A process and a system for welding rotor coils are presented. A plurality of rotor coils are arranged on a table of a machine. A welding tool welds the rotor coils on one end using a Friction Stir Welding process. Transition pieces are each arranged between the rotor coils to create a continuous welding path. A run-off tab is placed at an end of the welding path. The welding tool is changed to a milling tool after completion of the welding. The milling tool traces back along the welding path to separate the rotor coils. The milling tool may be changed to the welding tool to repeat the process for another end of the rotor coils. The process is completely automatic and controlled by a control unit.

A guiding device for coiling electrically conducting wires around an electrically conducting block of a rotor of an electric motor including a shaft extending axially in the rotor, the electrically conducting block including at least four notches for receiving wires. The guiding device includes at least two branches extending radially away from the shaft and disposed at 90 to one another, the branches being connected by an elastic linking mechanism.

A guiding device for coiling electrically conducting wires around an electrically conducting block of a rotor of an electric motor including a shaft extending axially in the rotor, the electrically conducting block including at least four notches for receiving wires. The guiding device includes at least two branches extending radially away from the shaft and disposed at 90 to one another, the branches being connected by an elastic linking mechanism.

A method of manufacturing an induction motor rotor assembly, the method includes the steps of: providing a rotor; machining a plurality of re-entrant slots axially along an outer surface of the rotor; positioning a sleeve concentrically over the outer surface of the rotor; applying a friction stir welding process to the sleeve along each re-entrant slot axially along the outer surface of the rotor to cause the sleeve material to plasticise and flow into the axial re-entrant slot to form an axial re-entrant slot bar; and providing an electrical connection at each of the opposing axial ends of the rotor between respective ones of opposing ends of each of the axial re-entrant slot bars to thereby form the induction motor rotor.

A method of manufacturing an induction motor rotor assembly, the method includes the steps of: providing a rotor; machining a plurality of re-entrant slots axially along an outer surface of the rotor; positioning a sleeve concentrically over the outer surface of the rotor; applying a friction stir welding process to the sleeve along each re-entrant slot axially along the outer surface of the rotor to cause the sleeve material to plasticise and flow into the axial re-entrant slot to form an axial re-entrant slot bar; and providing an electrical connection at each of the opposing axial ends of the rotor between respective ones of opposing ends of each of the axial re-entrant slot bars to thereby form the induction motor rotor.

A method for producing rotating electrical machines having a motor coil produced in a cantilevered manner for motors or generators, wherein the coil already surrounds the inner part during the manufacturing process, i.e. is pre-assembled, and this is also used as an aid for coil shaping during the production of the coil, includes a first step, in which the motor coil is wound in a stepwide process between two end faces over the magnetic inner part and completely surrounds the inner part, a second step, in which the shaping of the motor coil is carried out by pressing the winding wires by moving the shaft with the surface of the inner part against the inner side of the motor coil, in particular by eccentrically rolling off of the latter and pressing it against an abutment, and a third step, in which the pressed motor coil is baked by way of applying heat. Also provided is a rotating electrical machine.

A method for producing rotating electrical machines having a motor coil produced in a cantilevered manner for motors or generators, wherein the coil already surrounds the inner part during the manufacturing process, i.e. is pre-assembled, and this is also used as an aid for coil shaping during the production of the coil, includes a first step, in which the motor coil is wound in a stepwide process between two end faces over the magnetic inner part and completely surrounds the inner part, a second step, in which the shaping of the motor coil is carried out by pressing the winding wires by moving the shaft with the surface of the inner part against the inner side of the motor coil, in particular by eccentrically rolling off of the latter and pressing it against an abutment, and a third step, in which the pressed motor coil is baked by way of applying heat. Also provided is a rotating electrical machine.

An electrical machine, particularly a permanent magnet motor, having a number of poles and teeth or tooth groups that is divisible by a whole number A around which coil-forming loops of winding wire are arranged such that B coils are arranged in series, the coils having a number of windings equivalent to C/B where C is a whole number divisor of B and indicates the wire diameter as a quotient of a traditional standard winding, as well as a method to provide a corresponding winding structure.

An electrical machine, particularly a permanent magnet motor, having a number of poles and teeth or tooth groups that is divisible by a whole number A around which coil-forming loops of winding wire are arranged such that B coils are arranged in series, the coils having a number of windings equivalent to C/B where C is a whole number divisor of B and indicates the wire diameter as a quotient of a traditional standard winding, as well as a method to provide a corresponding winding structure.

An armature manufacturing method includes preparing a core member that includes a rotation shaft at a central portion and that is formed with plural teeth in a radiating shape centered on the rotation shaft; and winding winding wires onto slots between the plural teeth so as to form plural types of winding coil sections, each with a different winding wire diameter.