Abstract: A spacer for supporting conductors in a stator assembly of an electric machine includes a plurality of positioning elements cooperating with various conductors in the specials region of the winding arrangement. The spacer illustratively includes an insulating body formed of an electrically non-conductive material and including surfaces facing axially inwardly for contacting short conductors and crossover pockets for receiving crossover conductors which electrically connect an inner winding set and an outer winding set. The spacer further illustratively includes phase lead pockets facing axially outwardly for receiving a terminal phase lead conductor.

Abstract: A spacer for supporting conductors in a stator assembly of an electric machine includes a plurality of positioning elements cooperating with various conductors in the specials region of the winding arrangement. The spacer illustratively includes an insulating body formed of an electrically non-conductive material and including surfaces facing axially inwardly for contacting short conductors and crossover pockets for receiving crossover conductors which electrically connect an inner winding set and an outer winding set. The spacer further illustratively includes phase lead pockets facing axially outwardly for receiving a terminal phase lead conductor.

Abstract: Embodiments of the invention provide an electric machine module including a housing which can include a machine cavity. In some embodiments, an electric machine can be at least partially positioned within the machine cavity and can include a stator assembly. The stator assembly includes a stator core with slots. In some embodiments, conductors can be positioned in the slots and can include a first insulation. At least one insulation member can be disposed over at least a portion of the conductors. The insulation member can include a first element and a second element that can each comprise different constituent materials that include different properties.

Abstract: Embodiments of the invention provide an electric machine module including a housing. The housing can include a machine cavity. In some embodiments, an electric machine can be at least partially positioned within the machine cavity and can include a stator assembly. The stator assembly includes a stator core with slots, a weld end, and an insertion end. In some embodiments, conductors can be positioned in the slots so that portions of the conductors extend from the weld end and the insertion end. An insulation member including recesses can be coupled to at least a portion of the conductors that extend from the weld end of the stator assembly.

Abstract: An apparatus and method for forming at least one end turn and one slot segment of a coil for a stator of a dynamoelectric machine includes the utilization of a plurality of forming dies. Each forming die includes two lateral surfaces extending from a base and an end turn surface disposed substantially between and connecting the two lateral surfaces. Each forming die is disposed and pivotable into an arrangement where at least one lateral surface of a first forming die is substantially adjacent and parallel to at least one lateral surface of a second forming die, a slot segment thereby formable between lateral surfaces of adjacent forming dies and an end turn is at least partially formable between an end turn surface and a base of adjacent forming dies.

Abstract: An apparatus and method for forming at least one end turn and one slot segment of a coil for a stator of a dynamoelectric machine includes the utilization of a plurality of forming dies. Each forming die includes two lateral surfaces extending from a base and an end turn surface disposed substantially between and connecting the two lateral surfaces. Each forming die is disposed and pivotable into an arrangement where at least one lateral surface of a first forming die is substantially adjacent and parallel to at least one lateral surface of a second forming die, a slot segment thereby formable between lateral surfaces of adjacent forming dies and an end turn is at least partially formable between an end turn surface and a base of adjacent forming dies.

Abstract: A pair of semicylindrical magnet segments are secured against the inner surface of a motor shell of a permanent magnet motor by wedging an elastic locking element into each space between the magnets. Each locking element has an enlarged head portion that extends beyond opposite ends of the magnet segments, the lock elements maintaining the magnet segments in position, circumferentially, radially and axially, within the motor shell to form a shell-magnet subassembly. An assembly fixture is used to support and align the elements during their assembly. A motor armature, including a commutator, is inserted within the subassembly, and end caps having bearings and brushes are bolted to respective ends of the motor shell to form a complete motor.