A method of manufacturing a rotary electric machine armature that includes a cylindrical armature core in which a plurality of slots that extend in an axial direction are disposed in a circumferential direction and a coil wound around the armature core, the slots having respective radial openings that open in a radial direction, and the coil being formed by joining a plurality of segment conductors to each other.

A method of manufacturing a rotary electric machine armature that includes a cylindrical armature core in which a plurality of slots that extend in an axial direction are disposed in a circumferential direction and a coil wound around the armature core, the slots having respective radial openings that open in a radial direction, and the coil being formed by joining a plurality of segment conductors to each other.

A conductor wire insulating film separating method disclosed includes: a preparing step involving preparing rectangular cross-section coil pieces each of which is a conductor wire coated with insulating film and used to provide a stator coil of rotary electric machine; a delivering-in step involving, after the preparing step, delivering coil pieces into a laser separator, with coil pieces aligned such that extremities thereof are adjacent to each other; an applying step involving, after the delivering-in step, continuously applying film removing laser to the extremities of the aligned coil pieces such that the laser is applied to one extremity and then to another extremity, thus removing at least portions of the insulating film from the extremities of the coil pieces; and a delivering-out step involving delivering the coil pieces, from which the at least portions of the insulating film have been removed by the applying step, out of the laser separator.

A stator has a stator coil provided on an annular stator core. The stator coil is formed of electrical conductor wires each including an electrical conductor and an insulating coat. Each of the electrical conductor wires has a pair of exposed portions where the electrical conductor is exposed from the insulating coat and a covered portion where the electrical conductor is covered with the insulating coat. The pair of exposed portions are formed respectively at opposite end portions of the electrical conductor wire. The covered portion is formed at other portions of the electrical conductor wire than the end portions. At a coil end part of the stator coil, each corresponding pair of the exposed portions of the electrical conductor wires are welded together and each of the covered portions of the electrical conductor wires includes a coat-removed portion where the insulating coat is locally removed from the covered portion.

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 drive unit includes a multi-phase AC motor including a plurality of first terminals, and a power converter including a plurality of second terminals. The power converter is fixed to an electric motor case so as to partially overlap the AC motor in an axial direction with a wall portion interposed therebetween. Each first terminal includes a first extended portion extending from the stator along the axial direction, and a first fastening portion. Each second terminal includes a second extended portion extending along an extending direction at a portion of the power converter that does not overlap the AC motor in the axial direction; and a second fastening portion. The electric motor case includes a communication hole formed in the wall portion, and a service hole formed in a portion located on an extension line of the fastener parallel to an insertion direction of the fastener.

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.

The reliability of a rotating electrical machine is improved. A method for manufacturing a stator used in a rotating electrical machine includes: a first step of arranging a first segment coil and a second segment coil to face each other; a second step of processing the first segment coil to generate a bridge part that comes into contact with the second segment coil; and a third step of joining the bridge part and the second segment coil by laser welding.

According to one embodiment, a stator includes a stator core and a stator coil configured by joining a plurality of coil segments mounted in slots of the stator core. Extending portions of the coil segments include a plurality of first extending portions, an inclined portion, and a joining end portion and a hook-shaped portion provided at an extending end of the inclined portion. The joining end portions are arranged side by side in a radial direction such that distal end surfaces are located at substantially the same height, the hook-shaped portions are meshed with each other, and a first engagement surface of one of the joining end portions faces and abuts on a first engagement surface of the other of the joining end portions.

A stator of an electric machine includes a laminated core having slots for receiving windings of a multiphase winding system. The windings have winding ends, which are encased with an insulator across a partial length. In order to encase the winding ends with the insulator, a strand of a thermoplastic material is extruded onto the winding ends via a nozzle. During extrusion, the nozzle is moved relative to the winding end along the longitudinal extent thereof and an oscillating movement of the nozzle transversely to the longitudinal extent of the winding end overlays the movement along the longitudinal extent. As a result the thermoplastic material lies on the winding end and around the respective winding end in the form of loops.