Abstract: A method of insulating a coil of an electrical machine includes applying an insulating varnish to a coil of conductive wire. The varnish includes (i) a resin; (ii) a first catalyst having a first activation temperature, the first catalyst being active at room temperature; and (iii) a second catalyst with a second activation temperature substantially higher than the first activation temperature. The varnish is allowed to partially cure at room temperature. The coil is mounted to a yoke to form a rotor of the electrical machine. The rotor is operated so as to heat the coil and activate the second catalyst to complete curing of the varnish.

Abstract: The molded commutator has commutator segments; cylindrical varistor pins press-fitted between the adjacent commutator segments; and molding material for molding commutator and varistor pins as an integral structure to form a molded commutator. Varistor pins suppress spark voltage between the commutator segments, extending the operating life of the brush.

Abstract: A method of manufacturing a power tool includes forming an armature by placing an electrically insulative sleeve on an armature shaft, securing a lamination stack having slots therein on the armature shaft with the insulative sleeve disposed therebetween, securing a commutator on one end of the armature shaft with the insulative sleeve disposed therebetween, winding magnet wires in the slots in the lamination stack and securing ends of the magnet wires to the commutator, and molding thermally conductive plastic to at least partially encase the magnet wires in plastic. The armature is then disposed in a stator to form an electric motor and the electric motor is disposed in a power tool. In an aspect, electrically insulative plastic is molded in the slots of the lamination stack to form slot liners and around the ends of the lamination stack to form end spiders.

Abstract: A commutator (10) includes a core (12) having a generally annular periphery (15). A plurality of commutator bars (14) is provided in a spaced relation about the periphery of the core. At least two of the commutator bars have a width different from each other.

Abstract: In a state in which a first divisional core and a second divisional core are arranged in a state spaced from each other and adjacent to each other, a first coil and a second coil are each wound around a tooth. The first coil and the second coil are in the same phase. In a state in which a plurality of divisional cores are arranged annularly so that their teeth are oriented in a radially inward direction, the first divisional core and the second divisional core are not adjacent to each other in the circumferential direction. A plurality of connection wires are shaped to converge at an end surface of a stator core. This facilitates the winding of the coils around the divisional cores. Further, the connection wires can be shortened.

Abstract: A brushless slip ring has a first conductive rotating member, and a second conductive non-rotating member that is positioned a predetermined distance away from the first conductive rotating member. A conductive semi-solid material electrically couples the first conductive rotating member to the second conductive non-rotating member. The semi-solid material is configured to transfer electric current from the rotating member to the non-rotating member.

Abstract: A fuel pump includes a pump portion for pumping fuel. The fuel pump further includes a magnet having magnetic poles circumferentially alternate with each other. The fuel pump further includes an armature on a radially inside of the magnet. The armature includes a rotor core provided with a coil formed of a wire. The armature is rotatable for driving the pump portion. A commutator, which is in a substantially disc shape, is provided to an axial end of the armature for rectifying electricity supplying to the coil. The rotor core has an axial end having an outer circumferential periphery defining a commutator-side collar portion extending toward the commutator. The coil is formed by winding the wire between an outer circumferential periphery of the commutator and the commutator-side collar portion.

Abstract: A method of making an armature includes placing a commutator and a lamination stack on an armature stack. Coil windings wound in slots in the lamination stack, the commutator and armature shaft are at least partially encapsulated in a first plastic. The commutator has a commutator ring divided into a plurality of segments with slots between the segments that are filled with a second plastic when the commutator is made by molding a core of the second plastic in the commutator ring before the commutator ring is mounted on the armature shaft. The mold used to mold the first plastic includes projections that extend between the tangs of the commutator and against notches at axial ends of the slots of the commutator. The notches filled with the second plastic and the projections of the mold prevent plastic flash from getting into the slots of the commutator ring.

Abstract: A method for manufacturing a stator of an electrical rotating machine that is configured to have a rotor mounted inside the stator. The stator has a laminated magnetic circuit having a stack of magnetic metal sheets disposed substantially parallel to a plane perpendicular to the axis of rotation of the rotor of the machine. The magnetic circuit has teeth that delimit longitudinally oriented slots. The method includes the step of installing electrically conductive wires in the slots and forming winding heads at the two axial ends of the magnetic circuit and installing this assembly on a vertical axis. The assembly is trapped between an outer sheath, forming part of the final motor, and a removable inner core substantially occupying a volume reserved for the rotor. The conductive wires in the slots are impregnated under vacuum with a slot-impregnating composition including a heat-setting resin and a filler, and the composition is polymerized.

