Abstract: A polyphase stator for an internally ventilated rotating electrical machine comprises a body (14) provided with slots and carrying a coil (12) having at least one winding per phase. A plurality of pairs of lateral branches are mounted in a slot of the body (14). A plurality of connecting heads (50 to 55) extend outside the body (14) so as to form a first lead-out (42) and interconnect each pair of lateral branches. A plurality of coupling feet (150 to 155) are offset circumferentially with respect to the plurality of connecting heads and extend outside the body (14) so as to form a second lead-out (43) and interconnect each pair of lateral branches. One of the pluralities has a generally pointed shape and has an axial length of between 15 and 20 mm. The stator is used with an alternator or alternator-stator for a motor vehicle. An internally ventilated electrical machine is equipped with the stator.

Abstract: A stator bar includes a substantially quadrangular conductive element made of a plurality of interwoven strands. The stator bar also includes an electric insulation applied around the conductive element and including a plurality of corners corresponding to corners of the conductive element. The electric insulation includes an inner insulation zone facing the conductive element, and an outer insulation zone surrounding the inner insulation zone. The radius of at least one of the corners is between 1.5-2.5 millimeters. Permittivity at the corners of the electric insulation decreases by 35-45% from the inner insulation zone facing the conductive element towards the outer insulation zone. The insulation includes at least one mica layer, where one of the at least one mica layer includes titanium dioxide (TiO2).

Abstract: Reliability related to an insulating process of conductor connection terminals of an electrical rotating machine stator using segment conductors is improved. An electrical rotating machine is configured so that stator coils 13 are inserted into slots 111 of a stator core 11, the stator coil 13 is formed by electrically connecting a stator coil connection terminal 41 of a segment conductor, the stator core 11 and the stator coils 13 are fixed with resin, and insulating members 24 and 25 are arranged so as to weave between the stator coil connection terminals 41 adjacent to each other in a circumferential direction.

Abstract: The present technology contemplates a stator or rotor of an electric machine comprising a main cylindrical body with a circular array of slots; at least one bar winding comprising a first and second plurality of basic conductors and a second plurality of special conductors. The first and second circular array comprise a first and second arc of legs of the first and second set of said conductors which are inserted as well as legs of the conductors. The present technology also contemplates electric machines and electric or hybrid drive vehicles comprising such stators of rotors.

Abstract: An electric rotating machine is provided that can ensure insulation quality between a coil end and an inside wall of a housing or of a case. The electric rotating machine includes a stator including a stator core and a stator winding. The stator core has a plurality of slots rowed in a circumferential direction. The stator winding is formed of a conductor rectangular in a cross section and is inserted into the slots, the conductor being provided with an insulating coated layer. The stator winding has a first segment transition bent section provided on a radially outside of the stator and a second segment transition bent section provided on a radially inside of the stator. The first segment transition bent section has a layer-transition bent section angle greater than a layer-transition bent section angle of the second segment transition bent section.

Abstract: A method (20) is described for making a stator (1) of an electric machine, the stator comprising a stator core (2), the stator core comprising a main body and a plurality of slots (8) which are axially extended inside the main body and are adapted to receive bar conductors. (5, 5?, 5?) of a bar stator winding. The method (20) comprises the steps of : inserting (23) at least one preshaped insulating sheet (10) inside at least one of said slots (8); hot shaping (26) said preshaped insulating sheet (10) inside the slot, along the entire axial extension of the slot (8) or along a substantial portion thereof, in order to confer form regularity and stability to said preshaped insulating sheet (10). Through the described process, it is possible to make stators with bar winding having a stator core with relatively high height and slot fill factor.

Abstract: A stator assembly for an electric machine including a stator core supporting a plurality of electrical conductors. A plurality of elongated insulator spacers is interwoven between the conductors proximate connection ends thereof in axially spaced relation to the stator core.

Abstract: A rotating electrical machine includes a stator and a rotor. The stator winding includes a plurality of conductor segments inserted through the slots from one end surface of the stator core with end portions of the conductor segments projecting out beyond another end surface of the stator core. The conductor segments include an undeformed portion, a plastically deformed portion formed at the end portions thereof and a tapered portion. The plastically deformed portion has a dimension of the plastically deformed portion along a circumferential direction that is greater than a dimension of the undeformed portion along the circumferential direction and so that a dimension of the plastically deformed portion along a radial direction is smaller than a dimension of the undeformed portion along the radial direction. The conductor segments are welded together at tops of the plastically deformed portions thereof.

