The present invention relates to an electric machine (1) having a rotor (3) and a stator (2), wherein the stator (2) and/or the rotor (3) has an electrical plug-in winding (4), which comprises a plurality of rigid insulated electrical conductor elements (5); the conductor elements (5) are arranged in grooves of the stator or of the rotor and their conductor ends (17) project out of the grooves; the conductor ends of the conductor elements (5) are each connected to conductor ends of other conductor elements (5) in order to form the electrical plug-in winding (4); the conductor elements (5) have an electrically insulating insulation sheath (9); characterized in that each conductor element (5) has a multiplicity of flexible fibres (8), in particular of a conductor strand of flexible fibres (8), made of carbon nanotubes or graphene and in that the insulation sheath (9) surrounds the multiplicity of fibres (8) like a hose and is designed in such a way that it gives the electrical conductor element (5) a rigid form.

An armature manufacturing method includes an insulating member disposing step for disposing an insulating member on a core so that first portions of the insulating member protrude to one side in an axial direction from end faces of tooth portions on the one side in the axial direction. The armature manufacturing method includes a bending step for bending, toward each of the tooth portions, the first portions of the insulating member that protrude from the end face of each of the tooth portions on the one side. The armature manufacturing method includes a winding looping step for looping a winding around each of the plurality of tooth portions on which the bent first portions are disposed.

An armature manufacturing method includes an insulating member disposing step for disposing an insulating member on a core so that first portions of the insulating member protrude to one side in an axial direction from end faces of tooth portions on the one side in the axial direction. The armature manufacturing method includes a bending step for bending, toward each of the tooth portions, the first portions of the insulating member that protrude from the end face of each of the tooth portions on the one side. The armature manufacturing method includes a winding looping step for looping a winding around each of the plurality of tooth portions on which the bent first portions are disposed.

A varnish injection system for an electric motor includes a pair of varnish injection assemblies and a biasing device. Each varnish injection assembly includes an injector arm and a varnish injector nozzle attached to the injector arm and operable to provide a varnish to a gap defined between the stator core and one or more wires among the plurality of wires. The biasing device connects the pair of varnish injection assemblies and is configured to exert a compressive force urging the pair of varnish injection assemblies toward each other.

Stator for an electric machine includes a stator core which has an axial end side, and a a plurality of shaped conductors which protrude from the stator core at the end side and which each have, at the end side, at least one end portion having a free end of the shaped conductor. Arrangements of at least two of the end portions are connected to one another in an electrically conductive and mechanical manner in such a way that each arrangement forms a connecting portion which has a first cross-sectional area that lies in a predefined cross-sectional plane and that has corner portions and side portions lying between the corner portions. A plurality of insulation elements each envelop at least one of the connecting portions and are each formed from an electrically insulating material.

A method includes obtaining pre-weld image data of the electric motor stator from one or more image sensors; performing a welding process in response to obtaining the pre-weld image data, obtaining post-weld image data of the electric motor stator from the one or more image sensors in response to performing the welding process, obtaining epoxy image data of the electric motor stator from the one or more image sensors in response to obtaining the post-weld image data, performing a difference-based image processing routine based on the post-weld image data and the epoxy image data to generate a digital twin of the electric motor stator, and determining one or more epoxy characteristics of the electric motor stator based on the digital twin.

A compound winding motor stator includes a stator core and a coil winding structure. The stator core has a yoke, and a plurality of winding portions formed toward the center of the yoke in an equally distanced manner. The winding portions are defined as a plurality of first winding portions and a plurality of second winding portions. The first winding portions and the second winding portions are arranged in a staggered manner. The coil winding structure has first windings configured as rectangular windings and disposed on the first winding portions, and second windings configured as trapezoid windings and disposed on the second winding portions. Accordingly, the rectangular windings and the trapezoid windings are arranged in a staggered manner, that improves the slot fill factor of the motor stator, thereby increasing the efficiency of the motor.

A compound winding motor stator includes a stator core and a coil winding structure. The stator core has a yoke, and a plurality of winding portions formed toward the center of the yoke in an equally distanced manner. The winding portions are defined as a plurality of first winding portions and a plurality of second winding portions. The first winding portions and the second winding portions are arranged in a staggered manner. The coil winding structure has first windings configured as rectangular windings and disposed on the first winding portions, and second windings configured as trapezoid windings and disposed on the second winding portions. Accordingly, the rectangular windings and the trapezoid windings are arranged in a staggered manner, that improves the slot fill factor of the motor stator, thereby increasing the efficiency of the motor.

A coil for an electric machine including a conductive strand having a first end, a second end, and a plurality of windings between the first and second ends and an electric insulating body within which the conductive strand is at least partially encased, wherein at least a portion of the insulating body includes perforations that allow a coolant to penetrate into the insulating body to cool the coil during use of the electric machine. A method of making the coil includes molding or printing the insulating body about the conductive strand so as to have perforations therein.

In an electric motor (310), an electrical insulation body (70) includes a first insulation part (71), a second insulation part (72), and a third insulation part (73). The third insulation part includes a first side surface insulation body (731) disposed on a first side surface of a tooth base part (842) of a stator tooth (84) on the first side in a circumferential direction (DX), a second side surface insulation body (732) disposed on a second side surface of the tooth base part of the stator tooth on a second side in the circumferential direction, and a connection part (733) that connects the first side surface insulation body and the second side surface insulation body. The connection part is disposed on the first side in the axial direction with respect to the tooth base part while being in contact with a first insulation part.