Abstract: A method includes heating a housing of an electric machine to thermally expand the housing, positioning a mount having power and control electronics assembled thereon and in contact therewith in the housing and against an internal stop defined within the housing, and allowing the housing to cool and thermally contract against the mount thereby forming an interference fit between the housing and the mount. The interference fit secures the mount within the housing. The mount and the housing have coefficients of thermal expansion such that the interference fit is maintained across an operating temperature range of the machine. The electric machine may also include a segmented or non-segmented stator within the housing.

Abstract: A method is provided for manufacturing a stator of an electrical rotating machine. The method includes: impregnating a first winding head with a first composition that includes a heat-setting resin and a filler of a first particle size; impregnating conductive wires in a slot region with a slot-impregnating composition that includes a heat-setting resin and another filler of a second particle size smaller than the first particle size of the filler of the first composition; and impregnating a second winding head with a composition that includes a heat-setting resin and a filler of a particle size larger than the second particle size.

Abstract: A commutator (10) includes a core (12) having a generally annular periphery (15). A plurality of commutator bars (14) is provided in a spaced relation about the periphery of the core. At least two of the commutator bars have a width different from each other.

Abstract: The invention relates to a method for producing a stator winding (100) for a stator of an electrical machine, in particular for a motor vehicle. Provision is made for the at least one section (102) of the stator winding (100) to be positioned in one plane, and for regions of the section (A, B, C) to be bent toward one another along at least one folding line (108), with the result that a lap winding is produced. The invention also relates to a corresponding stator winding (100) and an electrical machine with a stator winding (100).

Abstract: The invention is characterized in that in a motor rotor constituted by a motor shaft (30), a permanent magnet (31) surrounding the motor shaft (30) around an axis, a pair of end rings (32, 32) surrounding the motor shaft (30) around the axis and pinching the permanent magnet (31) from both sides in an axial direction, and a hollow cylindrical outer sleeve (33) surrounding the permanent magnet (31) and a pair of end rings (32, 32) in a fastening state around the axis, one end portion or both end portions of the outer sleeve (33) protrudes in the axial direction than an end surface of the end ring (32). A rotating balance correction is executed by pruning away a part of the protruding portion.

Abstract: An armature for an electric motor has a lamination stack on a shaft with a commutator mounted on one end of the shaft. Magnet wires wound in slots in the lamination stack, the commutator and armature shaft are at least partially encapsulated in thermoset. The commutator has a commutator ring divided into a plurality of segments with slots between the segments that are filled with a second plastic when the commutator is made by molding a core of the second plastic, such as phenolic, in the commutator ring before the commutator ring is mounted on the armature shaft. Prior to molding the thermoset, the commutator ring is sealed. The seal prevents the thermoset from flowing into the slots between the commutator ring segments or over the commutator ring.

Abstract: A motor assembly (10) includes a permanent magnet DC motor (16) having a shaft (24) mounted for rotation with a face gear pinion (26) associated with the shaft. A jack shaft and clutch assembly (18) is associated with the face gear pinion and is constructed and arranged to prevent back drive of the motor under certain operating conditions. A spur or helical pinion (40) is operatively associated with the jack shaft and clutch assembly. A drive member (56) is operatively associated with the spur or helical pinion such that movement of the shaft and face gear pinion moves the spur or helical pinion to drive the drive member. A housing structure is defined by an upper housing (14) joined with a lower housing (12). The motor, the face gear pinion, the jack shaft and clutch assembly, the spur or helical pinion and the drive member are housed within the housing structure. Only one of the upper or lower housings includes mounting structure (25) constructed and arranged to mount the motor assembly to another object.

Abstract: A rotor exhibits a carbon commutator (4). For the manufacture of the rotor, an insulating support (9) is positioned on the rotor shaft (1). The insulating support (9) features lugs (13), around which the winding ends (8) of the rotor coils (3) are wound; after the removal of the insulation, the winding ends (8) are provided with an electrically conductive adhesive. The commutator (4) is the put on the lugs (13) with the winding ends (8). By means of this process, the winding ends (8) are mechanically and electrically directly connected to the corresponding commutator segments.

Abstract: A slip ring has a substrate material and a sliding contact surface made of gold or a gold alloy. The sliding contact surface is stabilized by a support base. The slip ring is used in slip ring transmitters, in particular in wind power plants or industrial robots, for transmitting control signals and control currents and generator currents. An extended service life, in conjunction with improved quality, a reduced drop in voltage and considerable savings in the amount of gold used can be achieved with the slip ring.

