A fan assembly having a reduced dimension formed by several modifications is described. The fan assembly includes a stator having stator coils positioned within a recessed portion of a pillow that receives the motor. The stator may include wire connections positioned between adjacent stator coils and designed to terminate wires of the stator coils. The wire terminations may be on a protrusion or a post positioned between adjacent stator coils, or alternatively, the wire terminations may be disposed on protruding features of a bushing. The protrusion may be formed from an electrically conductive material and electrically connected to a motor control circuit via a flexible printed circuit. In some embodiments, the protrusion is part of an electrically neutral stator bushing having several pins. Also, a gap region between the bushing and a flange feature is designed to improve an adhesive joint.

The present invention provides a connection structure and a manufacturing method therefor capable of increasing reliability of a connection part compared to the prior arts. A connection structure according to the present invention includes a plurality of conductive members, a connection part that electrically connects the conductive members, and an electrically insulating molded body in which the connection part is embedded. It is thereby possible to physically reinforce the connection part of the conductive members, keep the connection part in a hermetically sealed condition, thereby prevent corrosion and increase reliability compared to the prior arts.

A brush-commutated direct-current motor comprises a stator with a plurality of exciter poles, a rotor with a plurality of pole teeth, which is rotatable relative to the stator about an axis of rotation, grooves arranged between the pole teeth, and coil windings arranged on the pole teeth and a commutator which is arranged on the rotor and a plurality of lamellae to which the coil windings are connected. For manufacturing such direct-current motor the coil windings are arranged on the pole teeth in winding cycles, in each of which a coil winding is wound onto each pole tooth. It is provided that on each pole tooth a first coil winding wound around the pole tooth in a first winding direction and a second coil winding wound around the pole tooth in a second winding direction opposite to the first winding direction are arranged.

A centralized power distribution member A configured to feed power to windings of a stator S of a multi-phase motor includes a plurality of annular busbars 10 each including a power feeding terminal 20 and connection terminals 15 to be connected to one ends of the windings of each phase on one side edge, an annular holder 30 made of synthetic resin and configured to accommodate the busbars 10 laminated in a radial direction in a mutually insulated manner, neutral point busbars 50 configured to connect the other ends of the windings of each phase, and auxiliary holders 60, 60X made of synthetic resin and configured to accommodate the neutral point busbars 50. The auxiliary holders 60, 60X are arranged on one end surface side of the annular holder 30 where the power feeding terminals 20 and the connection terminals 15 are arranged.

Provided is a coil insertion method and device that are capable of mechanically manufacturing, with good efficiency, a spirally wound stator core. This coil insertion method comprises: a winding step for winding U-phase, V-phase, and W-phase coils; a step for inserting coils into a transfer block, in which the U-phase, V-phase, and W-phase coils are inserted and held in a plurality of holding grooves of the transfer block so as to spirally overlap, the transfer block having a columnar shape overall, and the holding grooves being formed in radial fashion so as to open from an axial center part toward an outer periphery; and a step for inserting coils into a stator core, in which the transfer block is inserted into an inner periphery of the stator core, and a side part of the coils held in the holding grooves is pressed radially outward toward predetermined slots of the stator core and inserted from the inner peripheral side of the stator core into the slots.

A method of manufacturing a winding assembly for an electrical machine, the method comprising: forming, by three-dimensional, 3D, printing, an electrically insulating body comprising a channel defining a winding path, the channel having an inlet and an outlet; heating the electrically insulating body to a temperature above the melting point of an electrically conducting material; flowing the electrically conducting material through the inlet to the outlet to fill the channel; and cooling the electrically insulating body to solidify the electrically conducting material within the channel, thereby forming said winding assembly.

The invention provides a coil molding attached to a stator of a motor, the coil molding including a coil wound around each of teeth of the stator, and a bus bar connected to the coil and molded integrally with the coil. The invention also provides another coil molding attached to a stator of a motor, the coil molding including a set of coils wound respectively around a plurality of teeth of the stator, the set of coils being molded integrally with each other.

A conductor shaping apparatus rotates one of a first shaping die and a second shaping die about a rotational axis with respect to the other so as to format least one bent portion in a conductor. The conductor shaping apparatus includes a holding section that holds the conductor, a first drive source that applies driving force to the first shaping die and rotates the first shaping die about the rotational axis, a second drive source that applies driving force to the second shaping die and rotates the second shaping die about the rotational axis, and a controller that controls the first and second drive sources so as to rotate one of the first and second shaping dies about the rotational axis with respect to the other and controls the first and second drive sources so as to integrally rotate the first and second shaping dies about the rotational axis.

The coil assembling apparatus includes a transport means for transporting in sequence a plurality of coil segments, each of the plurality of coil segments consisting of a pair of slot insertion portions and a linking portion for coupling the pair of slot insertion portions, a segment arrangement body capable of rotating around a center axis thereof and provided with a plurality of segment hold portions annularly arranged along a circumferential direction of the segment arrangement body, into which the plurality of coil segments transported by the transport means can be respectively inserted from an outer radial directions of the segment arrangement body, and a guide means for guiding to insert one slot insertion portion of the pair of slot insertion portions of each of the coil segments into one of the segment hold portions each time the segment arrangement body rotates by a first predetermined angle.

A stator includes insulation including a back insulation portion covering a back stator portion, a first tooth portion covering a first tooth, a second tooth portion covering a second tooth. A first flange portion has a first face that is in facing relationship with the back insulation portion. A second flange portion has a second face that is in facing relationship with the back insulation portion. The first face and the second face together substantially defining a boundary plane, such that a cross-sectional slot area is defined between the back insulation portion, the first tooth portion, the second tooth portion, and the boundary plane. A plurality of conductive wires are arranged in the cross-sectional slot area, the wires defining a cross-sectional winding area within the cross-sectional slot area. A ratio of the cross-sectional winding area to the cross-sectional slot area is greater than or equal to 0.45.