An electric motor includes a shaft, and a stator disposed around the outer periphery of the shaft and including a plurality of slots extending toward the shaft. A plurality of coil units are arranged respectively in the plurality of slots. The coil units are each formed of a plurality of wires connected in parallel. One of the coil units that is arranged in at least one of the plurality of slots formed in the stator includes a plurality of winding groups that are connected in series and that have a different number of turns from each other. The winding groups are arranged in the slot in descending order of the number of turns in the direction toward the shaft.

A method for manufacturing an armature (1) includes: a coil disposing step involving using a thermally expandable resin (Q) that expands by application of heat, and disposing a coil (30) in a core (10) such that the thermally expandable resin (Q) before expansion is disposed between a slot-housed portion (31) and an inner surface of a slot (11); a resin disposing step involving, before or after the coil disposing step, using a thermally melting resin (P) that melts by application of heat, and disposing the thermally melting resin (P) before melting such that the thermally melting resin (P) comes into contact with coil end portions (32); and a heating step involving, after the coil disposing step and the resin disposing step, heating, expanding, and then curing the thermally expandable resin (Q), and heating, melting, and then curing the thermally melting resin (P).

A rotor having multiple poles is provided and includes at each pole an end winding support forming a channel, a bus bar disposed in the channel and edge-wound coils disposed to extend around the end-winding support and the bus bar. The edge-wound coils are stacked radially and include an inner diameter coil routed to an adjacent pole and brazed to an inner diameter coil of the adjacent pole and an outer diameter coil brazed to the bus bar.

A six-phase flat wire wave winding structure. Each phase of wave winding structure has a wire-in end, a wire-out end, and a wire located between the wire-out end and the wire-in end. The six-phase flat wire wave winding structure is applicable to a 2M-layer (M=1, 2, 3 . . . ) six-phase motor whose quantity of slots of each phase in each pole is q, whose quantity of stator slots is 6q (q=1, 2, 3 . . . ) times of a quantity of poles, and whose quantity a of parallel branches is 1 or 2. Each phase of the wave winding structure has conductors in all layers of a same stator slot, and the wave windings are uniformly and symmetrically distributed. In addition, problems that a flat wire winding process is highly difficult and manufacturing costs are high due to an increase in a quantity of phases of the six-phase motor are effectively resolved.

In some examples, a stator assembly includes a stator body including a base portion and a plurality of stator teeth projecting radially inward from the base portion. The stator assembly further includes an electrically conductive member wound about a tooth of the plurality of stator teeth to define a winding about the tooth, the winding comprising a single layer of the conductive member and including a plurality of turns of the electrically conductive member, wherein the electrically conductive member has a thickness in the radial direction that is less than its width in a direction perpendicular to the radial direction.

A method of fabricating an electric machine stator includes inserting one or more electrical coils into a form and partially curing the one or more electrical coils. The method also includes populating the electric machine stator with the one or more electrical coils and curing the electric machine stator with one or more electrical coils.

Provided is a stator of a rotary electric machine in which a bonding portion of ends of coil segments is formed at a coil end of the stator without being inflated toward the opposite side to a stator core, and the coil end can be minimized in an axial direction. The stator of the rotary electric machine includes a stator core (10) having a plurality of slots and a coil segment (30) which is disposed in the stator core to form a stator winding (3). The ends of the coil segments are overlapped in the axial direction, and bonded through the bonding portion. The bonding portion is formed in a shape such that the bonding portion is melted and flows down from the end (6a) of the coil segment on the opposite side to the stator core toward the end (5a) of the coil segment on a side near the stator core.

The invention relates mainly to a rotary electrical machine stator, in particular for a motor vehicle, comprising: a stator body (11) with a central axis, the stator body (11) comprising a series of notches (15); a winding wound in the notches (15) in the stator body (11) forming a first chignon (231) and a second chignon (232) extending axially on both sides of the stator body (11); wherein at least one of the phase windings (PH1-PH3, PH1′-PH3′) is a shielded winding which comprises all the active portions (20) of the layer (C1, CN) situated at one of the radial ends at least of each notch (15) of the series, each extended firstly by a corresponding connection portion (21) of the first chignon (231), and secondly by a corresponding connection portion (21) of the second chignon (232).

A rotor having multiple poles is provided and includes at each pole an end winding support forming a channel, a bus bar disposed in the channel and edge-wound coils disposed to extend around the end-winding support and the bus bar. The edge-wound coils are stacked radially and include an inner diameter coil routed to an adjacent pole and brazed to an inner diameter coil of the adjacent pole and an outer diameter coil brazed to the bus bar.

A method for producing an electric motor includes: connecting a first phase coil of three-phase coils to a positive side of a source of electrical power for magnetizing; passing an electric current through the three-phase coils in a state where a center of a magnetic pole of a rotor is rotated a first angle with respect to a center of a magnetic pole of the first phase coil; switching a connection with the positive side of the source of electrical power from the first phase coil to a second phase coil; and passing an electric current through the three-phase coils in a state where the center of the magnetic pole of the rotor is rotated a second angle with respect to a center of a magnetic pole of the second phase coil.