A system for manufacturing a stator assembly having a stator core that includes slots and coils inserted into the slots includes a core loader, an insulation sheet inserter at a rear of the core loader to insert an insulation sheet into the slots, a coil former at a rear of the insulation sheet inserter to form the coils by bending, a preliminary aligner along the coil former to align the coils into a dummy core, a coil inserter at a rear of the insulation sheet inserter and connected to the preliminary aligner to insert the coils into the slots of the stator core, a coil winder at a rear of the coil inserter to twist end portions of the coils inserted into the stator core, and a varnish impregnator at a rear of the coil winder to impregnate varnish into the slots.

A winding overhang (20) configured for supporting windings of an electric motor (40) comprise a cylindrical wall (22) extending around a center axis (A). The cylindrical wall (22) includes a plurality of grooves (28a-28e) formed along the circumference (37, 38) of the cylindrical wall (22), each groove (28a-28e) having a constant width (W) along the circumference (37, 38); and a plurality of openings (26) having different heights (H1, H2, H3, H4, H5). Each opening (26) extends from an end surface (36) of cylindrical wall (22) and allows a wire (30a-30c) to pass between an outer area (34) outside the cylindrical wall (22) and an inner space (32) defined by the cylindrical wall (22).

A coil conductor of each of a U-phase, a V-phase, and a W-phase is provided with a configuration in which a terminal wiring conductor, a first tooth conductor wound around a first tooth, a bridging line conductor, a second tooth conductor wound around a second tooth, and a neutral-point connection conductor are connected in this order. The terminal wiring conductor is connected to the first tooth conductor at an upper side of an insulator. The bridging line conductor is disposed on an upper side of the insulator disposed on a stator core and along an outer side portion of a tooth of another phase. The neutral-point connection conductor is connected to the second tooth conductor at a lower side of the insulator.

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 motor includes: a rotor, a stator; and a cylindrical insulator fixed to an end portion of the stator. The stator includes a plurality of teeth, a plurality of winding wires each including a winding portion wound around each of the plurality of teeth, a neutral wire provided on one end side of the winding portion, and a power wire provided on the other end side of the winding portion, and a neutral point at which a plurality of neutral wires are electrically connected via a connecting member. The insulator is provided with a drawing notch penetrating from an outer side to an inner side of the insulator. The plurality of neutral wires are routed along an outer peripheral surface of the insulator, pass through the drawing notch, and are drawn from the outer side to the inner side of the insulator, and the plurality of neutral wires drawn are fixed.

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 rotary electric machine includes magnetic poles to which a coil is attached. A connection portion between a conductive member and a coil end of the coil is arranged in an inter-pole gap between the magnetic poles. The rotary electric machine may include a rotor and a stator. The magnetic poles may be magnetic poles of the stator.

A distributed winding for an electric machine may include a coil body with numerous grooves distributed over its circumference, where there are at least two poles for the winding, where there are at least two parallel winding strands for each pole, where each winding strand is composed of at least one wire, which has at least one groove region that runs axially in a groove and a connection region at both ends, where the connection regions protrude axially above the coil body, where each winding strand has contact pins that form connection regions on both ends, and where at least some of the contact pins in the same phase are located in adjacent grooves. That at least one of the adjacent contact pins in the same phase may be bent along the circumference in order to minimize the spacing between the contact pins.

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 stator of a brushless motor has an iron core, a bobbin, and a winding assembly. The iron core has multiple stator poles mounted on an interior annular surface of a core body and spaced apart from each other. The bobbin is mounted on one of two open ends of the core body and has a substrate, at least one neutral connector mounted on an upper surface of the substrate, and at least one neutral solder pad mounted in the at least one neutral connector. The winding assembly is formed by one wire wound on multiple stator poles and the connectors. The winding assembly is electrically connected to the at least one neutral solder pad.