Abstract: An armature core of a stator has an annular portion and a plurality of teeth extending radially from the annular portion. A segment coil is configured by electrically connecting a plurality of segment conductors together. The segment conductors extend axially through slots S, each of which is defined between each adjacent pair of the teeth. Each of the teeth has a width adjustment portion for decreasing a slot width in a direction perpendicular to a radial direction in the radially inward direction.

Abstract: A flat conductor wire in a U-phase first slot of a first group block and a flat conductor wire in a U-phase second slot of a second group block form an outer circumference base unit. A flat conductor wire in a U-phase second slot of the first group block and a flat conductor wire in the U-phase first slot of the second group block form an inner circumference base unit. The inner circumference base unit is located inside the outer circumference base unit. A coil end portion at one end of the inner circumference base unit and a coil end portion side at one end of the outer circumference base unit are bent toward the rotor side with respect to an in-slot conductor portion in the stator core. The coil end portion side at one end of the inner circumference base unit and the coil end portion side at one end of the outer circumference base unit are located further toward the axis of the rotor than an inner peripheral surface of the stator core.

Abstract: A stator for an electric rotating machine includes a stator core which has a plurality of slots and a stator winding which is provided at the stator core. The stator winding has a plurality of conductor segments each of which includes an inner conducting body accommodated in the slot of the stator core and coil ends exposed from the slot, and weld portions which are connected with each other by welding the conductor segments at at least one of the coil ends. The weld portions are annularly disposed with an interval therebetween. The weld portions are coated with an insulating resin material. The resin material is formed of a plurality of layered insulating films.

Abstract: A method for twisting preformed bar conductors of electric machines comprising: a) providing a twisting apparatus comprising a twisting device having at least a first and a second body extended around a twisting axis, respectively comprising a first and a second circular array of pockets with center on such axis, said bodies being relatively rotatable to each other around the twisting axis to assume a first insertion configuration in which respective pockets of the first and second array are radially aligned; loading, in a subset of said pockets, a first plurality of said preformed conductors leaving a first residual subset of pockets free; driving the first and the second body in relative rotation around said axis until a second insertion configuration is reached in which a second plurality of pockets of the first and second body of said residual subset are radially aligned with each other.

Abstract: A stator for an electric rotating machine is equipped with a stator winding made up of a plurality of conductor segments. Each of the conductor segments has a head and two legs. The legs are inserted through their respective slots formed in a stator core, so that each of the conductor segments has leg ends protruding from either one of opposed end surfaces of the stator core and the head thereof protruding from the other end surface. Radially adjacent two of the leg ends are provided as a coil end pair to be welded. At least one of the heads is interposed between adjacent two of the coil end pairs, thereby ensuring a distance between the two adjacent coil end pairs which is great enough to provide a required degree of electric insulation between the coil end pairs when the leg ends of the conductor segments are welded electrically.

Abstract: An alternating-current generator, in particular a three-phase generator, for a motor vehicle, having a rotor including north and south poles, particularly having claw-pole fingers extending in the axial direction and alternating as north and south poles at the rotor's periphery, a stator having a magnetic core, especially laminated core, having slots and a stator winding disposed in the magnetic core's slots, the stator winding having winding overhangs that are coolable by an approximately radial air flow produced by at least one fan mounted at the rotor, the stator being situated opposite the rotor, and the stator and the rotor having defined positions relative to each other, the multiphase stator winding being made up of winding elements, at least one winding element having more than two sections inserted in slots, and at least one winding element having more than one reversal section which brings about a change in the radial position.

Abstract: A method of forming a weld joint includes removing a portion of an insulator from a first core of a first magnet wire and a second core of a second magnet wire so that the first wire has a first heat affectable zone and a first insulator portion adjacent the first zone, and the second wire has a second heat affectable zone and a second insulator portion adjacent the second zone. The first and second insulator portions include the insulator disposed on the first and second cores, respectively. The first and second zones have a first and second distal end spaced apart from the first and second insulator portions, respectively. The method includes welding together only the first end and the second end to form the weld joint, wherein welding does not transfer heat to the first and second insulator portions sufficient to burn the insulator.

Abstract: A stator assembly includes a plurality of stator slots defining a plurality of slot layers. The assembly includes a plurality of hairpins each having respective first and second legs positioned in respective ones of the slot layers. Each of the hairpins is one of a short-pitched coil, a long-pitched coil and a full-pitched coil. The short-pitched, long-pitched and full-pitched coils are configured to extend over a first, second and third number of the stator slots, respectively. The hairpins may be divided into first, second, third, fourth, fifth and sixth hairpin layers. One of the hairpin layers includes at least one short-pitched coil, and another of the hairpin layers includes at least one long-pitched coil. The first, third and fifth hairpin layers each may include at least two short-pitched coils while the second, fourth and sixth hairpin layers each may include at least two long-pitched coils.

