electronic substrate 30.

Various embodiments associated with a segmented magnetic core are described. The segmented magnetic core can be made up of multiple singular structures so as to allow an individual singular structure to be removed with ease and without disturbing another magnetic core. This modular core design allows for a significant reduction in motor housing weight due to compatibility of the design with lightweight materials and the potential absence of extensive housing when so designed. This modular core design can be incorporated into a motor or a generator and this modular core design can be accomplished, in one example, by way of stacking and/or interlocking employing low cost assembly. In one example, a motor or a generator uses sensors to detect an operational failure in a magnetic core, notifying a user early of the failure.

A bent conductor segment (1a, 1b, 1c) for a stator winding of a stator of an electric machine is formed from a bent metal wire and has at least one first straight section (10a, 10b, 10c) with a first free end (11a, 11b, 11c) and a second free end (13a, 13b, 13c). One of the free ends (11a, 11b, 11c, 13a, 13b, 13c) of the conductor segment (1a, 1b, 1c) comprises a hard solder (2a, 2b, 2c) cohesively connected to said free end (11a, 11b, 11c, 13a, 13b, 13c).