A vehicle, electric machine, and method of manufacturing an electric machine include a stator having teeth extending from a yoke portion toward a rotor and defining slots between adjacent teeth with windings positioned within the slots, wherein the slots are coated with an electrically insulating material having an arcuate surface exiting the slots and extending at least partially over the teeth on at least one end face of the stator to form a winding guide for bending/positioning the windings. The winding guide may be formed by a molded epoxy that replaces insulating paper slot liners while providing a template for forming the hairpin bends of end windings.

The invention relates to a method for producing stranded wires, including the steps of applying an insulation layer to lines, separating the insulated lines, individually removing the insulation layer from the separated lines along a partial length of the lines, and bringing the lines together to form a stranded wire, wherein the partial lengths are arranged at the same level at least in sections for the purpose of forming a non-insulated contact region.

A coil insertion method includes winding U-phase, V-phase, and W-phase coils; inserting the U-phase, V-phase, and W-phase coils into a transfer block, such that the U-phase, V-phase, and W-phase coils are held in a plurality of holding grooves of the transfer block so as to spirally overlap, the transfer block having a columnar shape, and the holding grooves being formed in radial fashion around the transfer block so as to open from a center part of the transfer block toward an outer periphery thereof; inserting the transfer block into an inner periphery of the stator core; and pushing a side part of the coils held in the holding grooves radially outward toward predetermined slots of the stator core so that the coils are inserted from the inner peripheral side of the stator core into the slots.

A method of manufacturing of the bus bar assembly includes preparing a mold, positioning a bus bar and a shield in the mold, and molding a bus bar holder. The positioning includes inserting first positioning pins into bus bar through holes to cause the first positioning pins to hold the bus bar, providing the shield in the mold in a state where a lower surface of the shield and a distal end of the first positioning pin are in contact with each other, bringing a second positioning pin into contact with an upper surface of the shield and positioning the shield in a vertical direction, and bringing a third positioning pin extending downward from a lower surface of an upper mold into contact with an upper surface of the bus bar to position the bus bar in the vertical direction.

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 relates to a device, a system and a method for positioning the ends of at least first pair of legs of hairpin conductors extending from a stator core with respect to a welder tool. The device (300) comprises a first clamping element (302) and a second clamping element (303), wherein said first clamping element (302) and said second clamping element (303) are independently moveable radially. Said first clamping element (302) has a first clamping surface (304) and said second clamping element (303) has a second clamping surface (305), wherein the first and second clamping surfaces (304, 305) are radially facing each other. The clamping elements (302, 303) form a first, preferably radially inner, receiving section (306) between the first clamping surface (304) and the second clamping surface (305), having a first radial width (307) dimensioned to axially receive and clamp a first pair (5) of legs during welding, and a second, preferably radially outer, receiving section (308) inside the first and second clamping element, having a second radial width (309), dimensioned to receive at least a further pair (6) of legs during welding of the first pair of legs.

A manufacturing method of an electric pump includes engaging and welding first and second extended portions with first and second hooks, respectively, and cutting a plurality of connecting portions after the engaging and welding.

A rotary electric machine has a rotor and a stator. The stator comprises a stator coil. The stator coil has a bus bar made of a conductive member that is electrically connected to a coil terminal included in a coil end. The stator has a holder which accommodates the bus bar and is made of an insulating member. The holder is positioned so that the opening or the resin member faces towards the stator core.

A stator unit for including a plurality of coils includes a stator core configured to have the coils wound around the stator core; and a routing member including a plurality of groove configured to have wires routed in the groove, the wires extending from the coils.

A method for manufacturing an electro-mechanical device includes creating a plurality of substrates using a first additive manufacturing process. Each of the substrates includes a polymeric material. The substrates include a first substrate and a second substrate. The first substrate includes a first main body and defines a protrusion extending from the first main body. The second substrate includes a second main body and a recess defined in the second main body. The method includes coupling the first substrate to the second substrate by inserting the protrusion into the recess such that the protrusion elastically deforms to an elastically averaged configuration. The protrusion and the recess together form an elastic averaging coupling. The method includes creating a plurality of electrically conductive components using a second additive manufacturing process and then coupling the electrically conductive components to at least one of the substrates.