A rotor having multiple poles is provided and includes at each pole an end winding support forming a channel, a bus bar disposed in the channel and edge-wound coils disposed to extend around the end-winding support and the bus bar. The edge-wound coils are stacked radially and include an inner diameter coil routed to an adjacent pole and brazed to an inner diameter coil of the adjacent pole and an outer diameter coil brazed to the bus bar.

A vehicle includes a battery, an electric machine, a thermistor, and a controller. The electric machine is configured to draw electrical power from the battery to propel the vehicle. The electric machine has a rotor and a stator. The stator has a core, interconnected hairpins, and a neutral bar. The core defines slots. The interconnected hairpin windings are arranged within the slots and are arranged to form a plurality of electrical phases. The neutral bar is connected to each of the electrical phases and defines an orifice. The thermistor is disposed within the orifice and is configured to sense a temperature of the electric machine. The controller is programmed to control a power output of the electric machine based on the temperature of the electric machine.

A method and system of assembling hairpin conductors with a stator core, the system and method including: arranging the plurality of hairpin conductors into two or more sub-assembly fixtures, wherein the plurality of hairpin conductors are arranged in the two or more sub-assembly fixtures in two or more layers; activating a retaining mechanism to hold the plurality of hairpin conductors in place within the sub-assembly fixtures; meshing the two or more sub-assembly fixtures together to bring the hairpin conductors into alignment and form a layered conductor assembly; introducing the layered conductor assembly into the stator core by advancing the two or more sub-assembly fixtures in relation to the stator core in alignment with the locations on the stator core for the layered conductor assembly; and at an appropriate timing, deactivating the retaining mechanism to release the layered conductor assembly from the two or more sub-assembly fixtures.

The method for manufacturing an armature includes a step of independently pressing pressing-target segment conductors by a plurality of pressing jigs disposed for each of the pressing-target segment conductors, such that the plurality of pressing jigs are movable relative to each other, at least either one of first segment conductors and second segment conductors serving as the pressing-target segment conductors.

A method and apparatus for inserting an undulated coil assembly (90) in the hollow core (101) of a dynamoelectric machine, the coil having a planar configuration with adjacent superimposed linear portions (LI) extending parallel to each other and a plurality of turn portions (T) connecting the linear portions (LI), comprising positioning at least a first coil portion (90′) of the coil assembly around a support member (200); aligning a guide assembly (302,303,304) with respect to the end faces and the slots (102) of the core (101); engaging the superimposed linear portions (LI) along guide surfaces that form a passage (301) during the feeding along the guide assembly (302,303,304); feeding the first coil portion (90) from the support member (200) along the guide assembly (302,303,304) to change orientation of adjacent superimposed linear portions (LI) being fed and to insert the adjacent superimposed linear portions being fed in the slots (102); relatively moving the core (101) with respect to the guide assembly (302,303,304) to position the slots (102) for receiving the superimposed linear portions (LI). A hollow core of a dynamoelectric machine wound with an undulated coil assembly comprising superimposed linear portions positioned at different pitch distances (PT1,PT2) in two adjacent slots (102).

The invention relates to a device and a method for transferring conductor parts, in particular plug-in winding elements bent into a U-shape, also known as hairpins, into a desired arrangement.

The invention relates to a stator (2) comprising an annular body (4) having a side face (6) from which a plurality of radial teeth (8) extend, said teeth being angularly spaced in such a way as to define slots (10), and a plurality of conductive needles (15A, 15B), each conductive needle comprising two conductive segments (16A, 16B, 16C, 16D) connected by an elbow connector (18), the conductive segments being stacked one above the other in the slots (10) so as to form N layers which are parallel or substantially parallel to the side face (6) of the annular body. Each conductive needle (15A, 15B) comprises a conductive segment present in two separate slots, with one conductive segment present in a slot E in such a way as to occupy a layer (Ci) and another conductive segment present in a slot E+P in such a way as to occupy a layer (Ci+2), P being a pitch that is predetermined in a first direction of orientation.

A pre-fitting nest and a method serve for forming a crown from a plurality of U-shaped electrically conductive hairpins to then be able to install the crown in a machine element of an electric machine, e.g., a stator. Here, an accommodating member has a plurality of grooves in which the legs of the hairpins are accommodated. The grooves are annularly disposed about a center and extend perpendicularly to the plane of the accommodating member. With respect to their size and geometry, they are configured such that in each case a first leg of a hairpin rotates within the groove thus to enable an unconstrained positioning of the second leg of the hairpin in another groove. One or several crowns formed from hairpins are provided for introduction into a machine element and inserted into the machine element.

Provided is a method for manufacturing a coil unit that is suited to the bulk manufacturing of multiple sets of coil parts for a multi-axis linear motor actuator. This method of manufacturing a coil unit for a multi-axis linear motor actuator, which is constituted by disposing multiple sets of linear shaft motors 10 in a line at a prescribed pitch, includes: a step in which a coil fixing member 50 is prepared that holds receiving parts 51 that are capable of receiving multiple coil parts 15, which are equal in quantity to the multiple sets of linear shaft motors, with the coil parts being arranged in a line at the prescribed pitch; a step in which the multiple coil parts are disposed by being arranged in a line and secured to the coil fixing member; and a step in which electromagnetic shielding plates 70 that are longer than the coil parts are disposed along a center axis direction at locations corresponding to the spaces between at least adjacent coil parts among the multiple coil parts disposed in the line.

A method of producing an electromagnetic mat for forming a stator or rotor component of an electric machine. The electromagnetic mat has structural fibre lengths and a plurality of winding fibre lengths for forming a winding fibre that is in a winding pattern for forming one or more windings of the electric machine. The electromagnetic mat is formed by forming a support structure with the structural fibre lengths and inserting the winding fibre lengths into the support structure so that the winding fibre lengths extend across the structural fibre lengths and the structural fibre lengths lock the winding fibre lengths in position.