A method of forming a stack of laminates for a stator includes stamping in sequence a plurality of annular stator laminates from a continuous sheet of metal. The annular stator laminates each including an interior surface with a plurality of winding teeth and an exterior surface with a plurality of circumferentially spaced radially protruding ears wherein the plurality of circumferentially spaced radially protruding ears of each adjacently formed annular stator laminate is circumferentially offset from the circumferentially spaced radially protruding ears of immediately adjacent annular stator laminates. Clocking each of the annular stator laminates a predetermined angular rotation relative to an adjacent annular stator and stacking the annular stator laminates with the circumferentially spaced radially protruding ears aligned within the stack.

A stator for an electric machine includes slots for accommodating windings, the slots having a slot neck portion and a filling portion and extending radially between an inner circumference and an outer circumference of the stator, and including regular slots and misplaced slots. The slot neck portion of the misplaced slots has a dimension different from that of the regular slots. The plurality of slots and windings establish a plurality of phases, each phase occupying at least two adjacent slots, and the at least two adjacent slots include a regular slot and a misplaced slot resulting in reduced torque ripple and an associated reduction in vehicle NVH.

An electric machine includes a stator core having a plurality of stacked laminations that are arranged in sets that each define a circumferentially extending slot through a thickness of the set. The sets are circumferentially rotated relative to each other in sequence such that each slot only partially overlaps with one or more adjacent slots to form a continuous helical cooling path around the stator core. Windings are supported on the stator core.

Provided is a laminated iron core including: a laminate of electromagnetic steel sheets and a granular oxide that contains magnetite and covers a side surface of the laminate, in which a contact angle of a water droplet until 20 minutes elapses after dropping the water droplet on the side surface covered with the granular oxide is 80 or more. When heights of peaks detected in ranges of 2 of 41 to 42 and 38 to 39 in XRD measurement of the side surface covered with the granular oxide are represented by H1 and H2, respectively, H1/(H1+H2) is 0.8 or more.

An apparatus for fabricating a laminated core includes a lower mold including a die including a die hole, an upper mold including a punch, a stripper plate operable to restrict upward and downward movements of a metal sheet at a lowest descending position during punching out of the metal sheet by the punch, an adhesive applicator included in the lower mold and operable to apply an adhesive onto a lower surface of the metal sheet, and a controller configured or programmed to control the stripper plate and the adhesive applicator. The controller is configured or programmed to include a movement controller to control upward and downward movements of the stripper plate, and an applicator controller to cause the adhesive applicator to apply the adhesive onto the lower surface of the metal sheet while the stripper plate is not located at the lowest descending position.

A method of manufacturing a stator core includes die-cutting iron core materials from a band-shaped magnetic steel sheet and stacking the materials. Each material includes an inner circumference formed with three interconnecting lugs. At least one of the lugs included in one of two rows is located between the materials lengthwise adjacent to each other in the other row. Marginal regions are located in parts of the sheet located between the lugs of the materials adjacent to each other in a lengthwise direction of the sheet in a common row, between the material of the one row and the material of the other row and between the materials to be die-cut and each end of the sheet, respectively. The marginal regions are sized to be approximate to a web width in order to join remaining materials after the materials have been die-cut.

In a method for manufacturing a laminated iron core from a thin sheet, the method includes coining the thin sheet from below to form a thinned bridge portion on an outer peripheral portion of an iron core piece, blanking the iron core piece from the thin sheet from above or below after forming the bridge portion, and laminating the iron core piece on another iron core piece to manufacture the laminated iron core.

In a method for manufacturing a laminated iron core from a thin sheet, the method includes coining the thin sheet from above to form a thinned bridge portion on an outer peripheral portion of an iron core piece, blanking the iron core piece downwardly from the thin sheet using a set of an outer-shape blanking punch and a die after forming the bridge portion, wherein the outer-shape blanking punch includes a projection portion fitted into the bridge portion when blanking, and laminating the iron core piece on another iron core piece to manufacture the laminated iron core.

Winding bodies include: a first terminal wire that extends outward at a first axial end of a stator core from a radially innermost position inside slots; and a second terminal wire that extends outward at the first axial end of the stator core from a radially outermost position inside the slots, the first terminal wires are each led radially outward over coil ends of the stator winding, the second terminal wires are each led radially outward at positions that are nearer to the stator core than end portions of the first terminal wires that are led radially outward over the coil ends of the stator winding, and end portions of intraphase connecting second terminal wires are stacked in an axial direction with, placed in contact with, and connected to end portions of intraphase connecting first terminal wires that are subject to connection therewith.

A coil winding system that comprises a rotational movement element of the needles and a head (4) mounted thereon, the rotational movement element of the needles comprising a movement shaft (2a), arranged so as to move the head (4) linearly and rotationally. The rotational movement element of the needles further comprises an electro-magnetic element of rotational movement of the head (4) integrated to the movement shaft (2a).