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.

Stator for an electrical machine, comprising a stator core with stator slots which are formed along an axial direction with respect to a center axis of the stator and are arranged in a manner distributed in a circumferential direction with respect to the center axis, a hairpin winding with a large number of hairpin element arrangements which are arranged in the stator slots and each emerge from the end side of the stator core, and at least one insulation apparatus with a body in which a large number of passage openings which are arranged in a manner distributed in the circumferential direction are formed; wherein a respective hairpin element arrangement passes through one of the passage openings and the insulation apparatus specifies a distance of the hairpin element arrangement from an edge of the stator slot which receives the hairpin element arrangement.

An electric motor includes three busbars in contact at end surfaces thereof and including ring-segment-shaped base portions to provide electrical connection of the busbars. The base portion of a first busbar is in a first plane and the base portion of a second busbar is in a second plane. The base portion of the first busbar extends clockwise from the terminal of the first busbar and the base portion of the second busbar extends counterclockwise from the terminal of the second busbar. Terminals of the first and second busbars are spaced apart with the terminal of the third busbar between the first and third terminals. The third busbar includes a first region extending clockwise from its terminal and lying in the second plane and a second region extending counterclockwise from its terminal and lying in the first plane.

An electric motor includes three busbars in contact at end surfaces thereof and including ring-segment-shaped base portions to provide electrical connection of the busbars. The base portion of a first busbar is in a first plane and the base portion of a second busbar is in a second plane. The base portion of the first busbar extends clockwise from the terminal of the first busbar and the base portion of the second busbar extends counterclockwise from the terminal of the second busbar. Terminals of the first and second busbars are spaced apart with the terminal of the third busbar between the first and third terminals. The third busbar includes a first region extending clockwise from its terminal and lying in the second plane and a second region extending counterclockwise from its terminal and lying in the first plane.

A stator for an electric machine comprises a cylindrical core defining an inner cylindrical surface and an outer cylindrical surface with a plurality of slots formed between the inner cylindrical surface and the outer cylindrical surface. Windings are positioned on the cylindrical core. The leads of the windings include a plurality of inner leads associated with conductors in an inner layer of the slots and a plurality of outer leads associated with conductors in an outer layer of the slots. A bus bar assembly includes a plurality of inner bus bars and a plurality of outer bus bars, the plurality of inner bus bars connected to the plurality of inner leads, and the plurality of outer bus bars connected to the plurality of outer leads. The plurality of outer bus bars are positioned radially outward from the end turns of the windings and radially inward from the outer cylindrical surface.

A stator for an electric machine comprises a cylindrical core defining an inner cylindrical surface and an outer cylindrical surface with a plurality of slots formed between the inner cylindrical surface and the outer cylindrical surface. Windings are positioned on the cylindrical core. The leads of the windings include a plurality of inner leads associated with conductors in an inner layer of the slots and a plurality of outer leads associated with conductors in an outer layer of the slots. A bus bar assembly includes a plurality of inner bus bars and a plurality of outer bus bars, the plurality of inner bus bars connected to the plurality of inner leads, and the plurality of outer bus bars connected to the plurality of outer leads. The plurality of outer bus bars are positioned radially outward from the end turns of the windings and radially inward from the outer cylindrical surface.

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.

A stator for a rotary electric machine includes a stator core, a stator winding, and a sensor unit. The stator has a hollow cylindrical shape and includes slots. The stator winding includes segment conductors respectively inserted in the slots. The sensor unit includes a sensor holding conductor, and a temperature sensor. The sensor holding conductor is welded to first and second segment conductors among the segment conductors. The temperature sensor is held by the sensor holding conductor. The sensor holding conductor includes first and second end portions, and a bent portion. The first end portion is welded to an end portion of the first segment conductor. The second end portion is welded to an end portion of the second segment conductor. The bent portion couples the first end portion and the second end portion to each other. The temperature sensor is held at an inner side of the bent portion.

A modular motor system and methods wherein at least two dual radial gap motors with attachment points may be joined together in a modular manner for the purpose of providing the capability of incrementally increasing or decreasing the total power output of the modular.