A method of manufacturing a rotary electric machine armature that includes a cylindrical armature core in which a plurality of slots that extend in an axial direction are disposed in a circumferential direction and a coil wound around the armature core, the slots having respective radial openings that open in a radial direction, and the coil being formed by joining a plurality of segment conductors to each other.

A winding method for a stator module applicable to a motor having z slots, 2p poles, and m phases. The stator module includes a stator core and a winding coil. The winding coil is made of a flat wire. The winding method includes: forwardly winding some stator slots by means of the arrangement and connection of multiple U-shaped conductor sections, and then reversely winding the stator slots; afterwards, forwardly winding the remaining stator slots, and then reversely winding the stator slots; and cycling in this way.

A method of manufacturing a stator assembly for an electric motor or generator is disclosed, comprising: providing a plurality of stator windings, each stator winding formed from a multistrand cable that comprises a plurality of wires that are electrically insulated, connecting an end of the multistrand cable of each stator winding to a respective conductive stud and then mounting the stator windings in a stator housing.

A closed socket brazed joint assembly is provided. The assembly comprises: a first member composed of a first base material; a second member composed of a second base material with a first end composed of a first profile with at least first and second faying surfaces; a socket formed in said first member configured to receive the first end of the second member with a faying surface with at least two portions separated by a first fillet; wherein the socket further is configured such that in a first state before the application of energy to the joint there is a gap with a width between the faying surfaces of the first member and the faying surfaces of the second member; and, in the first state a slug of brazing fill material is disposed between the first end of the second member and at least one faying surface of the socket; and, wherein a second state is created when upon application of energy the brazing fill material melts and flows from between first end of the second member and the at least one faying surface of the socket filling aforesaid gap between the faying surfaces of the first and second members.

An electric machine assembly including a terminal assembly and three terminal lugs is provided. The terminal assembly may include three pairs of terminal leads. Each of the three terminal luges may define a pair of terminal lead through-holes and a pair of opposing radial sides. Each terminal lug may be compressed at one of the sides to deform a respective terminal lug and secure each of the pair of terminal leads within one of the pair of terminal lead through-holes. The assembly may further include a stator disposed within a housing and include end windings. Each of the terminal leads may include a base terminal portion. The terminal assembly and the stator may be arranged with one another such that each base terminal portion is aligned with one of the end windings for securing thereto. The assembly may further include three bridges.

A method of engaging wire ends of a stator assembly. The method involves advancing multiple fingers radially inwardly toward the wire ends, and rotating the fingers. The fingers have protrusions that engage the wire ends. A tooling assembly for engaging the wire ends has a first plate, a second plate, and has the fingers. The first plate has slots, and the second plate has teeth. The fingers have pins that ride in the slots of the first plate, and the fingers have teeth that mesh with the teeth of the second plate.

The invention relates to a method (100) for electrically contact-connecting a winding (40) of an electrical machine (1) to a printed circuit board (92), wherein the electrical machine (1) has an armature (10) with a large number of teeth (20), wherein at least one winding (40), which is formed by an electrical conductor (42), is formed on one of the teeth (20). The method comprises the following steps: routing (110) the conductor ends (45) of the electrical conductor (42) out of the armature (10) in the axial direction of the electrical machine (1), shortening (115) the conductor ends (45) to the same length, routing (120) the conductor ends (45) through in each case one passage opening (67) in a centring element (66), wherein the centring element (66) has a centring means (69) which centres and orients in parallel the routed-through conductor ends (45), wherein the routed-through conductor ends (45) emerge from the centring element (66), routing (125) the conductor ends (45) through in each case one passage opening (73) in a sealing element (72), wherein the routed-through conductor ends (45) emerge from the sealing element (72), inserting (130) the centring means (69) into in each case one passage opening (73) in a sealing element (72), arranging (135) the sealing element (72) at least partially within a passage opening (6) in a housing element (5), and electrically contact-connecting (140) the conductor ends (45) to the printed circuit board (92).

An interconnection board (52) of a stator (10) of an electrical machine (12), as well as a method for producing same, by means of which an electrical winding (16) of the stator (10) can be connected to customer-specific connecting plugs (56) for power supply, wherein the interconnection board (52) has a closed ring (61) as a plastic body (62), onto which closed ring (61) exactly three holding elements (63) are integrally formed, extending in the axial direction (3), in which holding elements respective axial connector plugs (54) made of metal extend in the axial direction, wherein the axial connector plugs (54) are each integrally configured with conductive elements (58) which can be directly electrically connected to connecting wires (30, 31) of the electrical winding (16).

A method of manufacturing a rotor of an electric motor or an electric generator includes positioning a plurality of amortisseur bars and using additive manufacturing to place electrically conductive material. More specifically, positioning the amortisseur bars may include circumferentially positioning the bars around a rotor stack and using additive manufacturing to place electrically conductive material may include forming a non-solid pattern of electrically conductive material, such as a pattern of electrically conductive traces, across opposite axial ends of the rotor stack to electrically interconnect an amortisseur circuit.

A method for manufacturing a stator in the related art has a problem that the size of a stator cannot be sufficiently reduced. A method for manufacturing a stator according to the present disclosure includes: a welding end holding process of holding, by welding clamps, a coil end that is one end of wiring composing each of the coils and another wiring different from that of the coil; an electrode end holding process of holding an energizing position provided in the other wiring by a conductive electrode clamp; and a welding process of energizing the electrode clamp, and joining the coil end and the other wiring clamped by the welding clamps to each other by the TIG welding.