Abstract: The present invention provides a compact winding for multi-phase electric machines. For each phase, a conductor with a specifically shaped overhang portion is provided. All but one of the various overhang portions are provided with a U-bent portion to accommodate a traversing portion of at least one of the other conductors. The width of the U-bent portions differs from phase to phase so that conductors can be inserted into the stator slots in a staggered fashion. A step deformation which has the same shape for all phases, is used for connecting different layers of the winding. Electric contacts to the windings are provided at the overhang portions without deviating from the staggered arrangement of traversing conductor portions.

Abstract: The present invention concerns a stator for an electric machine of the type that comprises a stator, a rotor and an air gap in-between, in particular an inner stator for an outer rotor motor; the stator comprising a stator core having a plurality of core teeth, electromagnetic windings arranged around the core teeth, a stator housing comprising a recessed space which is open at the air gap-facing side of the stator, the recessed space accommodating the stator core and the electromagnetic windings, and a water impermeable protective barrier sealing the recessed space at the open air gap-facing side in a fluid-tight manner, characterized in that the protective barrier is permanently bonded to the windings and the core teeth by potting material provided in the recessed space. The present invention further relates to a corresponding method of manufacturing as well as to the use of an air gap-facing protective barrier of a stator as a potting material barrier structure.

Abstract: A lubricant supported electric motor assembly includes an electric motor module, a shifting and first stage module, and a final drive module sequentially operably interconnected with one another for producing drive torque that is ultimately conducted to a wheel of a vehicle. The electric motor module includes a stator and a rotor defining an internal rotor cavity. The shifting and first stage module is disposed within the internal rotor cavity and includes a first planetary gear reducer assembly and an output gear selectively coupleable to said first planetary gear reducer assembly. The final drive module is disposed adjacent the shifting and first stage module and includes a second planetary gear reducer assembly operably coupled with the output gear. A shifting mechanism establishes selective coupling between the first planetary gear assembly and the output gear to transfer adjustable torque from the shifting and first stage module to the final drive device.

Abstract: A method and an apparatus for compact insertion of thick wire multiphase pseudo helical wave winding into a ferromagnetic core of an electrical machine, achieving high fill factor of the core slots, resulting in better heat transfer between the winding and the core, low mass and volume, and overall higher efficiency of electrical machine. An apparatus being fully programmable and physically adaptable to wide range of electric machine dimensions, where process is automated, simple, accurate, reliable and quick, while being suitable for mass production.

Abstract: A lubricant supported electric motor assembly includes an electric motor module, a shifting and first stage module, and a final drive module sequentially operably interconnected with one another for producing drive torque that is ultimately conducted to a wheel of a vehicle. The electric motor module includes a stator and a rotor defining an internal rotor cavity. The shifting and first stage module is disposed within the internal rotor cavity and includes a first planetary gear reducer assembly and an output gear selectively coupleable to said first planetary gear reducer assembly. The final drive module is disposed adjacent the shifting and first stage module and includes a second planetary gear reducer assembly operably coupled with the output gear. A shifting mechanism establishes selective coupling between the first planetary gear assembly and the output gear to transfer adjustable torque from the shifting and first stage module to the final drive device.

Abstract: A method and an apparatus for compact insertion of thick wire multiphase pseudo helical wave winding into a ferromagnetic core of an electrical machine, achieving high fill factor of the core slots, resulting in better heat transfer between the winding and the core, low mass and volume, and overall higher efficiency of electrical machine. An apparatus being fully programmable and physically adaptable to wide range of electric machine dimensions, where process is automated, simple, accurate, reliable and quick, while being suitable for mass production.