A method for manufacturing a coil with an insulating film 130 is provided that includes: a preparation step of preparing a formed workpiece W to which the insulating film has not yet been applied; and an electrodeposition coating step of generating, with the workpiece W immersed in an electrodeposition bath, a potential difference between a first electrode connected to the workpiece W and a second electrode in the electrodeposition bath. In the electrodeposition coating step, the insulating film is simultaneously applied to a portion of the workpiece W and another portion of the workpiece W in such a manner that a film thickness on the portion is thicker than a film thickness on the other portion.

A magnetic pin insertion system comprises a rotary drive of a workpiece (rotor or stator) that a set of axially oriented slots around a circumferential surface that are receptive of magnetic pins. A cartridge holds an axially oriented stack of magnetic pins in guide chutes for each axial section of the workpiece. A pre-loaded feed mechanism (a weight or push spring) pushes the pins into successive slots of the workpiece as the rotary drive rotates the workpiece. Each cartridge chute terminates in an adjustable tongue, with a specified gap from the workpiece, that provides a resistive surface for shearing each pin away from other pins in the stack as they are pushed into their successive slots.

A device for expanding leg portions of hairpins of a motor on which the hairpins are wound by bending them radially outward for each layer, wherein, after the hairpins are restrained radially outward to reduce dispersion, an expansion process on the hairpins may be carried out, so that the hairpins may be bent equally during the expansion process, making it possible to secure constant expansion quality.

An electric motor assembling device includes a lifting mechanism, a pressure mechanism, a press head mechanism, an assembling station and a control mechanism. The pressure mechanism is located at one side of the assembling station, and the lifting mechanism and the press head mechanism are located at the other side of the assembling station. The pressure mechanism includes a pressure mechanism body and a pushing portion connected with the pressure mechanism body, and the pushing portion is configured to be pushed into the assembling station relative to the pressure mechanism body. The press head mechanism includes an abutting portion at a side facing the assembling station. The lifting mechanism includes a clamping portion at a side facing the assembling station, and the clamping portion is configured to move in a direction running away from the assembling station relative to the press head mechanism.

A method for manufacturing a rotor for a rotary electric machine, the method including supporting a workpiece including a rotor core and a rotor shaft that is hollow and disposing the rotor shaft on an inner diameter side of the rotor core. Using an actuation member that is positionable in a hollow interior of the rotor shaft, having a cavity on a radially inner side, and is radially displaceable or deformable, so the actuation member radially faces or contacts a molding pressurization region on an inner peripheral surface of the rotor shaft. Applying a force in a radial direction to the actuation member while bringing the drive member into contact with a contacted portion of the actuation member in the cavity by applying a force in an axial direction to the drive member.

A rotor assembly includes a plurality of rotor laminations arranged in a stacked configuration, and a plurality of apertures formed in each of the rotor laminations, wherein the plurality of apertures of the plurality of rotor laminations are aligned to form a plurality of passages in the stacked configuration. A permanent magnet is inserted into each passage. At least one deformable locator extends into each aperture and is configured to be mechanically deformed into contact with a permanent magnet inserted into the aperture to thereby fixedly secure the permanent magnet within the stacked configuration.

A system includes a rotor core; a rotor stack extending circumferentially from the rotor core, the rotor stack including: a first end; a second end opposite to the first end; and a first slot in the rotor stack, the first slot extending from the first end to the second end; and a hairpin cooling pipe in the first slot of the rotor stack.

Shaping strip for forming an insulator, wherein the shaping strip has a main body having an upper side, and the shaping strip has first and second deflection elements projecting from the upper side of the main body. In a forming procedure of the insulator, in which the insulator is pushed in a thrust direction over the first and the second deflection elements, a first end of a first side of the insulator is pushed in the thrust direction along a second external side of the first deflection element, wherein the first deflection element folds over the first side of the insulator on a first target line, and subsequently one end of a second side of the insulator is pushed in the thrust direction along a second external side of the second deflection element and the second deflection element folds over the second side on a second target line.

A stator for an electric actuator or motor, including: a solid body; a ferromagnetic core region between the layers of semiconductor material, electrically insulated from the layers of semiconductor material; a plurality of conductive through vias through the solid body; a first plurality of conductive strips, which extend parallel to one another above the core; and a second plurality of conductive strips, which extend parallel to one another above the core and opposite to the first plurality of conductive strips; wherein the first plurality of conductive strips, the plurality of conductive through vias, and the second plurality of conductive strips form a winding or coil of the stator.

A method of making a stator carrier for an electric motor includes forming a first end component, forming a second end component, forming an intermediate component, and joining axial end faces of the first and second end components to respective opposite axial end faces of the intermediate component. Joining the axial end faces is done by friction or laser welding to form welds or weld regions between the components.