Abstract: A coil support for preformed flat coils of a stator of an electric rotary motor includes an annular supporting structure and a plurality of columns extending upwardly from the supporting structure. The columns are spaced apart from each other to form a corresponding plurality of coil receiving portions configured to hold the preformed flat coils in place before a potting operation. Each of the coil receiving portions is configured to support a lower part of one of the preformed flat coils.

Abstract: A cooling cage assembly for a rotary electric motor includes a cooling stator arrangement, and a first cylindrical part and a second cylindrical part fixedly mounted against respective opposite sides of the cooling stator arrangement. The cooling stator arrangement includes a stator and cooling tiles mounted against and around the outer circumference of the stator. Each cooling tile includes at least one channel extending from an upper side to a lower side of the cooling tile. The cooling cage assembly further includes a first plurality of fluidic bridges arranged on the upper side of the cooling tiles and a second plurality of fluidic bridges arranged on the lower side of the cooling tiles to form, together with the channel(s) of the cooling tiles, a serpentine flow path, for a cooling fluid, around the outer circumference of the stator.

Abstract: An elastic-locking winding carrier for a preformed coil assembly of a stator of an electric motor, includes a winding portion adapted to receive a winding having a wound electrical conductor to produce a coil. The winding portion includes upper and lower portions, first and second openings arranged on the winding portion, and first and second flexible members located inside respective first and second openings and extending thereacross. The first and second flexible members are arranged such that either of the first and second flexible members cooperates with a tooth of the stator as a function of the magnitude of the gap between the tooth and the lower portion of the winding portion when the preformed coil assembly is mounted on the tooth to fix the preformed coil assembly to the tooth.

Abstract: A stator for electric motors, includes a core having an upper and a lower portion and having teeth forming slots therebetween, first and second coil locking layers fixedly mounted on respective upper and lower portions of the core, and a plurality of preformed coil assemblies mounted on respective teeth of the core. Each coil wound carrier includes a winding section having an elongated opening configured to be adjusted around the corresponding tooth, and a first and a second winding carrier connected to opposite ends of the winding section. The first and second winding carriers include a projecting mating part, and the first and second coil locking rings include mating openings of complementary shape inside which are fitted the projecting mating part of respective first and second winding carriers of one of the preformed coil assemblies.

Abstract: A preformed coil assembly for a stator of an electric motor includes first and second winding carriers located on respective opposite ends of the preformed coil assembly and a winding part wound around the winding carriers to form first and second elongated winding portions with an elongated opening therebetween to be fitted around a tooth of a stator. The preformed coil assembly includes first and second insulation films disposed around the first and second winding portions. Each insulation film includes upper and lower folded portions resting against first and second opposite walls of respective winding carriers to provide first and second distances between respective opposite lateral sides of the tooth and a corresponding non-folded portion of respective first and second insulation films. The first and second distances are equal so that the preformed coil assembly is centered with respect to the tooth when mounted therearound.

Abstract: A stator cooling housing for a stator of a rotary electric motor includes a cylindrical frame adapted to be mounted around an iron core and having an outer lateral surface and inlet and outlet channels. A cylindrical jacket is arranged against the outer lateral surface of the cylindrical frame. The cylindrical jacket comprises an inner side having a plurality of cylindrical grooves forming with the outer lateral surface of the cylindrical frame adjacent fluid cooling channels arranged around the cylindrical frame from a frame upper portion to a frame lower portion. Fluid communication portions are arranged such that a cooling fluid is enabled to run from the inlet channel, through the adjacent fluid cooling channels from the frame upper portion to the frame lower portion, and through the outlet channel to form a cooling circuit.

Abstract: A stator cooling housing for a stator of a rotary electric motor includes a cylindrical frame adapted to be mounted around an iron core and having an outer lateral surface with cylindrical grooves or fins. The cylindrical frame includes a recess having a bottom part, at least one inlet channel, and at least one outlet channel. The stator cooling housing includes an add-on piece mounted into the recess, and a cylindrical jacket arranged against the outer lateral surface of the cylindrical frame to form with the cylindrical grooves or fins cylindrical cooling channels. The add-on piece includes a fluid cooling arrangement in fluid communication, on the one hand, with the inlet and outlet channel and, on the other hand, with the cylindrical cooling channels to form at least one cooling circuit.

Abstract: A stator assembly includes a stator having a plurality of teeth which are distributed around a circumference of the stator and point toward a central axis of the stator. The teeth alternately have a first cross-sectional profile and a second cross-sectional profile, and a plurality of slots being formed between the teeth. A plurality of coils are disposed around the teeth having the first cross-sectional profile. The second cross-sectional profile has a parallel-sided stem portion and an adjoining tapered head portion. A height of the stem portion of the second cross-sectional profile is less than a height of a respective one of the coils that is disposed around an adjacent one of the teeth having the first cross-sectional profile.