Abstract: The invention relates to a flat commutator (101) comprising a support body (102) that consists of an electrically insulating material, a large number of connecting segments (108) consisting of an electrically conductive material for connecting at least one respective end of a coil winding and a large number of bearing surface segments (112), which form a bearing surface (14) of the flat commutator (101), said bearing surface segments (112) being connected to the connecting segments (108) in a mechanically permanent, electrically conductive manner and the support body (102) and/or the connecting segments (108) being configured in one piece. The support body (102) is pre-fabricated and comprises openings (118), into which the connecting segments (108) are inserted.

Abstract: An outer rotor type multi-pole generator stator is provided in which a lead wire extending from a coil is connected by fusing to a connecting terminal fitted into and fixed to a bobbin wherein, in order to avoid the lead wire becoming slack after connection by fusing and enable assembly of the stator to be carried out efficiently, the connecting terminal (32) is formed from an external conductor connection terminal portion (32a) that is fitted into and fixed to a fitting hole (31), a connecting plate portion (32b) having one end thereof connected at right angles to the external conductor connection terminal portion (32a) and extending toward the radially inner side of the stator, and a clamping plate portion (32c) provided so as to be connected to the connecting plate portion (32b) so that the lead wire (33) can be held between the clamping plate portion (32c) and the other end portion of the connecting plate portion (32b) and connected by fusing, and the bobbin (24) is provided on the inner periphery thereof

Abstract: There is described an electrical machine with a rotor shaft, a slip ring, arranged on the rotor shaft, and at least two sliding contacts arranged along the circumference of the slip ring for producing an electrical connection with the slip ring. The electrical machine has one or more extraction devices arranged between the at least two sliding contacts directly via the slip ring and intended for extracting abraded material produced at the slip ring.

Abstract: A brush bag, a brush and a current transfer unit for a dynamo-electric machine comprising a commutator, in particular for an electromotor. The current transfer unit comprises at least the brush, which is embodied, in particular, as a multi-layer carbon brush, and a brush bag. The brush bag is configured in such a manner that the distance between the brush and the brush bag in a front guiding area is smaller than the distance in a rear guiding area. Beating of the brush on the brush bag is visibly reduced due to the configuration thereof and noise caused by the beat is avoided.

Abstract: A commutator having a plurality of segments, a short-circuit member assembly, a holding portion, and a plurality of spacing members is disclosed. The short-circuit member assembly includes a plurality of short-circuit pieces. Each short-circuit piece has an outer terminal, an inner terminal arranged radially inward from the outer terminal and circumferentially offset from the outer terminal at a predetermined offset angle, and a connecting portion connecting the inner terminal to the outer terminal. The holding portion covers the segments and at least a portion of the short-circuit member assembly to hold the segments and the short-circuit member assembly. The spacing members each have an insulated support portion and a plurality of insulated spacing projections formed integrally with the support portion. Each support portion extends in a radial direction of the short-circuit member assembly.

Abstract: Some embodiments of the present disclosure provide a method of making a rotor of an electric brushless motor configured to be light weight and prevent vibrations generated during an operation of the motor to be transferred to the shaft of the rotor. The method includes providing a shaft elongated in a rotational axis, providing a single body magnet comprising alternately magnetized portions, and providing a vibration absorption portion interposed between the shaft and single body magnet. The vibration absorption portion absorbs vibrations generated during the operation of the motor and may include an elastic or a non-elastic material. The method further includes providing a non-elastic portion configured to inhibit the expansion of the vibration absorption portion when the vibration portion is elastic.

Abstract: In a motor, an insulator covering an armature core has a lid covering an end surface of the armature core. The lid has an inner ring disposed radially inside slots of the armature core and an outer ring disposed radially outside the slots. Each of a plurality of slot insulators inserted into the slots has a blocking portion at a position in the inner ring.

Abstract: A method for forming an armature for an electric motor includes securing a lamination stack having slots therein on an armature shaft. A commutator is secured on one end of the armature shaft. Magnet wires are wound in the slots in the lamination stack and ends of the magnet wires are secured to the commutator. Plastic is molded around the lamination stack, commutator and magnet wires. Excess plastic is machined off. The magnet wires can have a layer of heat activated adhesive that is activated when the plastic is molded. Slots in the lamination stack can include slot liners formed of thermally conductive plastic. A fan can be formed when the thermally conductive plastic is molded to encapsulate the magnet wires.

