A rotating electrical machine connection component includes a plurality of linear conductors, and a first molded resin portion that covers portions of the plurality of linear conductors and connects the plurality of linear conductors to each other. Each of the plurality of linear conductors includes a first straight portion extending out of the first molded resin portion in a direction parallel to a rotational axis of the rotor and connected to the terminal block, a second straight portion extending out of the first molded resin portion in a different direction from the first straight portion and a bent portion bent between the first and second straight portions. Of each of the plurality of linear conductors, a part of the first straight portion, the bend portion and a part of the second straight portion are covered by the first molded resin portion.

A motor including a rotor, and a stator having a plurality of coils wound around slots, wherein at least any one of the coils includes a single aluminum wire, a single copper wire joined to the aluminum wire, a stranded wire (lead wire) joined to the copper wire, a cold-pressure-welded joint portion (joint portion) joined between the aluminum wire and the copper wire by cold pressure welding, and a non-pressure welded joint portion (joint portion) provided between the copper wire and the stranded wire (lead wire). A burr covered by an insulation member (insulation tube) is provided in the cold-pressure-welded joint portion (joint portion). A thickness of the insulation member (insulation tube) is larger than a height of the burr.

A stator (1) of a rotary electric machine includes a body (2) provided with slots (15), a coil (3) constituted of windings (4, 5, 6, 7, 8) that include first conductive segments (19) equipped with two first branches and second conductive segments (25) provided with two second branches. Each conductive segment is coated with insulation except for the presence of a bared surface on each one of the branches. The shapes of the bared surfaces complement one another. The first and second conductive segments are arranged in a staggered configuration and in opposite directions successively one after the other, with each slot accepting first branches and second branches positioned opposite with the bared surfaces thereof respectively in contact with one another in such a way as to form a continuous wire. The stator includes elements for keeping the bared surfaces in contact with one another in the slots.

The invention relates to a stator for an electric machine, comprising a plurality of rod conductors and at least one insulation disk that is arranged in an end face region of the stator and includes a plurality of interconnection pieces. Rod conductor contact surfaces and interconnection piece contact surfaces have corresponding shapes such that a planar contact can be created; for this purpose, the interconnection piece protrude from the insulation disk in the radial direction at least along the interconnection piece contact surface such that a plurality of interconnection piece contact surfaces can simultaneously come into contact with the associated rod conductor contact surfaces. The invention further related to an electric machine and to a manufacturing process.

A rotor coil for a revolving armature includes a strand coil that includes a part arranged in a core slot of the rotor and is composed of a plurality of element wires; and a solid coil welded to an end of the strand coil wherein the end of the strand coil and an end of the solid coil are welded by friction stir welding. A manufacturing method of a rotor coil includes the step of performing friction stir welding wherein the friction stir welding is performed for the butt joint with the end of the strand coil arranged in an advancing side defined by a rotation direction of a tool and with the solid coil arranged in a retreating side.

A method for manufacturing a stator of a waterproof motor includes disposing a first assembly in a mold where the first assembly includes a coil unit wound around an iron core assembly, and filling the mold with a thermosetting plastic which forms a housing after curing. The housing houses the coil unit and the iron core assembly. A recess is formed at one end of the housing. The method further includes disposing a second assembly in the recess of the housing where the second assembly includes a circuit unit, and filling the recess of the housing with a waterproof glue which envelopes the circuit unit after curing. According to the above, the stator of the waterproof motor is formed.

A conductor shaping apparatus includes a driving device that relatively rotates an upper die and a lower die and integrally rotates the upper and lower 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 so as to separate the one of the upper and lower dies from the other. 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.

A motor stator assembly includes a stator core, at least one winding coil, a circuit board, a metallic post and a covering member. The stator core includes plural poles. The winding coil is wound around the corresponding pole. The metallic post has a first end surface and a second end surface. The second end surface is attached on the circuit board. The covering member is used for partially covering the metallic post. The covering member includes plural protrusion parts and plural notches. A bottom surface of the notch is not higher than the first end surface. A top surface of the protrusion part is not lower than the first end surface. An outlet part of the winding coil is transferred through at least two of the plural notches and fixed on the first end surface.

A rotor core includes laminate steel plates extending in a radial direction with respect to a central axis. The laminate steel plates each include a base portion on a radially outer side of the central axis, and pieces separately disposed on a radially outer side of the base portion with penetrating portions therebetween, and arranged side by side at predetermined intervals in a circumferential direction. The laminate steel plates are laminated in an axial direction. The laminated steel plate at an upper end in the axial direction includes at least one of an outward projection extending radially outward from an outer edge portion of the base portion and an inward projection extending radially inward from an inner edge portion of the piece, and the laminated steel plate at a lower end in the axial direction includes an intervening portion between the base portion and the piece portion.

Provided are a rotor, a manufacturing method of the rotor, and a DC motor including the rotor, the rotor including: a core around which a winding is wound, the core being rotatable integrally with a shaft; a commutator being fixed to the shaft and having a terminal to be connected to one end of the winding; and a conduction plate being externally fitted onto the shaft via an insulator part between the terminal of the commutator and the core, the conduction plate having a connection part to be connected to the other end of the winding, wherein an axial direction position of the connection part is set in an intermediate portion that is between a winding projection of the winding and the terminal.