Abstract: Apparatus for producing electrical power from mechanical power, includes an electric generator with a rotor and with a stator. The electric generator is configured for conversion of mechanical power into a polyphase alternating current. The polyphase alternating current has more than three phases. The stator has a stator core with a stator bore. The stator core provides a plurality of stator slots arranged at a distance from one another. A plurality of coil portions are inserted in the stator slots, and the coil portions are connected to form coils. The coils include a plurality of Z-shaped portions and are laid out in a wave pattern.

Abstract: A conductor is provided for an electric machine having an axis, a radial direction extending outward from the axis, and a tangential direction perpendicular to the radial direction. The conductor includes a solid core, having radial faces substantially perpendicular to the radial direction of the electric machine and tangential faces substantially perpendicular to the tangential direction of the electric machine. At least one tangential depression is formed on at least one of the tangential faces. The tangential depression creates a tangential void within a rectangular envelope defined by the solid core. Therefore, the surface area of the solid core is greater than the surface area of the rectangular envelope.

Abstract: A stator assembly comprises a stator defining S slots. First and second windings are arranged in each of the S slots. The two windings have a width in a radial direction and a thickness in a direction perpendicular to the radial direction. A ratio of the width to the thickness is between 3.0:1 and 4.5:1.

Abstract: A stator includes an annular stator core and a stator coil. The stator coil is formed of electric conductor segments each of which is bent in its thickness direction to include, at least, an in-slot portion and an oblique portion. The in-slot portion is received in a corresponding slot of the stator core with its width direction coinciding with a radial direction of the stator core. The oblique portion protrudes from the in-slot portion outside the corresponding slot and extends, over its entire length, along the circumferential direction of the stator core obliquely with respect to an axial end face of the stator core. The oblique portion includes a thick section on the proximal side and a thin section on the distal side. Each corresponding pair of the oblique portions of the electric conductor segments are connected by joining the thin sections of the oblique portions.

Abstract: An electrical machine includes an armature and at least one field magnet arrangement separated by a gap from each other. The armature and/or the field magnet arrangement include a plurality of coils. Each coil includes conductive body sections. The body sections of the coils are joined electrically by conductive end sections. At least one of the end sections of at least one coil of the armature is tilted in a direction away from the armature towards the field magnet arrangement and/or at least one of the end sections of at least one coil of the field magnet arrangement is tilted in a direction away from the field magnet arrangement towards the armature. The electrical machine may be used in a wind turbine to generate electrical power.

Abstract: A wound member for manufacturing a coil is a wound member for manufacturing a coil for manufacturing a coil wound around a slot of a stator core. The wound member for manufacturing a coil includes: a first side to be an end side at one side of a coil end disposed at an inner peripheral side of the stator core; a second side disposed opposite to the first side, the second side being to be an end side at another side of a coil end disposed at an outer peripheral side of the stator core; and a third side and a fourth side that respectively couple the first side and the second side. The first side has a length shorter than a length of the second side.

Abstract: A stator of an electric machine of the power saving interval may include a stator core having a plurality of slots, and a stator winding wound around the slot, wherein the stator winding has a plurality of winding portions connected in parallel with one another for each phase, and each of the winding portions has a segment conductor inserted into three or more slots for each pole. As a result, it may be possible to increase the number of rotations and reduce the external size thereof while maintaining the same output.

Abstract: An electric machine includes a core with a plurality of slots. Electric conductors are positioned within the slots with connection ends extending from the in-slot portions. A plurality of insulation sleeves separate the plurality of electric conductors. Each insulation sleeve substantially covers one entire conductor, including the in-slot portions and the connection ends of the conductor. A tip portion on each connection end remains uncovered by the insulation sleeve and is electrically connected to another tip portion on another conductor. Air passages are formed between the plurality of insulation sleeves at the in-slot portions and at the connection ends of the plurality of electric conductors.

Abstract: A twisting method is described, for twisting free end portions of bar conductors for the stator or rotor bar winding of an electrical machine. The twisting method allows achieving a non uniform twisting of the bar conductors from the welding side of the stator or rotor core by means of a twisting fixture. The twisting fixture comprises a pocket member including a main structure provided with an arc of adjacent pockets and a secondary structure, provided with at least one further pocket, which can axially translate with respect to the main structure.

