A stator used for a motor and having excellent vibration resistance, waterproofness, and an insulating property. The stator used for a motor includes a stator core having a plurality of teeth arranged at substantially equal intervals on a same circumference, and an insulator covering the teeth, and coil portions are formed by wires being winded around portions of the insulator that covers the plurality of teeth. The insulator includes first wall portions provided on the center axis side with respect to the coil portion, and molded portions formed, by resin, on the center axis side with respect to the first wall portions. Wire extended portions of the wire pulled out from the coil portion straddle the first wall portions. Wire terminal end portions are connected to bus rings. The bus rings are embedded in the molded portions.

A conductive wire includes an angled protrusion having a tapered shape being integrated with a wire-shaped main body and configured to generate an arc between itself and an arc welding electrode, At least one of the pair of conductive members comprises an angled protrusion having a tapered shape. Welding of the conductive members is performed by melting the angled protrusion by generating an arc between the angled protrusion and an electrode.

A stator for an electric machine is fabricated by assembling a core and first and second winding assemblies. The first winding assembly (FWA) is fabricated by a 3D printing process and includes a plurality of U-shaped conductors (hairpins) having respective end-turns arranged in mutually axially-nested relationship to each other to form a ring, and further having two uprights disposed in one of the slots of the core. End-turns connect respective pairs of the uprights and are disposed adjacent to an end surface of the core, distal ends of the uprights projecting axially beyond an opposite end surface of the core. The second winding assembly (SWA) includes a plurality of bridges forming a second ring Opposite ends of each bridge define terminals that mate with ends of the uprights. The SWA further includes an electrically non-conductive casing in which at least one of the bridges is embedded.

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 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 device for positioning electrically conductive segments of a winding of a stator of a rotary electrical machine, including at least one rotative ring with at least one cam arranged around a revolution axis, the rotative ring being arranged to set in a radial motion at least two series of fingers to ensure the position of the conductive segments, wherein the two series of fingers are set in motion in opposite directions one to the other, such that a finger of a first series of fingers and a finger of a second series of fingers are configured to press two conductive segments of a pair of segments against each other.

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.

A manufacturing method of fan stator structure includes the steps of providing a fan stator; providing a plurality of coil lead wire holders at an end of the fan stator; and winding lead wires on the fan stator to form coils, and setting and connecting a front end and a back end of each of the lead wires to the coil lead wire holders. The above method eliminates the drawbacks of the conventional fan stator coil winding operation, such as requiring manual twisting and trimming of the lead wire front ends and back ends and leaking of tin solder occurred during welding of the lead wires to a circuit board.

A method for manufacturing a stator for a rotating electrical machine includes: installation step of installing coil pieces with rectangular cross section for stator coil in stator core; and joining step of joining ends of coil pieces by laser welding after installation step. The joining step includes a setting step of bringing the ends into contact with each other in radial direction that the ends cross over each other in an X-shape as viewed in the radial direction, and a radiation step of applying a laser beam with a wavelength of 0.6 μm or less in an axial direction toward a C-shaped side, as viewed in the radial direction, of a contact surface between the ends after the setting step. Part of the C-shaped side and part of an axially outer non-contact surface that is continuous with the contact surface between the ends are melted in the radiation step.

An electric drive unit includes a multi-phase AC motor including a plurality of first terminals, and a power converter including a plurality of second terminals. The power converter is fixed to an electric motor case so as to partially overlap the AC motor in an axial direction with a wall portion interposed therebetween. Each first terminal includes a first extended portion extending from the stator along the axial direction, and a first fastening portion. Each second terminal includes a second extended portion extending along an extending direction at a portion of the power converter that does not overlap the AC motor in the axial direction; and a second fastening portion. The electric motor case includes a communication hole formed in the wall portion, and a service hole formed in a portion located on an extension line of the fastener parallel to an insertion direction of the fastener.