Abstract: A winding assembly for a stator has a plurality of bridges each including an arcuate center section extending circumferentially over an end surface of a core at a first axial level relative thereto, first and second necks contiguous with respective first and second ends of the center section and extending therefrom axially away from the end surface, and first and second blocks contiguous with the respective necks and connected to the respective terminals of a pair of conductors at a second axial level farther from the end surface than the first axial level.

Abstract: A stator for an electric machine is fabricated by assembling a core and first and second winding assemblies. The first winding assembly (FWA) is fabricated by a 3D printing process and includes a plurality of U-shaped conductors (hairpins) having respective end-turns arranged in mutually axially-nested relationship to each other to form a ring, and further having two uprights disposed in one of the slots of the core. End-turns connect respective pairs of the uprights and are disposed adjacent to an end surface of the core, distal ends of the uprights projecting axially beyond an opposite end surface of the core. The second winding assembly (SWA) includes a plurality of bridges forming a second ring Opposite ends of each bridge define terminals that mate with ends of the uprights. The SWA further includes an electrically non-conductive casing in which at least one of the bridges is embedded.

Abstract: A winding assembly for a stator has a plurality of bridges each including an arcuate center section extending circumferentially over an end surface of a core at a first axial level relative thereto, first and second necks contiguous with respective first and second ends of the center section and extending therefrom axially away from the end surface, and first and second blocks contiguous with the respective necks and connected to the respective terminals of a pair of conductors at a second axial level farther from the end surface than the first axial level.

Abstract: A stator for an electric machine is formed in stratified layer forming a core having axial slots, and a plurality of hurdle-shaped conductors. Each conductor includes first and second uprights disposed in the slots, and a bridge connecting the uprights and extending circumferentially over a core end surface. The first upright is radially closer to a core central axis than the second upright. Each bridge steps radially outward from the first upright to the second upright. Radially adjacent bridges nest next to one another without crossing over one another. A junction between the first end of the bridge and the first upright defines a radially outward-facing ledge, and a junction between the second end and the second upright defines a radially inward-facing ledge. Each bridge passes over the outward-facing ledge of its radially inwardly adjacent conductor and passing over the inward-facing ledge of its radially outward adjacent conductor.

Abstract: A stator for an electric machine is fabricated by assembling a core and first and second winding assemblies. The first winding assembly (FWA) is fabricated by a 3D printing process and includes a plurality of U-shaped conductors (hairpins) having respective end-turns arranged in mutually axially-nested relationship to each other to form a ring, and further having two uprights disposed in one of the slots of the core. End-turns connect respective pairs of the uprights and are disposed adjacent to an end surface of the core, distal ends of the uprights projecting axially beyond an opposite end surface of the core. The second winding assembly (SWA) includes a plurality of bridges forming a second ring Opposite ends of each bridge define terminals that mate with ends of the uprights. The SWA further includes an electrically non-conductive casing in which at least one of the bridges is embedded.

Abstract: A stator for an electric machine is formed in stratified layer forming a core having axial slots, and a plurality of hurdle-shaped conductors. Each conductor includes first and second uprights disposed in the slots, and a bridge connecting the uprights and extending circumferentially over a core end surface. The first upright is radially closer to a core central axis than the second upright. Each bridge steps radially outward from the first upright to the second upright. Radially adjacent bridges nest next to one another without crossing over one another. A junction between the first end of the bridge and the first upright defines a radially outward-facing ledge, and a junction between the second end and the second upright defines a radially inward-facing ledge. Each bridge passes over the outward-facing ledge of its radially inwardly adjacent conductor and passing over the inward-facing ledge of its radially outward adjacent conductor.

Abstract: An electric machine includes a stator core defining slots having radial layers that each include adjacent first and second pin positions. Pins are disposed in corresponding ones of the slots and are interconnected to form a winding path. The path occupies the first and second positions of each layer, and, for each of the corresponding slots, the pins are in a same layer.

Abstract: An electric machine includes a stator core defining slots having radial layers that each include adjacent first and second pin positions. Pins are disposed in corresponding ones of the slots and are interconnected to form a winding path. The path occupies the first and second positions of each layer, and, for each of the corresponding slots, the pins are in a same layer.

Abstract: An electric motor system includes a stator and a cover. The stator has windings that are affixed to an end periphery of the stator. The cover is secured to stator and defines a channel and a plenum. The channel extends along the end periphery and is configured to direct cooling fluid about the windings. The plenum extends over at least twenty percent of an outer perimeter of the cover and is configured to direct cooling fluid into the channel.

Abstract: An electric motor system includes a stator and a cover. The stator has windings that are affixed to an end periphery of the stator. The cover is secured to stator and defines a channel and a plenum. The channel extends along the end periphery and is configured to direct cooling fluid about the windings. The plenum extends over at least twenty percent of an outer perimeter of the cover and is configured to direct cooling fluid into the channel.