Abstract: A method for gel curing a varnish of a stator assembly includes: applying an electrically-insulating material to a plurality of electrical conductors of a stator assembly; monitoring a temperature of the stator assembly using at least one temperature sensor; determining whether the temperature of the stator assembly has reached a target temperature; in response to determining that the temperature of the stator assembly is equal to the target temperature, heating the stator assembly using an induction heating element to maintain the temperature of the stator assembly at the target temperature for a predetermined amount of time; determining whether the temperature of the stator assembly is equal to the final target temperature; in response to determining that the target temperature is not equal to the final target temperature, increasing the target temperature by a predetermined amount of degrees.

Abstract: Systems and methods are provided for fixturing hairpins for joining by welding. A fixture system includes an outer structural ring fixed relative to an inner structural ring and mates with the component around its hairpin type conductor ends. Dielectric rings are disposed between conductor pairs. Clamp rings are disposed on opposite sides of the dielectric rings. One clamp ring and one dielectric ring define an opening receiving one conductor pair. Another clamp ring and another dielectric ring define another receiving another conductor pair. The clamp rings are movable toward one another to align and crowd the conductor pairs between the clamp rings and the dielectric rings prior to welding.

Abstract: A method for gel curing a varnish of a stator assembly includes: applying an electrically-insulating material to a plurality of electrical conductors of a stator assembly; monitoring a temperature of the stator assembly using at least one temperature sensor; determining whether the temperature of the stator assembly has reached a target temperature; in response to determining that the temperature of the stator assembly is equal to the target temperature, heating the stator assembly using the induction heating element to maintain the temperature of the stator assembly at the target temperature for a predetermined amount of time; determining whether the temperature of the stator assembly is equal to the final target temperature; in response to determining that the target temperature is not equal to the final target temperature, increasing the target temperature by a predetermined amount of degrees.

Abstract: A method of engaging wire ends of a stator assembly. The method involves advancing multiple fingers radially inwardly toward the wire ends, and rotating the fingers. The fingers have protrusions that engage the wire ends. A tooling assembly for engaging the wire ends has a first plate, a second plate, and has the fingers. The first plate has slots, and the second plate has teeth. The fingers have pins that ride in the slots of the first plate, and the fingers have teeth that mesh with the teeth of the second plate.

Abstract: A method of engaging wire ends of a stator assembly. The method involves advancing multiple fingers radially inwardly toward the wire ends, and rotating the fingers. The fingers have protrusions that engage the wire ends. A tooling assembly for engaging the wire ends has a first plate, a second plate, and has the fingers. The first plate has slots, and the second plate has teeth. The fingers have pins that ride in the slots of the first plate, and the fingers have teeth that mesh with the teeth of the second plate.