Embodiments of the present invention are directed to a generator for connecting to a predefined load, where the generator is designed and constructed to meet one or more requirements of the predefined load. In specific embodiments the one or more requirements include providing a minimum output voltage while starting the predefined load at or above ambient temperature and providing an output voltage that does not exceed an upper voltage limit while being driven at full speed without any load current at or below ambient temperatures, while maintaining high efficiency under a specified full load running condition and keeping the overall cost and size of the generator low.

Each lamination of the lamination stack comprises at least one assembly of coupling elements, said assembly comprising one insertion clamp, one receiving clamp and at least one receiving window, said coupling elements maintaining the same relative positioning from one another, the insertion clamp and the receiving clamp being defined by respective portions of the lamination axially projecting to the same side of the latter, each insertion clamp of a lamination being fitted, by interference, in the interior of a receiving clamp of an adjacent lamination, and each receiving clamp of a lamination being housed in the receiving window of at least one lamination of the stack.

Each lamination of the lamination stack comprises at least one assembly of coupling elements, said assembly comprising one insertion clamp, one receiving clamp and at least one receiving window, said coupling elements maintaining the same relative positioning from one another, the insertion clamp and the receiving clamp being defined by respective portions of the lamination axially projecting to the same side of the latter, each insertion clamp of a lamination being fitted, by interference, in the interior of a receiving clamp of an adjacent lamination, and each receiving clamp of a lamination being housed in the receiving window of at least one lamination of the stack.

A stator for a rotary electric machine includes a stator core and a stator coil. The stator core includes plate groups circumferentially shifted from and stacked on one another. The stator core has slots. The stator coil includes segment conductors inserted in the slots respectively. The stator coil is assembled with the stator core. The plate groups each have, as grooves that form the slots, first grooves, and second grooves wider than the first grooves. At least one of the slots is configured with one or more of the first grooves and one or more of the second grooves.

An electric machine stator is provided and includes laminations consolidated along an axial direction to form a core element such that the core element includes an end lamination at an axial end of the core element. The end lamination includes a body extending in a plane and a plurality of spacer protrusions protruding along the axial direction from the plane. Each of the spacer protrusions of the plurality of spacer protrusions is configured for consolidation with another core element to define a radial vent between the core element and the another core element.

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.

The present invention relates to a method for manufacturing an electric motor having a stator with stator slots and electrical conductors arranged therein. In order to achieve simple production, the following is planned, that at least two electrical conductors are sheathed in an extrusion process with an electrical insulator, which holds the at least two electrical conductors at a distance from one another and has at least one positioning contour, that the at least two electrical conductors together with the electrical insulator are inserted into an associated stator slot and fixed therein via the at least one positioning contour.

There is provided a method for producing a rotor laminated core by laminating circular core pieces. The method determines a first blanking area, a second blanking area and a third blanking area in the magnetic steel board, wherein the first blanking area defines a shape of the core piece, the second blanking area defines a shape of a magnet-insertion hole, and the third blanking area defines a shape of an arbitrary part in the magnetic steel board. The method also forms a temporary aperture in the second blanking area, forms a thinning part which extends from the temporary aperture to the third blanking area, and blanks the first blanking area, the second blanking area and the third blanking area, thereby producing each circular core piece including the thinning part and magnet-insertion holes formed in a circumferential direction.

A method of manufacturing an induction motor rotor assembly, the method includes the steps of: providing a rotor; machining a plurality of re-entrant slots axially along an outer surface of the rotor; positioning a sleeve concentrically over the outer surface of the rotor; applying a friction stir welding process to the sleeve along each re-entrant slot axially along the outer surface of the rotor to cause the sleeve material to plasticise and flow into the axial re-entrant slot to form an axial re-entrant slot bar; and providing an electrical connection at each of the opposing axial ends of the rotor between respective ones of opposing ends of each of the axial re-entrant slot bars to thereby form the induction motor rotor.

A method of making a component of a radial or axial flux electrical machine is provided. An additive manufacturing process is used to manufacture a plurality of laminas, including applying beams of energy to a successive plurality of ferromagnetic material particles and fusing them together to form a ferromagnetic helix or spiral, disposing an insulating material on said ferromagnetic helix or spiral, compressing the ferromagnetic helix or spiral to form a compressed ferromagnetic helix or spiral, and fixing the compressed ferromagnetic helix or spiral. A method of making a component of a transverse flux electrical machine is provided, including using an additive manufacturing process.