A method of making a stator for a rotating electrical machine in which a tooth segment from a high saturation induction material and a yoke segment from a silicon steel material. The tooth segment is bond to yoke segment, thereby producing a stator with at least two magnetic saturations.

An oriented magnetic core lamination technique and a method of producing circular lamination cores. The method includes cutting rectangular strips with teeth pointing in a single direction (may not be the traverse or rolling direction) from the steel sheet plane, as opposed to directly punching circular laminates from the steel sheet with the teeth pointing in all directions. The strips are cut in such a way that the short side is aligned to the direction that has the best magnetic properties. The strips can then be bent into a donut or toroidal shape, either inwardly (with teeth pointing to the circle center) or outwardly (with teeth pointing out of the center) depending on the design of the lamination core. The direction with the best magnetic properties may be determined by non-destructive methods such as magnetic Barkhausen noise (MBN) analysis, x-ray diffraction (XRD), or electron backscatter diffraction (EBSD).

A stator for an electric machine includes a laminated stator core having stator slots arranged along an axial direction parallel to a stator axis, electric conductors arranged in the stator slots; and fluidtight slot insulators arranged in the stator slots between the electric conductors and the laminated stator core, wherein the slot insulators each have a cooling channel spaced apart from the electric conductors in a radial direction arranged orthogonally to the axial direction.

A method for manufacturing a stator for an electric machine, having the following steps: inserting a cast body with a nozzle from a first side of the stator into the stator, inserting a cast counterbody from a second opposing side of the stator into the stator, casting the stator with thermoplastic, thermosetting plastic, or resin by means of the nozzle, curing the thermoplastic, thermosetting plastic, or resin, wherein following the curing a cast-on piece of the thermoplastic, thermosetting plastic, or resin is sheared off using a rotational movement of the cast body or cast counterbody.

A method for producing a stator includes: providing a main body, the main body having: a cavity for accommodating a rotor, and a plurality of slots, extending axially through the main body, the plurality of slots accommodating electrical conductors of a winding, providing slot insulation so as to ensure that a slot interior of each slot of the plurality of slots is electrically insulated from the main body and is fluidtight; and forming a respective end plate on each of two ends of the main body, the end plates being attached in a fluidtight manner to the main body so as to ensure that no fluid can get between the end plate and the main body and reach the cavity of the main body. Each end plate has a radial part and an axial part, and the axial part has an insert.

A stator of an electric machine includes: a laminated stator core having sheet-metal blanks which have apertures, the apertures being closed radially on an inside thereof by a web when viewed in a cross section extending in a radial direction of the stator; and stator windings, which are accommodated in the apertures of the laminated stator core. The web which closes a respective aperture radially on the inside is plastically deformed so as to introduce a mechanical stress into the web.

An electric machine may include a rotor having a notch at each pole wherein each notch is skewed by some mechanical angle. Notches may fluidly couple one end of the rotor to the other end of the rotor and provide pumping functionality for fluid therein.

The method and apparatus comprise the following features: —forming coil members (21) by bending an electric conductor (20) externally coated with an outer insulation (20′); wherein the bending is made at predetermined lengths from a reference position (16′), and wherein each one of the coil members (21), when formed, comprises at least one head portion (21′) and leg portions (21″) extending from said at least one head portion (21′); —feeding the electric conductor (20) to accomplish the bending; —cutting the electric conductor (20) to detach a formed coil member (21) from said electric conductor (20); —inserting the leg portions (21″) of the coil members (21) into slots of the stator, so that parts of said leg portions (21″) extend from one end of the stator and the head portions (21′) extend from an opposite end of the stator; —arranging at least one laser beam (13′a, 13′b) to remove the insulation (20′) from predetermined areas (20a, 20b) of the electric conductor (20); —radiating the surface of the electric conductor (20) with said at least one laser beam (13′a, 13′b) situated at a predetermined position (IP, 2P) with respect to the reference position (16′) along the length of the electric conductor (20) being fed, and at a predetermined stage of the bending of a coil member (20).

A stator includes a yoke extending to surround an axis, and having an outer circumference and an inner circumference. The yoke has a crimping portion projecting from the outer circumference, and a split surface provided at a position different from a position of the crimping portion. The yoke has a magnetic path which is provided between the outer circumference and the inner circumference and through which magnetic flux flows. When L1 represents the width of the magnetic path, and L2 represents the width of the yoke including the crimping portion, L1<L2<2.6×L1 is satisfied.

A stator assembly for a rotating electrical machine is operatively associated with an internal cooling circuit including a plurality of cooling channels disposed through a stator core. To directed a liquid coolant medium through the stator core without leakage, the internal cooling circuit is formed from a plurality of cooling tubes including linear tubes and elbow tubes. Linear tubes are disposed in the cooling channels and can be expanded with a hydraulic expansion tool to frictionally fit the linear tube therein. The elbow tubes can fluidly couple two or more linear tubes and are disposed proximately beyond the first and second axial end faces of the stator core. To encapsulate the elbow tubes, first and second stator end castings of thermally conductive, electrically isolating material can be cast adjacent the first and second axial end faces.