A stator for a rotary electric machine includes a stator coil configured such that a tip end of a conductor segment bent in a stator circumferential direction is joined to a tip end of another conductor segment in the same phase. A conductive material is exposed from the tip ends of the conductor segments, and a distance between the tip ends in different phases and adjacent to each other in the stator circumferential direction is larger than a distance between the tip ends in the same phase and adjacent to each other in the stator circumferential direction.

A coil-connecting method according to an embodiment includes: preparing a metal sleeve having a circular shape when viewed from an axial direction; processing the metal sleeve such that the metal sleeve has a non-circular shape when viewed from the axial direction, thereby obtaining a deformed sleeve; inserting a plurality of coils into the deformed sleeve, aligning the plurality of the coils by the deformed sleeve; and swaging the deformed sleeve after the plurality of the coils are inserted into the deformed sleeve, thereby connecting the deformed sleeve and the plurality of the coils together.

A method is presented for producing an arrangement of coil elements for a plug-in coil of an electric machine. The method includes providing a workpiece carrier and producing an arrangement of rod-shaped coil elements for a plug-in coil of an electric machine on the workpiece carrier, wherein the following is respectively provided for the rod-shaped coil elements: accommodating and holding the coil elements by means of a displacement device; supplying the coil element onto the workpiece carrier by means of the displacement device into an assigned proximal position on the workpiece carrier, wherein the coil elements are hereby displaced form a distal position into the assigned proximal position with respect to the workpiece carrier; and transferring the coil elements in the proximal position on the workpiece carrier from the displacement device by a gripping device, which is formed on the workpiece carrier.

A method for manufacturing an electro-mechanical device includes creating a plurality of substrates using a first additive manufacturing process. Each of the substrates includes a polymeric material. The substrates include a first substrate and a second substrate. The first substrate includes a first main body and defines a protrusion extending from the first main body. The second substrate includes a second main body and a recess defined in the second main body. The method includes coupling the first substrate to the second substrate by inserting the protrusion into the recess such that the protrusion elastically deforms to an elastically averaged configuration. The protrusion and the recess together form an elastic averaging coupling. The method includes creating a plurality of electrically conductive components using a second additive manufacturing process and then coupling the electrically conductive components to at least one of the substrates.

A manufacturing method of an electric pump includes engaging and welding first and second extended portions with first and second hooks, respectively, and cutting a plurality of connecting portions after the engaging and welding.

A component for an electric machine includes a flat region in which an electric line runs when the component is integrated into the electric machine and which includes a sharp edged structure. A polymer layer adheres to the flat region without further aid such as to mask the sharp-edged structure and thereby protect from damage the electric line on the flat region. The polymer layer is made of cured plastic adhesive and jetted onto the flat region in the form of threads, such that the threads are spin-coated on top of one another in the form of overlapping loops and form a network structure which spans the sharp-edged structure.

A method of manufacturing a stator assembly for an electric machine includes providing multiple stator windings. Each stator winding is connected to a conductive terminal. The method includes assembling multiple busbars into a busbar assembly. The busbars are arranged flexibly relative to each other in the busbar assembly. The method also includes connecting the busbar assembly to some of the conductive terminals.

The invention relates to a method for producing an electrically conductive connection between a copper component 23, 23a and an aluminum component 24 by means of cold metal transfer welding, in which a welding wire is periodically moved back and forth from the material of a component to be welded.

A fan assembly having a reduced dimension formed by several modifications is described. The fan assembly includes a stator having stator coils positioned within a recessed portion of a pillow that receives the motor. The stator may include wire connections positioned between adjacent stator coils and designed to terminate wires of the stator coils. The wire terminations may be on a protrusion or a post positioned between adjacent stator coils, or alternatively, the wire terminations may be disposed on protruding features of a bushing. The protrusion may be formed from an electrically conductive material and electrically connected to a motor control circuit via a flexible printed circuit. In some embodiments, the protrusion is part of an electrically neutral stator bushing having several pins. Also, a gap region between the bushing and a flange feature is designed to improve an adhesive joint.

Disclosed is an apparatus for peeling a coil of a motor, including a pallet on which the coil is mounted; a conveying part formed long in a lengthwise direction and configured to convey the pallet; a clamper located at the side surface of the conveying part and formed to be movable toward the conveying part and to fix the tip portion of the coil; and a laser irradiating part located at a side surface of the conveying part to radiate laser at a peeling work spot and to peel a coating layer of a tip portion of the coil. Therefore, a bonding force between the coil and the bus bar can be easily increased.