An electromechanical flywheel machine includes a flywheel mass and a motor-generator having a rotor rotatable about a stationary inner stator having stator windings.

A stator includes a hollow cylindrical stator core and a stator coil formed of a plurality of electric conductor segments. Each of the electric conductor segments includes, at least, an in-slot portion received in a corresponding slot of the stator core and a protruding portion that protrudes from the in-slot portion outside of the corresponding slot. Each of the electric conductor segments also has an insulating coat covering its outer surface. For each intersecting pair of the protruding portions of the electric conductor segments, at least one of the two protruding portions of the intersecting pair has an indentation formed in a side face thereof radially facing the other protruding portion at the intersection of the two protruding portions. Further, a thickness of the insulating coats at the indentations is substantially equal to a thickness of the insulating coats at the in-slot portions of the electric conductor segments.

In one embodiment, an electric machine is provided. The electric machine includes a machine housing and a stator disposed at least partially within the housing, the stator comprising a plurality of teeth and an aluminum winding wound around at least one tooth of the plurality of teeth. The electric machine further includes a radially embedded permanent magnet rotor disposed at least partially within the housing, the rotor comprising at least one radially embedded permanent magnet and configured to provide increased flux to reduce motor efficiency loss compared to a copper winding.

A method of manufacturing a laminated stator core includes: blanking an electrical steel sheet at 1.sup.st to N.sup.th (N is a natural number equal to or greater than 2) positions arranged in a row in the width direction of the electrical steel sheet to form 1.sup.st to N.sup.th blank members, and laminating the 1.sup.st to N.sup.th blank members to form a laminated stator core. The shape or arrangement of at least one odd-shaped part of a plurality of odd-shaped parts in the k.sup.th (k is a natural number of 1 to N) blank member differs from the shape or arrangement of at least one odd-shaped part of a plurality of odd-shaped parts in the m.sup.th (m is a natural number of 1 to N and satisfying m≠k) blank member such that the shapes of given two blank members do not agree with each other.

A laminated core manufacturing method is linearly arranging and punching out a plurality of separate core pieces formed of a back yoke portion and a magnetic-pole teeth portion protruding from the back yoke portion and die-cut caulking. The manufacturing method includes: a first step of punching out a first region located on an opposite side to the magnetic-pole teeth portion between adjacent ends of the back yoke portions of the core pieces; a second step of punching out a second region located on a side of the magnetic-pole teeth portion between the adjacent ends of the back yoke portions of the core pieces; a third step of punching out a region that brings the first region punched out in the first step and the second region punched out in the second step into communication; and a fourth step of forming the magnetic-pole teeth portion by punching.

A method of progressive processing includes feeding a strip-shaped sheet to a press machine; pressing the strip-shaped sheet with the press machine; and joining the strip-shaped sheet with a new strip-shaped sheet by applying a tape over an end of the strip-shaped sheet located in a direction opposite a direction in which the strip-shaped sheet is fed and an end of the new strip-shaped sheet located in a direction in which the new strip-shaped sheet is fed.

A process for assembly of a brushless air core motor-generator includes assembling a rotor formed from two spaced apart rotor portions having magnetic poles that drive magnetic flux circumferentially through the rotor portions and back and forth across an armature airgap between the rotor portions. An air core armature is made by coating a nonmagnetic armature form with a tacky adhesive layer, and winding armature windings in a winding pattern onto the form with a winding head, using wire comprised of bundled multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their lengths where located inside the magnetic flux in the armature airgap. The armature windings are adhered to the nonmagnetic form simultaneously as the winding head traverses the winding pattern while applying pressure to the wire against the tacky adhesive, so tack of the tacky adhesive layer holds the wire to the armature form during the winding process, in the winding pattern later required for magnetic torque production. The air core armature is inserted into the armature airgap and mounted to a stator of the motor-generator for production of magnetically induced torque between the rotor and the stator.

A stator/rotor lamination sheet for a stator/rotor lamination of generators and electric motors has spacers, wherein the spacers are monolithic lamination sections that are bent out of a lamination sheet plane about a bending edge and create corresponding recesses in the lamination sheet, wherein the spacers transversely protrude from the lamination sheet plane. A method for manufacturing the stator/rotor lamination sheet provides that a stator/rotor lamination sheet is punched out of a metal sheet; lamination sections are partially punched out out of the metal sheet; and the partially punched-out lamination sections are bent out of a lamination sheet plane of the lamination sheet to form spacers of the lamination sheet.

An armature includes plural core configuration members and plural insulators integrated with the core configuration members, each insulator including a coupling portion that couples a pair of insulation portions. The armature includes plural coil wires, each including a pair of wound portions wound onto respective core configuration members, and a crossing wire connecting the pair of wound portions. Plural armature configuration units are configured independently by integrating a pair of the core configuration members with each insulator and winding the coil wire onto the pair of core configuration members. Plural armature configuration sections are configured by combining two armature configuration units adjacent in the circumferential direction. In each armature configuration section, the coupling portion and the crossing wire of one armature configuration unit are side by side with the coupling portion and crossing wire of the other armature configuration units along a direction orthogonal to an axial direction of the armature configuration section.

There are provided a core unit manufacturing apparatus and a core unit manufacturing method including: a molding device that fills a resin into a space portion in a core body; a resin transfer unit that transfers a resin material to the molding device to supply the resin material thereto; and a core transfer unit that carries the core body in and out of a part between a pair of dies of the molding device. The resin transfer unit and the core transfer unit are arranged such that: the resin transfer unit supplies the resin to the molding device from one side position of side surfaces of the molding device; and the core transfer unit carries the core body in and out of the molding device from the other side position of the side surfaces of the molding device, the other side position being different from one side position.