An electric generator phase ring handling tool, a phase ring loading tool, base loader, and a system and a method for servicing or installing one or more phase rings in an electric generator using the handling tool, the loading tool and the base loader. Phase rings can be picked up and transported to a generator, inserted into the generator, adjusted while inside the generator, and removed. Installation, removal and servicing of the rings in a generator avoids use of a crane and allows shorten generator outage duration. Without using a crane for installation, removal and servicing, the safety of workers performing these operations is enhanced. Also, increased precision in transporting, placing, installing, removing, and adjusting the rings is obtained, minimizing the risk of damage to the rings and the generator.

A stator includes an annular stator core, a coil, an insulating resin, and a positioning component (first positioning component). The stator core includes a plurality of slots that are arranged in an annular shape and extend through the stator core in an axial direction. The coil includes an insertion portion that passes through the slots. The insulating resin includes a continuous filling portion that is located in a center portion in the axial direction inside a slot of the plurality of slots and that continuously fills a space between an inner wall of the slot and the insertion portion. The positioning component (first positioning component) positions the insertion portion in a state where, on one side in the axial direction with respect to the continuous filling portion, at least a portion of the positioning component enters between the inner wall of the slot and the insertion portion.

A method for producing a winding mat for a stator or a rotor of an electric motor includes providing two conductor strands with at least one conductor in each instance; feeding the conductor strands in each instance to a receiving device along an X direction of a Cartesian coordinate system; simultaneously forming oppositely arranged winding heads at the two conductor strands, each forming a gable. A layer step is stamped in the gables preferably simultaneously. Subsequently, bars extending in opposite direction are formed before the receiving devices are detached from the conductor strands, and the conductor strands are transported by one conveying cycle. The above-mentioned steps are repeated until a winding mat with a defined quantity of windings comprising two winding heads and four bars, respectively, has been produced.

A manufacturing device includes: an upper plate on which a plunger is mounted; a lower plate arranged under the upper plate; and a tray placed on it, on which a laminated core body is mounted. The tray includes: a cylindrical section inserted in a shaft hole of the laminated core body; and a brim section contacting the lower plate from above and an outer portion of the laminated core body from below. The cylindrical section has a resin arrangement hole in which a resin tablet is arranged and the plunger for pressing it is inserted. The brim section has: a plurality of resin flow path grooves extending radially from the arrangement hole on a lower surface opposing the lower plate; and a plurality of gates, each of which extends upward from each of the plurality of flow path grooves and communicates with each of a plurality of magnet insertion holes.

A method produces an electric motor having a motor housing and a stator that has a stator carrier and a number of phase connections. An electronics housing is joined to the motor housing and has a connection side. A substantially pot-shaped rotor bell is produced by way of a deep-drawing process such that a bell base runs oblique to a peripheral bell wall, and that the bell base has a larger wall thickness than the bell wall. The rotor bell and the stator are inserted into a receptacle in the motor housing, wherein the rotor bell and the stator are added into the motor housing by a stamping unit so as to produce an electrical connection between the phase connections and the connection side.

A method of manufacturing a stator sleeve starts with wrapping a cylindrical mandrel with a heated prepreg tape using automated fiber placement. The prepreg tape has a continuous fiber reinforcement within a polymer matrix. Next, cool and remove the cylindrical mandrel from the wrapped prepreg tape resulting in an unfinished cylindrically shaped stator sleeve. Each end of the unfinished stator sleeve is trimmed. Next, abut a first and a second end ring respectively against a first and a second ends of the trimmed stator sleeve using a cylindrical fixture tool. The first and second end rings are the same material as the polymer matrix of the prepreg tape. Finally, laser welding or melt bonding the first and second rings to the first and second ends of the trimmed stator sleeve.

An apparatus for manufacturing a rotor includes a first die configured to contact a first end face of a rotor core to close first openings of magnet housing holes, and a second die configured to contact a second end face of the rotor core on a side opposite to the first end face. The second die includes a passage configured to introduce a thermoplastic in a molten state into second openings of the magnet housing holes. The second openings are on a side opposite to the first openings. The second die also includes a heater configured to heat the passage.

An electric generator phase ring handling tool, a phase ring loading tool, base loader, and a system and a method for servicing or installing one or more phase rings in an electric generator using the handling tool, the loading tool and the base loader. Phase rings can be picked up and transported to a generator, inserted into the generator, adjusted while inside the generator, and removed. Installation, removal and servicing of the rings in a generator avoids use of a crane and allows shorten generator outage duration. Without using a crane for installation, removal and servicing, the safety of workers performing these operations is enhanced. Also, increased precision in transporting, placing, installing, removing, and adjusting the rings is obtained, minimizing the risk of damage to the rings and the generator.

A resolver includes a stator having a stator body formed of a first plastic material and a cover covering a side of the stator. The cover has a cover body formed of a second plastic material. The first plastic material of the stator body is attached to the second plastic material of the cover body by a plastic weld.

A method and device for producing a winding mat for a stator or rotor of an electric motor, in which two conductor strands are each fed to a respective receiving device along an X direction. Oppositely disposed winding heads are formed by a shaping tool and a layer step is stamped in the winding heads in the opposite sense in a Y direction. Bars that extend in a Z direction are formed by a movement of the receiving devices on a curved path, and a lifting movement of the receiving devices is carried out. The conductor strands are transferred to a conveying device and transported in X direction by one conveying cycle. The steps are repeated until a winding mat has been produced having a defined quantity of windings formed in each instance by the two conductor strands and in each instance comprise two winding heads and four bars.