A novel dynamo-electrical machine is provided that can inhibit an increase in the height of a coil end positioned toward a turn portion and improve the cooling performance around the turn portion of a segment coil. A segment coil 31 includes a first linear portion 34r, a second linear portion 34a, and a turn portion 33 including a top portion 33c. The first linear portion 34r is inserted into a specified slot 22. The second linear portion 34a is inserted into another particular slot 22 different from the specified slot 22. The turn portion 33 extends from one end face portion of a stator core 21 toward the outside of the axial direction of the stator core 21 and connects the first linear portion 34r and the second linear portion 34a. The linear portions 34r and 34a of the multiple segment coils 31 are inserted and placed in the slots 22 in a layering manner from the inner periphery to the outer periphery in the radial direction. A bent portion 37 is formed between each of the linear portions 34r and 34a and the turn portion of the segment coils 31 layered in the radial direction. The bent portion 37 tilts the top portion 33c of the turn portion 33 toward the end face of the stator core 21.

A cutting unit has a support member having insertion holes, and a movable member having through holes connected thereto. The respective left sides of upper surfaces of the square through holes are first movable blades, and the respective right sides thereof are second movable blades. Firstly, the movable member 14 is moved to the right by a predetermined amount to cut peeled-off portions of segment end portions only, and then the movable member is moved to the left by a predetermined amount to cut peeled-off portions of the segment end portions only. Distal ends of the coil segments can be cut into a uniform length to enable high quality welding, through this process.

A method for joining copper hairpins includes providing at least two ends to be joined to one another of the copper hairpins, and joining the copper hairpins. The copper hairpins are joined by laser beam welding with a machining beam having a wavelength of less than 1000 nm.

A method for introducing an insulating layer between stator or rotor grooves and for introducing winding packets with wire webs of coil wires of a coil winding is provided. The coil winding may be inserted into the stator or rotor grooves from a transfer tool. The method has the steps of: inserting insulating layers into transfer grooves of the transfer tool, wherein at least one section of each of the insulating layers lies radially outside of the transfer groove; transferring the wire webs of the winding packets into the transfer grooves; closing the insulating layers by folding the sections in the direction of the wire webs of the winding packets and fixing the sections in the folded position of the sections; and inserting the winding packets into respective stator or rotor grooves such that the folded sections are arranged between groove bases of the stator or rotor grooves and the wire webs of the winding packets.

A method for determining a position of a workpiece for a laser machining process includes the steps of: radiating a measurement beam to at least one workpiece and a support device surrounding the workpiece along at least one first and along at least one second measurement path, the first path forming a predetermined angle with the second path; acquiring a portion of the radiated measurement beam, reflected by the support device and the workpiece, along the first and along the second measurement path and generating a corresponding measurement signal, the support device and the workpiece comprising a reflectivity different from each other; and determining a position of the workpiece based on the measurement signal. A method for machining a workpiece by a laser beam includes the method for determining the position of the workpiece. An apparatus for determining a position of a workpiece is configured for conducting the methods.

A method of joining electrical connections together includes evaluating at least one weld joint between at least two substrates, determining mismatch between the at least two substrates, and welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes compensating for mismatch between the at least two substrates by welding on both sides but not overlapping a joint line between the at least two substrates with a first welding step and increasing melt volume and penetration depth of a weld between the at least two substrates with a second welding step.

A flat wire stator which includes an iron core and a flat wire winding; the flat wire winding includes a first phase winding, the first phase winding includes a plurality of coils, the plurality of coils are distributed in rotational symmetry around an axis of the iron core, the coils are wound in a portion of iron core slots in the plurality of iron core slots, and first ends and second ends of the coils are located at the same end of the iron core; and the plurality of coils are connected in series in sequence, the first end of each coil is connected to the first end of one coil of two coils adjacent to the coil, and the second end of the each coil is connected to the second end of the other coil of the two coils adjacent to the one coil.

A winding method for a stator module applicable to a motor having z slots, 2p poles, and m phases. The stator module includes a stator core and a winding coil. The winding coil is made of a flat wire. The winding method includes: forwardly winding some stator slots by means of the arrangement and connection of multiple U-shaped conductor sections, and then reversely winding the stator slots; afterwards, forwardly winding the remaining stator slots, and then reversely winding the stator slots; and cycling in this way.

A distributed winding for an electric machine may include a coil body with numerous grooves distributed over its circumference, where there are at least two poles for the winding, where there are at least two parallel winding strands for each pole, where each winding strand is composed of at least one wire, which has at least one groove region that runs axially in a groove and a connection region at both ends, where the connection regions protrude axially above the coil body, where each winding strand has contact pins that form connection regions on both ends, and where at least some of the contact pins in the same phase are located in adjacent grooves. That at least one of the adjacent contact pins in the same phase may be bent along the circumference in order to minimize the spacing between the contact pins.

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.