The present invention provides a busbar comprising terminals, a body connected to the terminals and includes a plurality of blades, wherein the body includes an inner body, an outer body, and connecting parts, the outer body is disposed outside the inner body, the connecting parts are arranged in a periphery of the inner body at regular intervals and connect the inner body to the outer body, the terminals are disposed in the inner body so that connection ends of the terminals are disposed between the adjacent connecting parts, the plurality of blades protrude from an upper surface of the outer body and are arranged in a circumferential direction with respect to a center of the busbar, the outer body includes a cooling hole formed to pass through from a lower surface thereof to the upper surface, and the cooling hole is disposed between adjacent blades, thereby providing an advantageous effect of reducing the number of parts to be manufactured such that manufacturing costs and manufacturing processes can be reduced.

A method for manufacturing a rotor assembly for an electrical machine includes printing a first part of a rotor shaft. The method also includes printing a rotor core onto the first part of the rotor shaft. In addition, the method includes printing a second part of the rotor shaft onto the rotor core; printing a first part of the rotor winding. The method also includes coupling the first part of the rotor winding to the rotor core. After coupling the first part of the rotor winding to the rotor core, the method includes printing a second part of the rotor winding onto the first part of the rotor winding to form the rotor assembly.

A core for an electric machine includes a core body with a tooth arranged along a rotation axis, a winding with a flat wire coil fixed to the core body and seated on the tooth of the core body, and a flat wire jumper. The flat wire jumper is supported by the core body and is connected to the flat wire coil to place the flat wire coil in electrical communication with flat wire coils of the winding. Methods of making cores with flat wire jumpers and generators having cores with flat wire jumpers are also described.

A generator includes a stator with a stator winding, a rotor core with a rotor tooth supported for rotation relative to the stator about a rotation axis, and a field winding. The field winding includes a field coil that is seated on the rotor tooth. The field coil includes two or more flat wire turns stacked with one another and formed such edges of the field coil tightly engage circumferential faces of the tooth. Electrical systems and methods of making generators are also described.

An electric machine rotor assembly includes a rotor core defining a rotor axis. Windings are seated in the rotor core. A plurality of wedges circumferentially spaced apart around the rotor core relative to the rotor axis. Each rotor core extends axially and separates between two respective portions of the windings. A supply end plate is mounted at a first axial end of the rotor core. A return end plate is mounted at a second axial end of the rotor core opposite the first axial end. A flow path for coolant fluid extends through the supply end plate into the wedges, through the wedges and into the return end plate, and through the return end plate.

A rotor for an electrical machine includes a rotor core having a plurality of circumferentially spaced apart rotor poles. Windings are seated in gaps between circumferentially adjacent pairs of the rotor poles. A wedge secures the windings in each gap. The wedge includes a first member made of a first material and at least one second member made of a second material. The second material has a higher electrical conductivity than the first material. The wedge is configured to supply Q-axis damping. A pair of end plates is connected electrically to the at least one second member at opposing longitudinal ends thereof thereby completing a Q-axis winding circuit for each wedge.

A winding of a generator of a wind power installation, in particular of the rotor. The winding comprises a plurality of coils which are each wound using a flat ribbon conductor, wherein the flat ribbon conductors have in each case two ends and at least two flat ribbon conductors are connected to one another. The flat ribbon conductors, in each case viewed from the respective end, are incised or punched at least up to a predefined length of the flat ribbon conductor in the longitudinal direction, such that at least two part-end pieces of the flat ribbon conductor which have in each case a substantially identical width are created. The part-end pieces herein are bent in such a manner that the part-end pieces overlap at least in a connection region, wherein the connection regions of two ends overlap in a common connection region and are connected there. Also provided is a method for producing such a winding.

An electric motor is provided including: a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly. The brush assembly defines a first side facing the stator and a second side. The brush assembly includes a brush card mount having openings, brushes in sliding contact with the commutator, and thermally-conductive brush holders that support the brushes. Each brush holder includes a base piece disposed between the first side of the brush assembly and the stator, and a main piece including a brush-holder portion and two side flat portions. The brush-holder portion is axially received through a brush card mount opening from the first side of the brush assembly and protrude over the second side to house a brush. The two side flat portions are axially sandwiched between the base piece and the brush card mount.

When teeth (12) are allocated in a circumferential direction in sequence of a U phase, a V phase and a W phase, a forward wound coil wound on each of the phases is provided as a coil of the U phase, the V phase and the W phase, and a reverse wound coil wound on each of the phases is provided as the coil of a U phase, a V phase and a W phase, the coils are electrically connected between the neighboring segments in an order of the U phase, the W phase, the W phase, the V phase, the U phase, the U phase, the W phase, the V phase and the V phase, and the wire (14) drawn between the armature core (8) and the commutator (10) is drawn around the rotation shaft in the same direction.

A wedge for securing windings in a slot in the rotor poles of a rotor core of an electrical machine includes an elongate wedge body extending in an axial direction along a longitudinal axis. The wedge body includes layers perpendicular to the axial direction. The layers vary in electrical conductivity from layer to layer to inhibit eddy currents within the wedge body.