A terminal connection of a rotary electromagnetic device and a method of connecting a terminal to an aluminum stator wire of the rotary electromagnetic device without changing stator configuration is described. A de-insulated portion at one of ends of the stator wire is connected to a small connection wire made of copper by ultrasonic welding to form a mutually welded stator wire and connection wire portion. The mutually welded stator wire and connection wire portion are soldered to the terminal to, therefore, form an electric connection between the stator wire and the terminal.

A stator for an electrical machine, the stator having a yoke with longitudinal grooves, which extend along an inner peripheral edge parallel to a longitudinal axis of the yoke and are separated by stator teeth, wherein compressed strands are inserted into the longitudinal grooves, which strands each consist of individual wires, wherein respective ends of the strands exit the grooves at a yoke head and protrude from the yoke, while extending parallel to the axis, wherein the wires of each strand are electrically conductively connected at ends of the strand, and a first end of a first strand, which protrudes from one yoke head, is electrically conductively joined to a second end of a second strand, which protrudes from the one yoke head and comes from another groove, by a separate electrically conductive connecting element to form an electrical winding, the first end and the second end mechanically not touching.

A wire holder for a stator of an electric motor includes a main body including a first wall portion and a second wall portion, and a partially annular clamp section which extends over 90 to 210 in a circumferential direction. The second wall portion defines an end surface of the clamp section and projects radially inwards, and includes at least two clamp sockets on the end surface and pointing away from the clamp section in an axial direction. The clamp sockets include at least one slot into which a winding connection wire can be laid.

A busbar apparatus includes a busbar to be connected to an external device, and a holder to hold the busbar and made of an insulating material. The busbar includes a terminal portion to be connected to the external device, an intermediate portion continuous with the terminal portion, and a connection portion continuous with the intermediate portion. The intermediate portion includes an edge portion including portions extending along a first axis. The terminal portion extends from the edge portion. The connection portion extends from the edge portion away from the terminal portion. The terminal portion has a thickness direction extending along a second axis not parallel to the first axis. The connection portion has a thickness direction not parallel to the second axis.

Three substrate side terminal members are provided on a circuit substrate on which electronic components for controlling a brushless motor are disposed. Two of the substrate side terminal members protrude on a side in close proximity to bearing retaining members, and the remaining one substrate side terminal member protrudes on a side separated from the bearing retaining members. Ends of flexible wire members, the other ends of which are held in engagement with stator side terminal members, are held in engagement with the three substrate side terminal members.

Provided are a one body type terminal assembly of a driving motor for a vehicle and a manufacturing method thereof, the one body type terminal assembly including a bus bar assembly including a plurality of ring-shaped bus bars overlapping each other, each of which is primarily insert-injection-molded and of which an outer surface is surrounded with an insulating material; and flanges which are simultaneously insert-injection-molded with the bus bar assembly to be formed to protrude from an outer circumferential surface of the bus bar assembly at intervals when the bus bar assembly is secondarily insert-injection-molded.

A conductor shaping apparatus includes a driving device that relatively rotates an upper die and a lower die and integrally rotates the two dies with respect to a shaping member. The driving device rotates one of the upper and lower dies in a direction from an edgewise bent portion to a distal end of a conductor. One of the upper and lower dies includes a supporting surface configured to support a side surface of an end portion of the conductor as the edgewise bent portion is formed in the end portion, and a guide surface that is formed to intersect the support surface. The guide surface extends away from the end portion of the conductor in a direction opposite to a bent direction of a flatwise bent portion closest to the edgewise bent portion as it extends away from the supporting surface on an opposite side of a rotational axis.

In a motor stator, terminal wires of a coil are led out respectively from a feed-side and a neutral-side coil end. With three circumferentially adjacent first-, second-, and third-phase coils as one set, the leading end portion and intermediate portion of one of three terminal wires led out from the neutral side are connected to each of the remaining terminal wires. A structure wherein the first- and second-phase terminal wires are connected together in one position, and the second- and third-phase terminal wires are connected together in a different position from the one position, is adopted, thus compacting the size of one wire connection portion.

A stator of an electric machine includes a laminated core having slots for receiving windings of a multiphase winding system. The windings have winding ends, which are encased with an insulator across a partial length. In order to encase the winding ends with the insulator, a strand of a thermoplastic material is extruded onto the winding ends via a nozzle. During extrusion, the nozzle is moved relative to the winding end along the longitudinal extent thereof and an oscillating movement of the nozzle transversely to the longitudinal extent of the winding end overlays the movement along the longitudinal extent. As a result the thermoplastic material lies on the winding end and around the respective winding end in the form of loops.

A system includes a pair of terminal leads joined together. An insulative sleeve is wrapped around the pair of terminal leads. Lacing binds around the insulative sleeve. Cured epoxy can encase the insulative sleeve and lacing. The insulative sleeve can include fiberglass. The insulative sleeve can be wrapped more than 360 around the pair of terminal leads so that a first edge of the insulative sleeve is tucked under a second edge of the insulative sleeve.