A method for monitoring an attachment area during laser welding of bent bar-type conductors containing copper, includes the steps of arranging a first bar-type conductor relative to a second bar-type conductor in partially overlapping fashion and welding the first and second bar-type conductors to one another using a processing laser beam, the welding including forming a weld bead interconnecting the bar-type conductors to one another. After the welding, at least one measurement variable is measured on at least one portion of the weld bead, wherein the at least one measurement variable changes with the temperature of the weld bead as a function of the time during a cooling down of the weld bead. A parameter depending on a heat capacity of the weld bead is determined from the at least one measured measurement variable, and the attachment area qualitatively or quantitatively determined from the parameter.

A method and arrangement is disclosed herein for making a stator with 3D printed end turns. The stator includes a stator lamination stack with semi-closed slots. Straight I-pin wire segments are housed in the slots of the stator lam stack and form the in-slot segments of a stator winding arrangement. The end turns of the winding arrangement are provided by a conductive material that is 3D printed material at both axial ends of the straight I-pins. The end turns result in a winding arrangement with diamond coils that are inter-locked. The 3D printing of the end turns makes the winding arrangement possible, as the winding arrangement is configured such that it cannot be inserted into the lamination stack in a radial direction (i.e., via any slot openings at the inner diameter or outer diameter).

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.

A method is provided for producing a stator arrangement that has a stator core and a winding arrangement. The stator core has stator slots. The winding arrangement has winding elements with a conductor and an insulation layer. Each winding element has two interconnected winding element legs with two winding element end portions on each winding element leg. The method includes positioning the winding elements on the stator core so that the winding element legs extend through one of the stator slots with winding element end portions protruding on a first side of the stator core. The method then includes using a first laser arrangement to remove the insulation layer from regions of the winding element end portions. The method then includes pressing the first and second winding element end portions against one another and using a second laser arrangement to carry out welding.

To improve quality and reduce reject in the large-scale production of components of an electrical machine provided with coil windings, a welding method is provided for welding conductor ends organized into groups of conductor ends of a component for an electrical machine. The method includes detecting a relative position of a first conductor end and a second conductor end of a group of conductor ends, and controlling a welding energy input to the conductor ends to be welded depending on the detected relative position. A welding apparatus for performing the welding method is also provided.

Method for producing an active part (1) for a rotating electric machine (101), comprising the following steps: providing a core (2) for the active part (1) and shaped conductors (6) which are inserted into the core (2), joining in each case two of the end faces (9) to one another; and welding a respective pair (10) of the end faces (9) by means of a laser beam which is guided along a pattern having a trajectory (15).

A switching module includes a housing that can be attached directly to an end of a stator and over line and neutral phase hairpins of the stator, electrically conductive platforms disposed in the housing and that can contact some of the hairpins, switches disposed in the housing, connected with the platforms, and that can selectively change connections of the hairpins between wye and delta configurations, and a conduit defining a coolant channel through the housing.

A method of manufacturing a coil includes a preparation step of preparing a copper wire, a winding step of winding a plurality of aluminum wires around the copper wire, and a pressing step of pressing the copper wire and the plurality of aluminum wires so as to form an aluminum coat around the copper wire and form an anodized aluminum film on the surface of the aluminum coat.

A rotating electric machine having high efficiency and high reliability without causing an increase in size and cost is realized. Each of the rectangular wire segment coils has a first region portion and a second region portion connected to the first region portion and formed in the circumferential direction including a bent portion in the circumferential direction of the stator core 10, and a pair of the rectangular wire segment coils adjacent to each other at the coil ends of the plurality of rectangular wire segment coils has a conductive portion to which the first region portion of one of the rectangular wire segment coils and the second region portion of the other of the rectangular wire segment coils are connected. The second region portion has a conductive portion cross-section disposed on the same plane as the end portion cross-section of the first region portion, and the conductive portion cross-section is a cross-section in a direction different from a direction of the coil vertical cross-section of the second region portion. Each of the plurality of layers includes a first layer in which the first region portion appears at an axial end portion and a second layer in which the second region portion appears at an axial end portion when the coil end is viewed in an axial direction of the rotating electric machine.

A method for reworking a defective welded connection of a hairpin winding for a rotor or stator of an electrical machine, including providing the hairpin winding applied to a winding support. The hairpin winding has at least one conductor formed from multiple conductor sections. The conductor sections of the respective conductor are welded in pairs at a respective welded connection by a first welding method, and at least one of the welded connections is a defective welded connection. The defective welded connection is severed, and the conductor sections to be welded, which were previously connected by the defective welded connection, are connected by way of a connecting method that differs from the first welding method.