The present disclosure is directed to slotless electric motor, in particular, to a method of manufacturing a stator for a slotless electric motor. An aspect of the disclosure provides a method of manufacturing a stator for a slotless electric motor, the method comprising: disposing a conductor in the shape of an annular cylinder; bonding a plurality of bonded lengths of the conductor, wherein the plurality of bonded lengths are separated by non-bonded lengths; folding the conductor to provide a plurality of petals repeated along the conductor, wherein each petal comprises a pair of bonded lengths connected by a non-bonded length; rotating each petal about a point on the second circle to align in parallel the bonded lengths of all of the petals to thereby provide a stator comprising a cylindrically-shaped conductor wherein the bonded lengths are equidistantly disposed around and from a central longitudinal axis of the cylindrically-shaped conductor.

An apparatus has a plurality of poles facing an air gap, and the poles are configured to generate a magnetic field in the air gap. The poles include a group of unchanged poles and a group of reversible poles, where a polarity of each reversible pole is configured to be changed during an operation mode, and after the polarity has been changed, each reversible pole and at least an adjacent unchanged pole in effect merged into one augmented pole, such that the pole number of the magnetic field in the air gap is changed.

An apparatus has a plurality of poles facing an air gap, and the poles are configured to generate a magnetic field in the air gap. The poles include a group of unchanged poles and a group of reversible poles, where a polarity of each reversible pole is configured to be changed during an operation mode, and after the polarity has been changed, each reversible pole and at least an adjacent unchanged pole in effect merged into one augmented pole, such that the pole number of the magnetic field in the air gap is changed.

Various embodiments relate to a motor in which a structure of an insulator is improved. The motor includes an insulator module coupled to a top face of a stator core. The insulator module includes: each power terminal unit connected to each of 3-phases power lead wires; a neutral terminal unit connected to a neutral point of a coil; and an insulator body for achieving insulations between the power and neutral terminal units and the stator core, and between the power and neutral terminal units, wherein the power terminal unit and the neutral terminal unit are positioned at different vertical levels.

The invention relates to a method for producing an arrangement for a plug-in coil of an electrical machine, comprising the steps of: providing a core with slots; providing coil elements which are rod-shaped and have a proximal end and a distal end; inserting the coil elements into the slots from an end side of the core with the distal end at the front in such a way that the proximal end is arranged in the region of the end side and the distal end is arranged in the region of an opposite end side of the core or adjacent to it; and producing a respective jointed connection for the distal ends or the proximal ends of a first coil element and of a second coil element with an associated first connecting element on the opposite end side or the end side of the core, wherein, here, before joining between the respective joining partners, specifically the distal end or the proximal end of the first coil element and a first joining section of the first connecting element and also the distal end or the proximal end of the second coil element and a second joining section of the first connecting element, a connection is formed in each case, with which the relative position of the joining partners in relation to one another is defined. The invention further provides an arrangement for a plug-in coil of an electrical machine.

The invention relates to a method for producing an arrangement for a plug-in coil of an electrical machine, comprising the steps of: providing a core with slots; providing coil elements which are rod-shaped and have a proximal end and a distal end; inserting the coil elements into the slots from an end side of the core with the distal end at the front in such a way that the proximal end is arranged in the region of the end side and the distal end is arranged in the region of an opposite end side of the core or adjacent to it; and producing a respective jointed connection for the distal ends or the proximal ends of a first coil element and of a second coil element with an associated first connecting element on the opposite end side or the end side of the core, wherein, here, before joining between the respective joining partners, specifically the distal end or the proximal end of the first coil element and a first joining section of the first connecting element and also the distal end or the proximal end of the second coil element and a second joining section of the first connecting element, a connection is formed in each case, with which the relative position of the joining partners in relation to one another is defined. The invention further provides an arrangement for a plug-in coil of an electrical machine.

A stator for a rotary electric machine includes a stator core and a stator winding. The stator core has a hollow cylindrical shape and includes slots. The stator winding includes segment conductors held in the slots. The slots extending outward in a radial direction from an inner peripheral surface of the stator core. The slots include first and second slots. The second slot is shallower than the first slot. The segment conductors include a segment conductor including a first rectilinear portion held in the first slot, a second rectilinear portion held in the second slot, and a coupler coupling the first rectilinear portion and the second rectilinear portion to each other. The first rectilinear portion and the second rectilinear portion protrude from an end surface of the stator core.

A stator for a rotary electric machine includes a stator core and a stator winding. The stator core has a hollow cylindrical shape and includes slots. The stator winding includes segment conductors held in the slots. The slots extending outward in a radial direction from an inner peripheral surface of the stator core. The slots include first and second slots. The second slot is shallower than the first slot. The segment conductors include a segment conductor including a first rectilinear portion held in the first slot, a second rectilinear portion held in the second slot, and a coupler coupling the first rectilinear portion and the second rectilinear portion to each other. The first rectilinear portion and the second rectilinear portion protrude from an end surface of the stator core.

A brushless DC motor (BLDC) includes a stator having a ring-shaped body with multiple stator posts extending axially outward from the ring-shaped body. A plurality of stator windings are each wound about a corresponding one of the stator posts. A rotor support structure is positioned radially inward of the multiple stator posts. A rotor including a shaft is received in the rotor support structure. A first rotor disk is fixed to a first end of the shaft. At least a first set of magnets is disposed about the rotor disk and positioned radially adjacent to the stator posts such that the first set of magnets and the stator windings define a first radial flux flowpath. A second set of magnets positioned relative to the stator posts in one of an axial adjacency or a radial adjacency such that a second flux flowpath is defined.

A brushless DC motor (BLDC) includes a stator having a ring-shaped body with multiple stator posts extending axially outward from the ring-shaped body. A plurality of stator windings are each wound about a corresponding one of the stator posts. A rotor support structure is positioned radially inward of the multiple stator posts. A rotor including a shaft is received in the rotor support structure. A first rotor disk is fixed to a first end of the shaft. At least a first set of magnets is disposed about the rotor disk and positioned radially adjacent to the stator posts such that the first set of magnets and the stator windings define a first radial flux flowpath. A second set of magnets positioned relative to the stator posts in one of an axial adjacency or a radial adjacency such that a second flux flowpath is defined.