Abstract: A commutator for an electric machine comprises a support member made from insulating molding compound, a plurality of metal conductor segments (3), disposed thereon in evenly spaced manner around the commutator axis, with terminal elements disposed thereon for a rotor winding, and an interference-suppression device, to which the conductor segments are connected in electrically conductive manner.

Abstract: In accordance with one embodiment, the present technique provides an apparatus for assembling a rotor. The exemplary apparatus includes a base that has a central aperture and a seating surface for receiving the rotor. An arbor then extends through the central aperture, the arbor having a longitudinal axis that is substantially orthogonal to the seating surface, and including threaded ends opposite with respect to one another. The exemplary apparatus also includes at least one member of a family of fixtures coupleable to the arbor, the family including a pressure fixture that has first and second piston assemblies disposed at diametrically opposite locations to one another, the family also including a support fixture coupleable the arbor and having members extending axially therefrom, the members being configured to support securing members of the rotor.

Abstract: A commutator main body has a cylindrical insulating body, and a plurality of segments arranged in an outer circumference of the insulating body. A short-circuit member is arranged in an end in an axial direction of the insulating body. The short-circuit member has a plurality of first short-circuit pieces and a plurality of second short-circuit pieces. A tabular insulating portion covers first coupling portions of the first short-circuit pieces, and second coupling portions of the second short-circuit pieces. The insulating portion has a restriction recess, and the end in the axial direction has a restriction projection. The restriction projection is engaged with the restriction recess, whereby the movement of the short-circuit member in the circumferential direction with respect to the commutator main body is restricted. Accordingly, the assembly of the short-circuit member in the commutator main body is facilitated.

Abstract: A method for making a rotor for a permanent magnet motor, the method, in at least certain aspects, including connecting a series of a plurality of guides to a hollow rotor body, the guides spaced-apart and extending longitudinally of the rotor body, the rotor body being generally cylindrical with an interior surface, applying a plurality of magnets to the interior surface of the rotor body, and emplacing a shunt structure over the plurality of magnets to inhibit inter-magnet action during rotor assembly.

Abstract: A pool cleaning vacuum employing multiple power supply sources and associated method includes a body including first, second and third vertically juxtaposed chambers formed therein. The chambers share a wall with the second chamber wherein the third chamber is isolated therefrom. A motor assembly and a filter section are housed within the first chamber. The filter section is located downstream of the motor assembly, and has an open lateral face exposed to the aqueous environment. An anchor shaft is seated within the second chamber and extends through an entire longitudinal length of the body. A vacuum head is pivotally attached to the anchor shaft. The vacuum head includes a conduit in communication with the filter section, and a plurality of wheels rotatably coupled to opposed corners thereof. A mechanism transmits a predetermined quantity of power to the motor assembly.

Abstract: A method of making a wound field for a brushless direct current motor, direct current generator, alternating current motor or alternating current generator, includes providing a base mold having an engagement face with at least one movable end turn form. A number of distinct phases is determined and at least one strand of conductive material is wound around at least one movable end turn forming tool per distinct phase. One conductive coil is created from each strand of conductive material for each distinct phase. Each conductive coil is formed into a configuration that indicates the number of poles required. Each conductive coil is then placed onto an insertion instrument. The insertion instrument and each conductive coil are inserted into a stator core. The insertion instrument is removed from the stator core, and the stator core is installed into one of the aforementioned motors or generators.

Abstract: The present invention relates to a method for mounting magnet elements on the surface of a rotor for use in a permanent magnet motor. The method comprises the steps of : providing a first tube like element, wherein said first tube like element has an inner diameter that corresponds to an outer diameter of said rotor, providing a second tube like element, wherein said second tube like element has an inner diameter that is larger than an outer diameter of said first tube like element, inserting said first tube like element into said second tube like element, in order to create a hollow space between them, inserting a number of magnet elements into said hollow space, and inserting said rotor into said first tube like element, whereupon said magnet elements are in a tight fit arrangement between said first tube like element and said second tube like element.

Abstract: A coil of a winding is wound around teeth of an armature core for a predetermined number of times in a motor. A start lead of the winding connects between the coil and a corresponding start segment among a plurality of segments of a commutator. A finish lead of the winding connects between the coil and a corresponding finish segment among the plurality of segments. The finish segment is located adjacent to a diametrically opposed one of the plurality of segments, which is circumferentially displaced by about 180 degrees from the start segment and is thereby diametrically opposed to the start segment.

