The disclosure relates to a method of providing a component for an electric machine having a body including multiple grooves and multiple indentations, and a cover including multiple recesses and multiple fixation elements. The method includes arranging at least one of the indentations at an edge of each of the grooves of the body, arranging at least one of the fixation elements at each of the recesses, and arranging the cover on the body with each of the recesses of the cover associated with a respective one of the grooves of the body, and each of the fixation elements of the cover arranged in a respective one of the indentations of the grooves of the body.

Stator for an electric machine includes a stator core which has an axial end side, and a a plurality of shaped conductors which protrude from the stator core at the end side and which each have, at the end side, at least one end portion having a free end of the shaped conductor. Arrangements of at least two of the end portions are connected to one another in an electrically conductive and mechanical manner in such a way that each arrangement forms a connecting portion which has a first cross-sectional area that lies in a predefined cross-sectional plane and that has corner portions and side portions lying between the corner portions. A plurality of insulation elements each envelop at least one of the connecting portions and are each formed from an electrically insulating material.

Provided are a coil capable of enhancing heat dissipation performance and/or voltage resistance, and a stator and a motor using the coil.

A coil includes a helical structure body made of strip-shaped flat conductors that are continuously joined into a helical form. In the helical structure body, a first turn of helix is separated from a second turn, which is continuous to the first turn, at a preset interval.

An insulation system for an electric machine coil includes the following layers situated in sequence over an insulated conductor: a first corona shield tape, a stress grading tape, a second corona shield tape having a first overlap length with the stress grading tape and a second greater overlap length with the first corona shield tape, an insulation tape, and a sealing tape.

A coil has a winding that is coated with an epoxy resin in at least some areas, wherein a ratio of a compressive strength of the epoxy resin to the tensile strength thereof at room temperature ranges between 2 and 5, the modulus of elasticity at room temperature is at least 5000 MPa, and at a glass transition temperature of the epoxy resin, the modulus of elasticity and the tensile strength have values amounting to at least 30% of the values at room temperature.

A method for producing a stator (20) of an electric machine is provided. The method includes providing a stator (20) with at least one stator slot (22) that is bounded by two stator teeth. The method proceeds by introducing electrical conductors (30) into the at least one stator slot (22). At least one conductor (30) has an expandable coating (25) applied partially to its surface. The method continues by activating the expandable coating (25) to bring about an expansion of the coating (25), as a result of which the conductors (30) are fixed within the stator slot (22).

Presented are segmented hairpin bar conductors for electric machines, methods for making/using such segmented bar conductors, electromagnetic motors using such segmented bar conductors, and vehicles equipped with an induction motor generator unit using segmented hairpin bar conductors. An electric machine includes a stator that defines multiple circumferentially spaced, radially elongated stator slots. A rotor is located adjacent and movable with respect to the stator. One or more permanent magnets are mounted to the rotor, and one or more U-shaped hairpin windings are mounted to the stator in juxtaposed spaced relation to the magnet(s). Each hairpin winding is formed from an array of collimated, electrically conductive wires that are bundled together into a unitary bar conductor. The segmented hairpin winding has a pair of hairpin legs, each of which adjoins and projects from a respective end of a hairpin crown. Each hairpin leg inserts into a respective one the stator slots.

Systems and methods for forming insulation on magnet wire are provided. An extruder that includes one or more rotating screws may receive a plurality of ingredients for a polymeric insulation material and process the plurality of ingredients to facilitate polymerization of the polymeric insulation material within the extruder. An application assembly in fluid communication with the extruder may apply the polymeric insulation material onto a wire. A curing device may then cure the polymeric insulation material.

An electric machine including a shaft, a rotor back assembly surrounding a portion of the shaft, and two or more permanent magnets radially positioned around the perimeter of the rotor back assembly. The electric machine also includes a rotor fan with multiple fan blades formed in an exterior surface of the rotor back assembly and one or more ventilation channels extending through the rotor back assembly. Methods of exporting heat from an electric machine, wither from a machine housing or through the shaft is also disclosed. The heat exportation methods feature the circulation of a fluid with the rotor fan through the ventilation channels and into contact with the housing, or exporting heat from the rotor back assembly through the shaft.

A method for inserting electrical conductors in slots of a component, wherein, in sections, an insulating film has two legs which are connected by a V-shaped or folded tip region. The legs lie against the slot edges such that damage to the electrical conductors by edges of the slot during the insertion thereof into the slots is avoided. The invention further relates to an associated device, to an associated cutting tool, and to an associated use.