A method for manufacturing an electromagnetic coil with an intentionally engineered heat flow path is provided. The method includes defining at least one preferential heat flow path for heat to flow for the electromagnetic coil. A coil cartridge in which to encase the electromagnetic coil is designed by selecting dimensions of different portions of the insulating coil cartridge that will result in the at least one preferential heat flow path. The electromagnetic coil is then encased in coil cartridge material to produce an encased electromagnetic coil.

There are provided leading guide members provided movably along a central axis direction of the stator core, each of the leading guide members being, by moving toward the stator core, inserted into an inside of the respective insulating member before the coil is inserted, and arranged ahead in a movement direction of the coil moving toward the respective slot, in a state of at least a part of the leading guide member being in contact with opening ends of the insulating member. The leading guide member has a quadrilateral shape when viewed in a longitudinal direction. The leading guide member is inclined with one end portion side in a radial direction of the stator core as an apex, and has a shape tapered toward a center line along the radial direction of the stator core; and the apex is arranged on an outer side in the radial direction of the stator core.

There are provided leading guide members provided movably along a central axis direction of the stator core, each of the leading guide members being, by moving toward the stator core, inserted into an inside of the respective insulating member before the coil is inserted, and arranged ahead in a movement direction of the coil moving toward the respective slot, in a state of at least a part of the leading guide member being in contact with opening ends of the insulating member. The leading guide member has a quadrilateral shape when viewed in a longitudinal direction. The leading guide member is inclined with one end portion side in a radial direction of the stator core as an apex, and has a shape tapered toward a center line along the radial direction of the stator core; and the apex is arranged on an outer side in the radial direction of the stator core.

Methods and apparatuses for forming a woven coil assembly (100), the coil assembly having adjacent superimposed linear portions (LI-L6, AL7-ALI2) extending parallel to each other in a first area (A1) of the coil assembly, and adjacent superimposed linear portions (L7-L12, AL13-AL18) extending parallel to each other in a second area (A2) of the coil assembly, wherein a plurality of head portions (T) connect the linear portions of the first area (AI) to the linear portions of the second area (A2).

Rectangular conductor wires are often used in alternator applications requiring a high slot fill to maximize output and efficiency. However for lower output and efficiency applications, round conductor wire may increase cost competiveness in these alternators. A common lamination for a core alternatively accommodates both rectangular conductor wires and round conductor wires for different applications without any other component changes. The lamina has a slot that aligns round wire in a single row within the slot and provides a predetermined clearance from the slot opening. A stator core formed from these laminae has a relatively high slot fill factor when wound with the round wire. The same stator core can be alternatively wound with square wire to increase the slot fill factor even higher. The common lamination results in two stator configurations: a high slot fill version (round wire) and a very high slot fill version (square wire).

Rectangular conductor wires are often used in alternator applications requiring a high slot fill to maximize output and efficiency. However for lower output and efficiency applications, round conductor wire may increase cost competiveness in these alternators. A common lamination for a core alternatively accommodates both rectangular conductor wires and round conductor wires for different applications without any other component changes. The lamina has a slot that aligns round wire in a single row within the slot and provides a predetermined clearance from the slot opening. A stator core formed from these laminae has a relatively high slot fill factor when wound with the round wire. The same stator core can be alternatively wound with square wire to increase the slot fill factor even higher. The common lamination results in two stator configurations: a high slot fill version (round wire) and a very high slot fill version (square wire).

The method for manufacturing an armature includes a step of independently pressing pressing-target segment conductors by a plurality of pressing jigs disposed for each of the pressing-target segment conductors, such that the plurality of pressing jigs are movable relative to each other, at least either one of first segment conductors and second segment conductors serving as the pressing-target segment conductors.

The method for manufacturing an armature includes a step of independently pressing pressing-target segment conductors by a plurality of pressing jigs disposed for each of the pressing-target segment conductors, such that the plurality of pressing jigs are movable relative to each other, at least either one of first segment conductors and second segment conductors serving as the pressing-target segment conductors.

Stator for an electric motor, comprising the following components: at least one first basic stator, wherein the basic stator is formed from at least two basic stator modules which in an annular manner are disposed in series, wherein the first basic stator module conjointly with the at least second basic stator module forms a stator yoke, wherein each of the basic stator modules configures a stator tooth that extends radially from the stator yoke; at least one tooth shoe, wherein the tooth shoe is connected to the stator tooth in a force-fitting and/or form-fitting manner by means of a tongue-and-groove connection, in particular by means of a dovetail joint; at least one electric winding; at least one insulation which electrically isolates the basic stator from the winding, at least one expansion means; as well as at least one cooling device, wherein the components are able to be combined in a modular manner.

Stator for an electric motor, comprising the following components: at least one first basic stator, wherein the basic stator is formed from at least two basic stator modules which in an annular manner are disposed in series, wherein the first basic stator module conjointly with the at least second basic stator module forms a stator yoke, wherein each of the basic stator modules configures a stator tooth that extends radially from the stator yoke; at least one tooth shoe, wherein the tooth shoe is connected to the stator tooth in a force-fitting and/or form-fitting manner by means of a tongue-and-groove connection, in particular by means of a dovetail joint; at least one electric winding; at least one insulation which electrically isolates the basic stator from the winding, at least one expansion means; as well as at least one cooling device, wherein the components are able to be combined in a modular manner.