Abstract: The invention relates to a commutator comprising a support body (1), a plurality of conductor segments (13) that are secured in said body and a compensation unit (18) comprising several compensation elements (17), which electrically interconnect the conductor segments in pairs or groups. According to the invention, the compensation elements (17) are configured by wire sections (19) that are embedded in the support body. To produce a commutator of this type, at least the ends of the wire sections (19) that form the compensation elements and that are bent accordingly are connected to the assigned conductor segments (13) of an annular structure prior to the injection moulding of the support body (1). The injection moulding die (2) has a plurality of basin-shaped supporting limbs (31), which are arranged concentrically around the axis (5) of one of the sections of the injection moulding and with which the wire sections engage (19).

Abstract: A method of assembling a cooling module with the module having a shroud (38) having a cover (42) receiving bearing structure (40). The cover has an opening (68) therein. A fan (36) is provided for moving air. A rotor and stator assembly (30) has an opened end and includes a stator, including permanent magnet structure (14), and a rotor having laminations (16), windings (21), a shaft (18) and a commutator (20). A brush and connector unit (52?) including brushes. The method mounts the fan to a first end of the shaft. The rotor and stator assembly is coupled to the cover to substantially close the opened end, with a second end of the shaft being received by the bearing structure. The brush and connector unit is inserted through the opening such that the brushes are associated with the commutator. The brush and connector unit is secured to the cover.

Abstract: A slip ring module (76) for a rotor (40) of an electrical machine (10), in particular, an alternator is disclosed, comprising at least one first slip ring (79) with at least one first connecting conductor (103) held in sections of an insulation material (101) for the slip ring module (76), in electrically conducting connection with at least one first slip ring (79) and with an end (115) of the connection conductor (103), facing away from the first slip ring (79), provided for connection to an excitation coil (61). The invention is characterised in that the slip ring module (76) has a further formed conductor (139) forming a direct electrical connection from the first connection conductor (103) to a surface (142) of the slip ring module (76). An electric machine is also provided, in particular, an alternator for motor vehicles, comprising a rotor (40), supporting an excitation coil (61), said slip ring module (76) providing the power supply to the excitation coil (61).

Abstract: A commutator includes a conductive part that has a cylindrical body and a plurality of coil latching portions at intervals circumferentially on one axial end; and an insulating part formed inside the conductive part. The conductive part includes segments that are insulated for each latching portion by cutting axially the conductive part, and latching claws that are provided in a projecting state on an inner peripheral surface of the segments and embedded in the insulating part, wherein the latching claws include axial latching claws that are long in an axial direction and project inward, and circumferential latching claws that project circumferentially.

Abstract: The invention relates to a face commutator (101) having a supporting body (102) consisting of an electrically insulating material, a large number of connection segments (108) consisting of an electrically conductive material for connecting in each case at least one end of a coil winding, and a large number of contact surface segments (112) which form a contact surface (14) of the face commutator (101), the contact surface segments (112) being mechanically rigidly and electrically conductively connected to the connection segments (108), and the supporting body (102) and/or the connection segments (108) having an integral design, and the supporting body (102) being prefabricated and having openings (118) into which the connection segments (108) are inserted, characterized in that the supporting body (102), at least in sections, is overdimensioned in the region of the openings (118) in relation to the inserted connection segments (108), in that the connection segments (108) are fixed owing to a clamping effect o

Abstract: A method of forming a stator for an electric machine having a cascaded winding includes the steps of: providing a stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, forming a plurality of A conductors and a plurality of B conductors, arranging the A and B conductors into a wire pack, rolling the wire pack into a cylindrical shape and inserting the wire pack within the stator core, and expanding the wire pack radially outward such that the wire pack is inserted within the slots of the stator core.

Abstract: Means for transferring electric power and/or signals comprises an electrical power slip-ring system (EPSR) (3) comprising a housing (4) containing an electrical slip-rings, the housing (4) being connected to a support structure (6) of a vessel (7) and a brush carrier unit (8) that is in slidable contact with the electrical conductor means, the brush carrier (8) being fixed to a turret (2). A swivel unit (10) extends thorough the centre of the housing (4). The turret (2) and support structure (6) may be disposed on the vessel in various configurations such as an internal turret configuration, a submerged turret configuration or an external turret configuration.

