A hairpin type stator inspection apparatus is provided for testing performance of a stator wound with hairpin type stator coils. The hairpin type stator inspection apparatus includes: a conveyor provided on a frame for transferring the stator including a plurality of stator terminals along a predetermined path: a plurality of clamp terminals, which are installed to be movable to the frame by a driver in up and down, front and rear, and left and right directions in order to clamp the stator terminals: a controller that applies a driving control signal to the driver to change a position of the clamp terminals according to a position of the stator terminals; and an inspection portion that applies power to the stator terminals through the clamp terminals and inspects the electrical circuit of the stator.

To provide an on-vehicle brushless motor device capable of being downsized with respect to an axial direction of a rotor and a method of manufacturing the same. The on-vehicle brushless motor device 1 includes a brushless motor 10 and an electronic substrate 30. The brushless motor 10 includes a rotor 12 and a stator 16 including a plurality of coils 18 arranged around the rotor 12. The electronic substrate 30 includes a through hole 34 penetrating in the axial direction X of the rotor 12 and includes a substrate body 32 arranged along a plane P intersecting the axial direction X on the side opposite to the output shaft of the brushless motor 10, and a terminal 40 fixed on the surface of the substrate body 32 on the side opposite to the rotor 12. A coil wire 20 of the coil 18 is inserted into the through hole 34 and is welded to the terminal 40 on the opposite side of the rotor 12 with respect to the substrate body 32.

An apparatus and methods are provided for a segmented stator comprising over-molded windings and an incorporated bus bar for a multi-phase electric motor. The segmented stator comprises a plurality of stator segments that are arranged into a circular configuration. Each stator segment comprises a divided core that includes a core back portion and a core tooth portion. An insulator is disposed on at least the core tooth portion, and a winding of magnet wire is disposed on the insulator. An over-molded encapsulation is applied to fixate the divided core and the winding. A bus bar is incorporated into the stator segments and placed into electrical communication with the windings. The bus bar includes annular conductors that may be over-molded such that the bus bar is encapsulated within the segmented stator. Connectors coupled with the bus bar are configured for passing an electric current to the stator segments.

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.

An electric motor including a motor rotor and a motor stator including a stator core including a plurality of stator teeth spaced along a circumferential direction of the stator core, a plurality of coil groups, wherein each of the plurality of coil groups includes a plurality of coils wound on a corresponding stator tooth, and an incoming line terminal and an outgoing terminal both comprising a same number of coil ends, and two motor lead groups, wherein a number of the plurality of motor leads of each of the two motor lead groups is equal to a number of the plurality of coil groups, and wherein each of the plurality of motor leads is connected to one incoming line terminal or one outgoing line terminal of one corresponding coil group of the plurality of coil groups.

To provide an on-vehicle brushless motor device capable of being downsized with respect to an axial direction of a rotor and a method of manufacturing the same. The on-vehicle brushless motor device 1 includes a brushless motor 10 and an electronic substrate 30. The brushless motor 10 includes a rotor 12 and a stator 16 including a plurality of coils 18 arranged around the rotor 12. The electronic substrate 30 is arranged on a side opposite to an output side of the brushless motor 10 along a plane P intersecting an axial direction X. The on-vehicle brushless motor device 1 further includes a soldering portion 40 that connects a coil wire 20 of the coil 18 and the electronic substrate 30.

A motor includes a housing and a metal shield plate. The housing includes a bearing holder. The shield plate includes a shield plate main body and a protrusion that protrudes upward from the shield plate main body. The protrusion has a tubular shape. In manufacturing the motor, the protrusion of the shield plate is inserted into a through-hole in the bearing holder. A working deformation portion is then formed such that an upper end of the protrusion is deformed to contact an upper surface of the bearing holder.

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.

Disclosed are various embodiments for Torque Tunnel Halbach Array electric machines having a rotor comprising a plurality of rotor assemblies configured to form a magnetic torque tunnel having at least a first magnetic pole tunnel segment and a second magnetic pole tunnel segment, each of the rotor assemblies having a plurality of flux shaping Halbach Arrays configured to focus the Flux Density Distribution in the magnetic torque tunnel and a stator having a plurality of coils configured to form a coil winding assembly, the coil winding assembly positioned within the magnetic torque tunnel, such that at least one of the plurality of coils is surrounded by the first magnetic pole tunnel segment or the second magnetic pole tunnel segment, alternatively the rotor may be the coil winding assembly and the stator may be the magnetic torque tunnel.

Stator and method for producing a stator for an electrical machine, comprising a stator main body (34) which has radial stator teeth (14) for receiving coils (17) of an electrical winding and, on an end side of the stator main body (34), has an insulating lamination (40) with receiving pockets (46) for insulation-displacement terminal elements (70), wherein the coils (17) are wound by means of a winding wire which is inserted into the receiving pockets (46), wherein an interconnection plate (52) has annular conductors (84) on which in each case a plurality of insulation-displacement terminal elements (70) are arranged, which insulation-displacement terminal elements axially engage into the receiving pockets (46) in order to make electrical contact with the winding wire, wherein the interconnection plate (52) is manufactured from plastic and has annular grooves (59) which are open axially at the bottom and into which the annular conductors (84) are inserted.