Abstract: A modular stator includes a first stator module and a second stator module. The first stator module includes a plurality of first coil end regions and a plurality of first junctions. The second stator module includes a plurality of second coil end regions and a plurality of second junctions. The first stator module and the second stator module are joined at the plurality of first junctions and the plurality of second junctions.

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.

Abstract: A modular stator includes a first stator module and a second stator module. The first stator module includes a plurality of first coil end regions and a plurality of first junctions. The second stator module includes a plurality of second coil end regions and a plurality of second junctions. The first stator module and the second stator module are joined at the plurality of first junctions and the plurality of second junctions.

Abstract: A slot flaring apparatus is presented herein. The slot flaring apparatus includes a base and flaring tool. The base is configured to receive and secure a stator that has a plurality of core slots. The flaring tool is configured to be controllably pressed against the stator and has a plurality of flaring teeth. Moreover, each tooth of the plurality of flaring teeth is configured to insert into and form a respective slot liner which has been inserted into the corresponding core slot.

Abstract: An electric motor for a hybrid or electric vehicle drive unit includes a housing with a stator fixed within the housing and including a plurality of end windings. A rotor is disposed within the housing and connected to a drive shaft. An isolating ring is disposed within the housing between the end windings and the housing.

Abstract: An electric motor for a hybrid or electric vehicle drive unit includes a housing with a stator fixed within the housing and including a plurality of end windings. A rotor is disposed within the housing and connected to a drive shaft. An isolating ring is disposed within the housing between the end windings and the housing.

Abstract: A slot flaring apparatus is presented herein. The slot flaring apparatus includes a base and flaring tool. The base is configured to receive and secure a stator that has a plurality of core slots. The flaring tool is configured to be controllably pressed against the stator and has a plurality of flaring teeth. Moreover, each tooth of the plurality of flaring teeth is configured to insert into and form a respective slot liner which has been inserted into the corresponding core slot.

Abstract: A fixture assembly for welding a plurality of stator wire end pairs may include an anvil, a movable clamp configured to translate between an unclamped state and a clamped state, a first grounding electrode, and a second grounding electrode. The movable clamp may be configured to urge the plurality of stator wire ends against the anvil when in the clamped state. The moveable clamp includes a separator feature that generally extends toward the anvil. Each of the first grounding electrode and second grounding electrodes may be configured to translate between a clamped state and an unclamped state. When in the clamped state, each of the first and second grounding electrodes is configured to urge a pair of the plurality of stator wire end pairs against the separator feature.

Abstract: A fixture assembly for welding a plurality of stator wire end pairs may include an anvil, a movable clamp configured to translate between an unclamped state and a clamped state, a first grounding electrode, and a second grounding electrode. The movable clamp may be configured to urge the plurality of stator wire ends against the anvil when in the clamped state. The moveable clamp includes a separator feature that generally extends toward the anvil. Each of the first grounding electrode and second grounding electrodes may be configured to translate between a clamped state and an unclamped state. When in the clamped state, each of the first and second grounding electrodes is configured to urge a pair of the plurality of stator wire end pairs against the separator feature.

Abstract: An insulation assembly is provided that includes a generally annularly-shaped main body and at least two spaced-apart fingers extending radially inwards from the main body. The spaced-apart fingers define a gap between the fingers. A slot liner may be inserted within the gap. The main body may include a plurality of circumferentially distributed segments. Each one of the plurality of segments may be operatively connected to another of the plurality of segments to form the continuous main body. The slot liner may be formed as a single extruded piece defining a plurality of cavities. A plurality of conductors (extendable from the stator assembly) may be axially inserted within a respective one of the plurality of cavities. The insulation assembly electrically isolates the conductors in the electric motor from the stator stack and from other conductors.

Abstract: A stator assembly includes a stator stack and a plurality of conductors extending from the stator stack. An isolator/assembly ring is located on the stator stack. The isolator/assembly ring includes a plurality of inwardly protruding fingers. A method of assembling the stator assembly includes threading the plurality of conductors through the stator stack such that each of the plurality of fingers on the isolator/assembly ring is located between respective ones of the plurality of conductors.

