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.

A method and an apparatus are provided for manufacturing a stator with a plurality of hairpin conductors. For inserting the hairpin conductors (15, 15) into the slots (11) of a stator core (12) a stator core template (22) is provided. Hairpin conductors (15) are axially inserted into slots (21) of the stator core template (22) such that the hairpin conductor (15) is arranged at a first position (P1) within said slot (21). The hairpin conductor (15) is then moved within said slot (21) to a different position (P2). A complete nest (20) of hairpin conductors (15) formed within the stator core template (22) is then transferred to the stator core (12).

An assembly for assembling a winding group of a bar winding for an electric machine is provided. The winding group includes a plurality of bar conductors, each bar conductor having a first leg, a second leg and a bridge portion connecting the first leg to the second leg, and being shaped so that the first and second legs are mutually spread by a predetermined distance. The assembly includes an annular fixture delimiting a plurality of slots, each slot receiving at least one portion of either the first leg or the second leg, a guiding device defining an annular containment housing, receiving at least partially the first and second legs of the plurality of legs of the plurality of bar conductors that are housed in the plurality of slots, forming at least one radial containment wall for the first and second legs.

A coil insertion guide device includes a positioning jig that positions a stator core; and a guide member that is provided in the positioning jig so as to be able to contact an end face of the stator core in an axial direction. A coil inserted into the slots along the radial direction of the stator core is guided by the guide members. The guide member includes a guide groove. The guide groove includes, on a side close to the end face of the stator core, a cuff support groove that houses and supports a cuff of one of the insulating members that protrudes from the end face of the stator core, and on a side far from the end face, a coil guide groove that protrudes toward an inside of the slot more than the cuff support groove and contacts the coil to guide movement of the coil.

A placement and replacement system and method for placing and replacing the electrical components of electromagnetic rotary machine, wherein the system comprises a frame, multiple of system fixing means to attach the system to the electromagnetic rotary machine, moving means for inserting electrical components to the electromagnetic rotary machine and extracting the electrical components from the electromagnetic rotary machine to place or replace the electrical components.

A stator (1) for an electric machine (101), wherein the stator (1) has N≥3 phases (U, V, W), P≥2 pole pairs, and q≥1 holes, the stator (1) comprises a stator core (3) having at least 2NPq slots (4) and a number of 2NPqL shaped conductors (5) arranged in an even number of L≥4 layers (6a-h) radially layered in the slots (4), the shaped conductors (5) form 2q paths (7a-d) per phase and are arranged in 2P winding zones (8), which each extend radially over L layers (6a-h) and in the circumferential direction over at least q directly adjacent slots (4), the shaped conductors (5) of each path are connected in a series circuit, which is provided by connectors (9a-e, 10a-f, 11a-g) arranged at both end faces (2a, 2b) of the stator core, each path comprises L/2 groups (12a-d) of shaped conductors (5) successively connected in series, each group (12a-d) is formed by at least one arrangement (13a, 13b) of at least four shaped conductors (5) which are arranged alternately in two immediately adjacent layers (6a-g) and are connected in series by first connectors (9a-e) which each provide an offset by qN slots (4) and an offset by one layer, and pairs of groups (12a-d) adjacent with respect to the series connection are each connected by a second connector (10a-f) which provides an offset by a plurality of slots (4) and an offset by two layers.

To provide a stator core which is configured to substantially reduce the effects of electromagnetic brake and thus improve the efficiency of power generation, and to provide a power generation system capable of implementing such stator core to improve the efficiency of power generation, a stator core for power generation by magnetic or electromagnetic induction, comprising a nucleus; and a wire, wound around said nucleus, wherein the wire is wound towards a winding direction such as to form a plurality of wire intersections, is disclosed herein.

An electric machine includes a stator core and interconnected hairpins attached to the stator core and defining a path. A pair of the interconnected hairpins have first and second ends, respectively, and are circumferentially spaced apart from each other. A jumper is interconnected between the first and second ends. The jumper has a body defining first and second holes that receive the first and second ends, respectively. The first hole is defined by a perimeter having opposing first and second walls and opposing third and fourth walls.

A process for assembly of a brushless air core motor-generator includes assembling a rotor formed from two spaced apart rotor portions having magnetic poles that drive magnetic flux circumferentially through the rotor portions and back and forth across an armature airgap between the rotor portions. An air core armature is made by coating a nonmagnetic armature form with a tacky adhesive layer, and winding armature windings in a winding pattern onto the form with a winding head, using wire comprised of bundled multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their lengths where located inside the magnetic flux in the armature airgap. The armature windings are adhered to the nonmagnetic form simultaneously as the winding head traverses the winding pattern while applying pressure to the wire against the tacky adhesive, so tack of the tacky adhesive layer holds the wire to the armature form during the winding process, in the winding pattern later required for magnetic torque production. The air core armature is inserted into the armature airgap and mounted to a stator of the motor-generator for production of magnetically induced torque between the rotor and the stator.

Certain aspects relate to a continuous winding formed from a conductor of rectangular cross-section, the winding having a compound bend in the crowns connecting successive linear segments where the compound bend does not stress the conductor insulation to its failure point. The compound bend can be formed by applying force to the conductor in a first direction, thereby shaping a first bend in the conductor to form a u-shaped conductor having a crown and two linear segments, where the crown includes a v-shaped bend and two straight segments on either side of the v-shaped bend that each connect to one of the linear segments. A second bend can be formed by applying force to the conductor in a second direction perpendicular to the first direction. The shape of the second bend can depend on the desired radius of the winding when circularly wound and positioned in a stator.