A method of manufacturing a stator assembly for an electric machine includes providing multiple stator windings. Each stator winding is connected to a conductive terminal. The method includes assembling multiple busbars into a busbar assembly. The busbars are arranged flexibly relative to each other in the busbar assembly. The method also includes connecting the busbar assembly to some of the conductive terminals.

A method of manufacturing a stator assembly for an electric machine includes providing multiple stator windings. Each stator winding is connected to a conductive terminal. The method includes assembling multiple busbars into a busbar assembly. The busbars are arranged flexibly relative to each other in the busbar assembly. The method also includes connecting the busbar assembly to some of the conductive terminals.

A stator of an electric motor having a stator core with a plurality of salient stator poles, an insulating cap, a stator winding consisting of a winding wire, and an interconnection unit with a plurality of winding-wire receptacles having an inside, wherein the winding wire is surrounded by a material constituting the winding-wire receptacle and connected and welded thereto on the inside. The stator is of an electric motor which is of a very high quality and precision so that high-current applications are possible. Without any major adjustments, the stator is combinable with different winding connections and is flexibly adaptable to the rest of the motor and possibly to the electronics design. The manufacturing method is capable of being flexibly adapted to different wire diameters.

A stator of an electric motor having a stator core with a plurality of salient stator poles, an insulating cap, a stator winding consisting of a winding wire, and an interconnection unit with a plurality of winding-wire receptacles having an inside, wherein the winding wire is surrounded by a material constituting the winding-wire receptacle and connected and welded thereto on the inside. The stator is of an electric motor which is of a very high quality and precision so that high-current applications are possible. Without any major adjustments, the stator is combinable with different winding connections and is flexibly adaptable to the rest of the motor and possibly to the electronics design. The manufacturing method is capable of being flexibly adapted to different wire diameters.

A method for insulating connection ends of a stator winding includes a resin placing step of placing a resin member formed of a thermosetting resin which is to be melted by heating on connection ends in a coil end portion of a stator winding of a rotary electric machine, a melting step of melting the resin member by heating to cover the connection ends with a melted resin, and a curing step of curing the melted resin after the melting step. Recesses and projections for positioning that correspond to the arrangement locations of the connection ends can be provided on a surface of the resin member.

Grooves are formed at equal intervals in the circumferential direction on an outer peripheral edge of a circular block, and inner rods are housed in these grooves and arranged to be movable radially along radial directions. The outer rods are provided to be movable radially along radial directions, and respectively face the inner rods. Respective one slot insertion portions of coil segments are inserted into gaps between the inner rods and also into the holding member. The respective other slot insertion portions are inserted into gaps between the outer rods. Thereafter, the whole outer rods are rotated to rotate the coil segments around the slot insertion portions, then the holding member is lowered, and the whole outer rods are further rotated without interference between the holding member and the slot insertion portions to bring the coil segments into close contact with one another.

Grooves are formed at equal intervals in the circumferential direction on an outer peripheral edge of a circular block, and inner rods are housed in these grooves and arranged to be movable radially along radial directions. The outer rods are provided to be movable radially along radial directions, and respectively face the inner rods. Respective one slot insertion portions of coil segments are inserted into gaps between the inner rods and also into the holding member. The respective other slot insertion portions are inserted into gaps between the outer rods. Thereafter, the whole outer rods are rotated to rotate the coil segments around the slot insertion portions, then the holding member is lowered, and the whole outer rods are further rotated without interference between the holding member and the slot insertion portions to bring the coil segments into close contact with one another.

The invention relates to a stator of an electric machine, comprising: a laminated stator core (3), which has a stator axis (2), comprises a plurality of stator teeth (5) and a plurality of stator slots (6) formed between the stator teeth (5), and is formed by a plurality of stacked stator laminations (4); and - electrical conductor elements (10), which run through the stator slots (6) of the laminated stator core (3) and are provided in order to form an electrical winding, more particularly a plug-in winding. In each of the stator slots (6), a slot insulator (11), more particularly a slot insulation paper, is provided in order to electrically insulate the conductor elements (10) from the laminated stator core (3). The stator laminations (4) each have a plurality of lamination teeth (7) and a lamination yoke (8), which connects the lamination teeth (7). The stator teeth (5) of the laminated stator core (3) are each formed by stacked lamination teeth (7) of the stator laminations (4). The stator is characterized in that, in the laminated stator core (3), at least one stator lamination (4) is provided which is rotated in peripheral direction with respect to the stator axis (2), relative to other of the stator laminations (4) of the laminated stator core (3), such that, in each stator slot (6) of the laminated stator core (3), a lamination tooth portion (12) of one of the lamination teeth (7) of said stator lamination protrudes into the stator slot (6).

The invention relates to a stator of an electric machine, comprising: a laminated stator core (3), which has a stator axis (2), comprises a plurality of stator teeth (5) and a plurality of stator slots (6) formed between the stator teeth (5), and is formed by a plurality of stacked stator laminations (4); and - electrical conductor elements (10), which run through the stator slots (6) of the laminated stator core (3) and are provided in order to form an electrical winding, more particularly a plug-in winding. In each of the stator slots (6), a slot insulator (11), more particularly a slot insulation paper, is provided in order to electrically insulate the conductor elements (10) from the laminated stator core (3). The stator laminations (4) each have a plurality of lamination teeth (7) and a lamination yoke (8), which connects the lamination teeth (7). The stator teeth (5) of the laminated stator core (3) are each formed by stacked lamination teeth (7) of the stator laminations (4). The stator is characterized in that, in the laminated stator core (3), at least one stator lamination (4) is provided which is rotated in peripheral direction with respect to the stator axis (2), relative to other of the stator laminations (4) of the laminated stator core (3), such that, in each stator slot (6) of the laminated stator core (3), a lamination tooth portion (12) of one of the lamination teeth (7) of said stator lamination protrudes into the stator slot (6).

A distributed winding coil structure for automatic winding in a fractional slot three-phase AC motor has a stator in which the slot number 6N (N is a positive integer) of the slots positioned in the circumferential direction is greater than 1.5 times the pole number 2P (P is a positive integer), and the value obtained by dividing the slot number 6N by the pole number 2P is an irreducible fraction. Six coil groups are provided which include coils positioned in a wave winding inside a slot at a slot pitch of X or X+1, if the quotient obtained by dividing the slot number 6N by the pole number 2P is X (X is a positive integer), and each of the six coil groups is positioned so as to be offset by 60 degrees in the circumferential direction.