Abstract: A method of preparing a plurality of bar-wound stator conductors for electrical interconnection includes inserting the plurality of conductors into a stator, twisting a conductor such that a first conductor of a first row is adjacent to a second conductor of a second row; trimming the adjacent first and second conductors to a common length using a trimming device; and grinding the trimmed first and second conductors to a pre-determined surface profile using a rotary cutting tool.

Abstract: A bar wound stator assembly includes a connection module attached to a stator core at a weld end of the stator assembly. The connection module provides all required electrical connections to connect shaped plurality of hairpin bar connectors of the stator assembly within a first pole pair of a winding set of conductors. All of the hairpin bar conductors include an identical span. The connection module completes each phase of the winding set, to connect each phase of the winding set to define a connection configuration, e.g., a wye or a delta connection configuration, and to connect the stator assembly to all external connections.

Abstract: An electric motor comprises a rotor hub defining a first slot and a rotor stack defining a second slot. A rotor key has a shape corresponding to the cross-sectional shape of the first slot such that the rotor key is removably retained within the first slot. The rotor key is inserted into the first slot on the rotor hub and the second slot on the rotor stack.

Abstract: An insulation assembly is provided that includes a generally annularly-shaped main body and at least two spaced-apart fingers extending radially inwards from the main body. The spaced-apart fingers define a gap between the fingers. A slot liner may be inserted within the gap. The main body may include a plurality of circumferentially distributed segments. Each one of the plurality of segments may be operatively connected to another of the plurality of segments to form the continuous main body. The slot liner may be formed as a single extruded piece defining a plurality of cavities. A plurality of conductors (extendable from the stator assembly) may be axially inserted within a respective one of the plurality of cavities. The insulation assembly electrically isolates the conductors in the electric motor from the stator stack and from other conductors.

Abstract: A modular transmission assembly includes a transmission housing that defines a hollow interior. The transmission housing extends along a central axis between a front end and a rear end. A rear motor module is disposed in, and is operatively connected to, the transmission housing. An inner module is disposed in, and is operatively connected to, the transmission housing. A main shaft is disposed along the central axis such that each of the rear and inner modules radially surround the main shaft. A front motor is disposed in the transmission housing and radially surrounds the main shaft. The inner module is axially disposed between the rear motor module and the front motor. An input module is connected to the front end of the transmission housing. The front motor is axially disposed between the inner module and the input module.

Abstract: An electric motor includes a rotor and a stator assembly concentrically located about the rotor. The stator assembly includes a stator stack and a plurality of spaced apart stator teeth extending radially from the stator stack. The plurality of stator teeth define a plurality of stator slots. A plurality of slot liners are each inserted within a respective one of the stator slots. The slot liners are each formed from a length of extruded dielectric material. A method of manufacturing the electric motor includes inserting the extruded slot liners into the stator slots, then inserting a plurality of conductors into the respective one of the plurality of cavities that are defined by the extruded slot liner.

Abstract: A stator assembly includes a stator stack and a plurality of conductors extending from the stator stack. An isolator/assembly ring is located on the stator stack. The isolator/assembly ring includes a plurality of inwardly protruding fingers. A method of assembling the stator assembly includes threading the plurality of conductors through the stator stack such that each of the plurality of fingers on the isolator/assembly ring is located between respective ones of the plurality of conductors.

Abstract: A modular transmission assembly includes a transmission housing that defines a hollow interior. The transmission housing extends along a central axis between a front end and a rear end. A rear motor module is disposed in, and is operatively connected to, the transmission housing. An inner module is disposed in, and is operatively connected to, the transmission housing. A main shaft is disposed along the central axis such that each of the rear and inner modules radially surround the main shaft. A front motor is disposed in the transmission housing and radially surrounds the main shaft. The inner module is axially disposed between the rear motor module and the front motor. An input module is connected to the front end of the transmission housing. The front motor is axially disposed between the inner module and the input module.