Abstract: A direct-current motor includes a stator having a magnetic field system, a rotor disposed around the stator, a commutator which rotates together with the rotor, and power supply brushes which are urged in the axial direction by urging members so as to come into contact with the sliding contact surfaces. The rotor includes an armature core around which armature coils are wound, and a rotary shaft which rotates together with the armature core. The commutator has segments extending radially. The segments have sliding contact surfaces orthogonal to an axial line of the rotary shaft. At least a part of each power supply brush comes into contact with the sliding contact surface at a position further radially outward than the armature coil.

Abstract: Stator designs have wide-mouth slots between adjacent poles. Wire coils with high slot fill conductivity are formed around the poles. In some designs, the wire coils are wave wound around the poles. Thick bar conductors can be used for making the wire coils. The wire coils may be inserted using nozzle dispensers or transferred from a pre-form mandrel. In other designs, the wire coils are pre-formed on transferable pockets that are then mounted on the poles. Optional pole extensions or shoes can be attached to the stator poles after the wire coils are formed around the poles.

Abstract: A method of manufacturing a radial core type double rotor brushless direct-current motor is provided. A double rotor structure is employed with inner and outer rotors which are doubly disposed such that a stator core is completely divided. A rotational shaft is rotatably mounted on a housing of an apparatus, cylindrical inner and outer yokes are rotatably mounted on the center of the housing, inner and outer rotors including a number of magnets which are mounted with opposing polarities on the outer surface of the inner yoke and the inner surface of the outer yoke, and a number of cores assemblies are installed between the inner and outer rotors in which a number of coils are wound around a number of division type cores, respectively.

Abstract: At least a winding of a stator stack 2 is molded by injecting a fused resin molding material into a space formed between a top mold and a bottom mold member. When the stator stack 2 of the resolver, which is annular and includes a coiled winding 7, is sandwiched between the top mold member 10 and bottom mold member 20, a movable disc 12 is urged by a spring device 13, into close engagement with the bottom mold member 20. While the movable disc 12 is closely engaged with the bottom mold member 20, the stack 2 of the resolver is sandwiched between the bottom mold member 20 and the top mold member 10. This method prevents the generation of gaps between the stator stack 2 and mold 10, 20 due to unevenness of the thickness in the stator stack 2.

Abstract: Coils are electrically connected to a commutator, which includes commutator segments that are arranged one after another in a circumferential direction of a dielectric body along an outer peripheral surface of the dielectric body. Each commutator segment includes a slidably contacting portion, a claw portion and a bending fulcrum portion. The slidably contacting portion is provided in one axial side of the commutator segment and is slidably contactable with each brush. The claw portion is provided in the other axial side of the commutator segment and is engageable with the corresponding coil. The bending fulcrum portion is formed on a claw portion side of the slidably contacting portion and is bent upon radially inwardly pressing the claw portion by a fusing electrode.

Abstract: The method for resolving the stator having a coil disposed in the slots provided around an inner circumferential face of a cylindrical iron core and having an opening portion includes a step of enlarging the opening portion of the slot, and a step of extracting the coil from the slot.

Abstract: A stator for a motor includes a stator core, an insulator, and coils. The stator core includes an annular portion and teeth, which extend radially from the annular portion. The stator core is divided into core segments in the circumferential direction. Each core segment has an arcuate portion and one of the teeth, which extends from the arcuate portion. The insulator insulates each coil wound around one of the teeth from the stator core. The insulator includes coupling portions at positions corresponding to the circumferential ends of the arcuate portions. Each coupling portion couples the adjacent core segments to be rotatable relative to each other. The insulator facilitates manufacture of the stator.

Abstract: A rotor assembly for an electric motor is constructed by adding bars made out of a conducting material such as copper, to spaces between the teeth of a stack of discs, inserting bars referred to as “slugs”, also made out of a conducting material such as copper, in the spaces between the bars on either side of the stack of discs, radially compressing the bars and discs, one or both of which are plated or otherwise coated with a braising material, and then heating the rotor to allow the bars to be braised to the slugs.

Abstract: A manufacturing method of a stator for vehicular rotary electric machine includes: forming an indentation in a radial direction in a side face of each of electrical conductors in the machine by pressing; inserting the electrical conductors in a radially side-by-side relationship with each other in slots of the machine; bending each of the electrical conductors and radially adjacent electrical conductors in different circumferential directions by a predetermined pole pitch such that the indentations formed in respective side faces of the adjacent electrical conductors pass each other in a face-to-face relationship; and bonding on each of the electrical conductors to one end of the adjacent electrical conductors.