Abstract: A coil support for preformed flat coils of a stator of an electric rotary motor includes an annular supporting structure and a plurality of columns extending upwardly from the supporting structure. The columns are spaced apart from each other to form a corresponding plurality of coil receiving portions configured to hold the preformed flat coils in place before a potting operation. Each of the coil receiving portions is configured to support a lower part of one of the preformed flat coils.

Abstract: A prefabricated coil for placement on a tooth for a direct drive is orthocyclically wound from a wire of circular cross section. The coil includes two straight portions having an inner surface facing an interior of the coil and an outer surface opposite and parallel to the inner surface. A distance between the inner surface and the outer surface defines a thickness of the coil. Two coil overhangs connect the straight portions. A distance between the coil overhangs defines a height of the straight portions. The inner and outer surfaces of the straight portions have the height of the straight portions and a width of the straight portions. A sheet-like insulator covers the straight portions. The wire and the sheet-like insulator are bonded together such that the coil is self-supporting under the application of pressure and temperature. The sheet-like insulator has a joint region at the outer surface.

Abstract: An elastic-locking winding carrier for a preformed coil assembly of a stator of an electric motor, includes a winding portion adapted to receive a winding having a wound electrical conductor to produce a coil. The winding portion includes upper and lower portions, first and second openings arranged on the winding portion, and first and second flexible members located inside respective first and second openings and extending thereacross. The first and second flexible members are arranged such that either of the first and second flexible members cooperates with a tooth of the stator as a function of the magnitude of the gap between the tooth and the lower portion of the winding portion when the preformed coil assembly is mounted on the tooth to fix the preformed coil assembly to the tooth.

Abstract: A stator for electric motors, includes a core having an upper and a lower portion and having teeth forming slots (16) therebetween, first and second coil locking layers fixedly mounted on respective upper and lower portions of the core, and a plurality of preformed coil assemblies mounted on respective teeth of the core. Each coil wound carrier includes a winding section having an elongated opening configured to be adjusted around the corresponding tooth, and a first and a second winding carrier connected to opposite ends of the winding section. The first and second winding carriers include a projecting mating part, and the first and second coil locking rings include mating openings of complementary shape inside which are fitted the projecting mating part of respective first and second winding carriers of one of the preformed coil assemblies.

Abstract: In a cooled housing for the stator of a direct drive, cooling ducts extend on an outer peripheral surface of the housing, the cooling ducts being sealed by an annular cover extending around the peripheral surface. The cover includes openings as an inlet and outlet for a cooling medium, and the cover is arranged such that sections of the peripheral surface of the housing remain free.

Abstract: A rotor for a synchronous motor includes teeth arranged at regular intervals, project from a rotor core in the radial direction, and taper in a cross-section in the direction of the rotor core. The rotor also includes tangentially magnetized magnets that are arranged in gaps between the teeth and are trapezoidal in cross-section. The teeth are connected via a flexible joint to the rotor core, and the teeth are deflected in the tangential direction such that in every other gap between two teeth, first magnets rest against outer stops at the ends of the teeth facing away from the rotor core.

Abstract: A prefabricated coil for placement on a tooth for a direct drive is orthocyclically wound from a wire of circular cross section. The coil includes two straight portions having an inner surface facing an interior of the coil and an outer surface opposite and parallel to the inner surface. A distance between the inner surface and the outer surface defines a thickness of the coil. Two coil overhangs connect the straight portions. A distance between the coil overhangs defines a height of the straight portions. The inner and outer surfaces of the straight portions have the height of the straight portions and a width of the straight portions. A sheet-like insulator covers the straight portions. The wire and the sheet-like insulator are bonded together such that the coil is self-supporting under the application of pressure and temperature. The sheet-like insulator has a joint region at the outer surface.

Abstract: A stator assembly includes a stator having a plurality of teeth which are distributed around a circumference of the stator and point toward a central axis of the stator. The teeth alternately have a first cross-sectional profile and a second cross-sectional profile, and a plurality of slots being formed between the teeth. A plurality of coils are disposed around the teeth having the first cross-sectional profile. The second cross-sectional profile has a parallel-sided stem portion and an adjoining tapered head portion. A height of the stem portion of the second cross-sectional profile is less than a height of a respective one of the coils that is disposed around an adjacent one of the teeth having the first cross-sectional profile.

Abstract: In a cooled housing for the stator of a direct drive, cooling ducts extend on an outer peripheral surface of the housing, the cooling ducts being sealed by an annular cover extending around the peripheral surface. The cover includes openings as an inlet and outlet for a cooling medium, and the cover is arranged such that sections of the peripheral surface of the housing remain free.

Abstract: A rotor for a synchronous motor includes teeth arranged at regular intervals, project from a rotor core in the radial direction, and taper in a cross-section in the direction of the rotor core. The rotor also includes tangentially magnetized magnets that are arranged in gaps between the teeth and are trapezoidal in cross-section. The teeth are connected via a flexible joint to the rotor core, and the teeth are deflected in the tangential direction such that in every other gap between two teeth, first magnets rest against outer stops at the ends of the teeth facing away from the rotor core.