Abstract: An electric machine includes a stator having a magnetic core crossed longitudinally by a stator slot and stator winding having a phase and series of rigid, U-shaped bars inserted through the slot. The slot defines “entry” and “exit” sides in which cusps and legs of the bars are placed. The legs coming out the “exit” side are twisted through relative double folds each of which defines internal and external folds in opposite directions. Ends of the legs are electrically connected to each other to form electrical paths of the winding. A width of the cusps is identical for the bars. The ends of a pair in a part of the winding are initially not adjacent to each other and folded toward each other to be arranged parallel to each other in a circumferential direction so that the ends touch each other to allow an electrical connection between the ends.

Abstract: A multi-gap rotating electric machine includes a rotor, a stator core and a stator coil. The stator core has inner and outer core parts respectively located radially inside and outside of the rotor and each having partially or fully closed slots. The stator coil is formed of electric conductor segments each having a first leg portion inserted in one of the slots of the inner core part, a second leg portion inserted in one of the slots of the outer core part, and a connecting portion connecting the first and second leg portions on one axial side of the rotor. The first and second leg portions respectively have radially inner and outer coil end parts formed on the opposite axial side to the connecting portion. Corresponding radially inner coil end parts are joined to each other, and corresponding radially outer coil end parts are joined to each other.

Abstract: A stator for a generator with closed magnetic path comprises a coil support frame and a conductive wire unit arranged on the coil support frame. The conductive wire unit comprises a plurality of stacked basic conductive wire units. The basic conductive wire unit comprises a conductive wire layer and a magnetic-conducting sheet conformably stacked on and insulated from the conductive wire layer. The conductive wire layer comprises a plurality of conductive wires arranged in parallel and insulated from each other, or a conductive sheet with a plurality of elongated through gaps extending from a central region of the conductive sheet to a circumferential region of the conductive sheet, elongated portions between the elongated gaps function as conductive wires connected in parallel between the central region and the circumferential region. The conductive wire unit further comprises a shaped magnetic-conducting basic plate.

Abstract: A stator includes a stator coil that is formed of electric conductor segments welded to one another. Each of the electric conductor segments includes at least one joining portion that is welded to another one of the electric conductor segments. The joining portion includes a first part and a second part that are arranged in a longitudinal direction of the electric wire segment. The second part includes a distal end of the electric wire segment, and the first part is on the opposite side to the distal end. The first part extends with its cross-sectional area perpendicular to the longitudinal direction continuously decreasing at a first predetermined rate toward the second part. The second part extends with its cross-sectional area perpendicular to the longitudinal direction continuously decreasing at a second predetermined rate toward the distal end. The second predetermined rate is less than the first predetermined rate.

Abstract: A stator for an electric rotating machine is provided which includes a stator winding made up of a plurality of conductor segments. Each of the conductor segments has a leg which includes an in-slot portion into one of slots of a stator core and a protrusive end extending outside the slot. The protrusive ends of the conductor segments are welded together to form a stator winding. The conductor segments are broken down into first conductor segments and second conductor segments. The protrusive ends of the first and second conductor segments include outwardly-oriented bends and inwardly-oriented bends for increasing an interval between every pair of adjacent two of the protrusive ends to be welded, thus ensuring a required degree of electrical insulation between the pairs of the protrusive ends and permits the height of a coil end of the stator winding to be decreased.

Abstract: A rotating electric machine includes a rotor, a stator and an Insulating resin. The stator includes a stator core and a stator coil that is partially received in slots of the stator core so as to have a pair of coil end parts protruding outside of the slots respectively on opposite axial sides of the stator core. The stator coil is formed of a plurality of electric wire segments, each of which includes an electric conductor and an Insulating coat that covers an outer surface of the electric conductor. The insulating resin is applied to the coil end parts of the stator coil so as to cover the outer surfaces of the insulating coats of the electric wire segments forming the stator coil. Further, a tensile strength of the insulating coats of the electric wire segments is higher than an adhesion strength between the insulating resin and the Insulating coats.

Abstract: A turn part of a lead wire includes a projection part, a slope part and a second bent part. The projection part projects from a first slot to a direction parallel to an axial direction of the stator core. The slope part is diagonally extended at an angle of less than 90 degrees aiming to a Kth slot. The Kth slot is separated from the first slot at a specific interval via a first bent part that is bent in a circumferential direction from a tip of the projection part. The second bent part is connected with the slot accommodation part accommodated in the Kth slot, and is bent to the direction parallel to the axial direction of the stator core from a tip of the slope part.

