A wire material is hooked to a commutator segment and a commutator segment to form an equalizing line therebetween, and the wire material is wound in a distributed manner between a slot and a slot to form a main winding. Subsequently, the wire material is hooked to a commutator segment and a commutator segment to form an equalizing line therebetween, and the wire material is wound in a distributed manner between a slot and a slot to form a main winding. As described above, a process of forming the equalizing line and a process of forming the main winding are repeated while changing the commutator segment to which hooking is to be performed and the slot in which the main winding is to be formed until the number of times of hooking to one commutator segment becomes the same number for all the commutator segments and the number of times the main winding is formed in one slot becomes the same number for all the slots.

An apparatus used in terminating and winding coils of a core of a dynamo electric machine. The coils being formed from at least an electric wire and the core having a longitudinal axis. The coils are wound by relatively moving a wire dispenser with respect to a core with relative motions of translation and rotation; at least a stretch of wire extends from the coil; and the stretch of wire is provided with a portion for a termination connection to a termination structure of the core, such as a tang. The method avoids waste cut wire in the apparatus. The core is provided with a groove at an end to receive at least a wire in the path of the wire for the termination of the coils. The apparatus comprises a wire deflector positioned adjacent the end of the core, where the groove is located, in order to intercept and align the wire with the groove. The apparatus can comprise a device for applying torques in two directions on a pulley wheel for feeding wire as a function of the position of the dispenser in the translation and the position of the core in the rotations.

A stator for an electric rotary machine including a stator core and a coil, wherein: the coil has plural slot coils and plural connection coils, each slot coil being inserted into the slot, each connection coil connecting the slot coils in a position lying further axially outwards than an axial end face of the stator core, and the coil being constituted in such a way that the slot coil and the connection coil are joined at an abutment portion; and in a hole portion, where the abutment portion is accommodated, of a insulation plate, the connection coil and the slot coil are spaced apart from the insulation plate in the circumferential direction to thereby form a first gap portion.

In a coil forming device, an edge line in an escape region is formed so that a clearance between the edge line in the escape region and a recess portion in an axis direction is larger than a minimum clearance between the edge line in an inclined region and the recess portion in the axis direction. When a second die is rotated relative to a first die in the clockwise direction the flat-square conductive material end is bent in flatwise bending by the recess portion and the inclined region of a protrusion portion, and then, the flat-square conductive material end reaches the escape region.

A method for welding a plurality of wire segment pairs is disclosed. Each wire segment pair has two adjacent wire segments, and each adjacent wire segment has a contact region where the wire segment is to be welded to the respective other wire segment. The wire segment pairs are successively guided between two elements of a pressing unit, and at a weld moment in which at least one of the wire segment pairs is located between the two elements. The pressing unit exerts a pressing force onto the wire segment pair such that the contact regions of the wire segments are pressed against each other. At each weld moment, laser radiation is irradiated onto the wire segment pair to which the pressing unit is exerting the pressing force, and the laser radiation is irradiated onto a region in which the contact regions are pressed against each other.

An electric motor may include a rotor assembly including a rotor shaft defining a rotational axis. An electric motor may include a stator assembly including a core, an insulator at least partially covering the core, and a plurality of windings, the insulator defining one of a post that protrudes in an axial direction parallel with the rotational axis or a receptacle in which the post is receivable. An electric motor may include a bus bar assembly including a non-conductive body and a plurality of conductors configured to make an electrical connection between at least two windings of the plurality of windings, the non-conductive body including the other of the post or the receptacle, wherein the receptacle includes at least one of an aperture or a recess, and wherein the post is received within the receptacle to secure the non-conductive body to the insulator.

A motor stator wiring structure includes a stator wiring frame, a connecting element, and a wire group. The stator wiring frame has a block which has a connecting portion. The connecting portion has a first mating surface. Each wire in the wire group has a bare wire segment, an encapsulation segment, and an extension segment. The encapsulation segments of the wires are assembled within channels of the connecting member. The connecting member has a second mating surface that is connected to the first mating surface of the connecting portion. Multiple coils are wound around the stator wiring frame, and the lead ends of the coils are respectively wound around the bare wire ends of the wires and soldered in place. This achieves the simplification of the production process, reduction of production costs, and adaptability to adjusting the wiring for motors of different size specifications in the motor stator wiring structure.

An article can include a ceramic insulator with an interior surface defining a recess, an insulator aperture in the interior surface, and an insulator cooling channel extending through at least a portion of the ceramic insulator to the insulator aperture. A first conductor can be at least partially disposed within the recess.

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 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.