Abstract: A support for a conductor in an electric machine, including a body receivable in a stator of the electric machine between adjacent coils, the body defining an axis, a conductor anchor extending from the body at an angle to the axis, the conductor anchor having at least two conductor contact points, the angle of the anchor causing bending of the conductor at at least two contact points when the conductor is disposed in the anchor and the body is disposed in the stator. A stator having a coil thereon, a conductor separate from the coil, and a support disposed in the stator and in supportive contact with the conductor. A method for supporting a conductor at a stator of an electric machine, including disposing the support in contact with the conductor, rotating the support to introduce plastic deformations in the conductor, and inserting the body into the stator.

Abstract: A method for securing a stator, including aligning a pin with an opening in a lamination stack, holding the pin with a support, the support having a surface thereof that is located at a distance from the lamination stack of at least 40 percent of a length of the pin that is exposed outside the lamination stack, and press fitting the pin into the opening. An electric machine, including a stator including a lamination stack having a first end and a second end and an ear depending from the stack, the ear including an opening, and a pin disposed, in press fit relationship, with the stator, the pin extending beyond the first and the second ends of the stator.

Abstract: A sealed stator for an electric machine is disclosed herein. In at least one embodiment, the sealed stator includes a stator core, stator windings positioned on the stator core, and an end ring coupled to the stator core. The stator core includes a plurality of slots. The windings include a plurality of interconnected conductors extending through the plurality of slots in the stator core. The end ring includes a plurality of segments arranged circumferentially around the end ring, each of the plurality of segments comprising a pocket compartment defined between two radial ribs. Each pocket compartment includes a radially outward pocket floor and a radially inward opening through the end ring. The plurality of interconnected conductors further extend through the openings in the end ring.

Abstract: A method of forming a stator winding includes providing a stator core having a plurality of longitudinally extending slots formed about a circumference thereof, providing a plurality of hairpin conductors each having a substantially rectangular cross-section and each having an apex portion and a pair of legs that terminate at respective ends, cutting a bevel at each leg end, inserting the hairpin legs into respective ones of the slots so that the leg ends extend from an axial end of the stator core, bending the hairpin legs to form a plurality of adjacent pairs of leg ends with beveled cuts facing one another, compressing the beveled cuts of each pair together, and resistance welding the pairs to form a plurality of welded joints.