Abstract: A stator for an electric rotating machine includes a hollow cylindrical stator core and a multi-phase stator coil comprised of a plurality of electric wires mounted on the stator core. The stator coil includes a plurality of phase windings each of which is formed of at least two electric wires. One of the two electric wires has an end portion led out from the radially inner periphery of one slot of the stator core while the other electric wire has an end portion led out from the radially outer periphery of another slot of the stator core. The end portions of the two electric wires are joined together to form a joint therebetween. The joint is positioned axially outward of a coil end part of the stator coil, which protrudes from an axial end face of the stator core, without radially protruding from the coil end part.

Abstract: A bar-wound stator, which is connectable to a plurality of fixed terminal points, includes a plurality of stator teeth and a plurality of magnet wires. Each of the plurality of magnet wires has a winding portion wound about at least one of the plurality of stator teeth and a junction portion extending away therefrom. A plurality of flexible leads each have a first portion ultrasonically welded directly to a respective one of the junction portions of the plurality of magnet wires. A second portion of each of the plurality of flexible leads extends flexibly away from the first portion and is configured for attachment to a respective one of the fixed terminal points.

Abstract: A stator includes a stator core and a stator coil comprised of a plurality of electric conductor segments mounted on the stator core. Each of the electric conductor segments has an insulating coat-removed portion. Each corresponding pair of the insulating coat-removed portions of the electric conductor segments are joined with a joint formed therebetween. Each of the electric conductor segments also has an oblique portion that is comprised of a first part and a second part. The first and second parts extend, along the circumferential direction of the stator core, obliquely with respect to an axial end face of the stator core respectively at first and second oblique angles ?1 and ?2, where ?2>?1. The second part is positioned closer to the joint, where the insulating coat-removed portion of the electric conductor segment is jointed to that of another electric conductor segment, than the first part is.

Abstract: A stator for an electric rotating machine includes a hollow cylindrical stator core having a plurality of slots and a stator coil formed by joining a plurality of electric wires mounted on the stator core. For each joined pair of the electric wires, one of the electric wires has an end portion led out from the radially inner periphery of one of the slots of the stator core while the other electric wire has an end portion led out from the radially outer periphery of another one of the slots of the stator core; the end portions are welded together to form a weld therebetween. Part of the welds formed between the end portions of the joined pairs of the electric wires are located on the radially inner periphery of the stator coil while the remaining welds are located on the radially outer periphery of the stator coil.

Abstract: A superconducting rotating electrical machine has a rotor with superconducting windings and a stator disposed around the rotor. The stator has a number of teeth disposed at a regular interval about a rotational axis of the rotor to define slots each between adjacent teeth and a plurality of windings, each winding having a strip-like wire member, the wire member having a plurality of rectangular cross-section wires in which said rectangular wires are arranged in parallel to each other and electrically insulated away from each other, the winding being constructed by winding the strip-like wire member a plurality of times to have first and second winding portions having a cross section in which the rectangular wires are positioned in matrix.

Abstract: The disclosed invention describes a motor/generator coil produced using rectangular electric current conductors of any thickness and width. A unique joint between the up and down segments of the coil turn enables an improved conductor packing ratio and geometrical orientation that minimizes the effect of eddy currents. The resulting coil produces higher power than typical wire wound motors but is lighter weight and physically smaller in size. In addition, the coil can be free-standing, and is capable of slotless and/or ironless core device configuration.

Abstract: A method (100) is described for twisting preformed bar conductors (25) of electric machines, said conductors (25) comprising a first and a second leg (5) joined together by a connection portion (15).

Abstract: A motor comprises a stator having open slots with a double layer formed coil lapped winding and the method to manufacture thereof.

Abstract: A stator which may be employed in an electric rotating machine. The stator includes a stator winding which includes in-slot portions disposed in slots of a stator core. The in-slot portions are arrayed in each of the slots in a form of multiple layers aligned in a radial direction of the stator core. The stator winding is made up of a first winding and a second winding which are connected together through a joint. The first winding is defined by a portion of the stator winding between the joint and an end of the stator winding which is to be connected to an external. The second winding includes the in-slot portion placed within at least one of the slots as an outermost layer that is one of the layers placed most outwardly in the radial direction of the stator core. This results in a great decrease in leakage current.

Abstract: In a method for manufacturing a bar winding for the stator of an electric machine, in particular of a claw pole alternator for motor vehicles, resistance welding is used to form mechanically and electrically reliable and permanent connections in the winding overhang of the stator even with winding configurations that include four or more superposed conductor segments, and even with the very small amount of working space that remains for the necessary connections, using a minimum of production-related outlay. With a design, in particular, of four radially superposed conductor segments in the winding overhang, particularly advantageous configurations result in terms of the placement of the bar ends and in terms of the design of the welding electrodes.

Abstract: A rotating electrical machine includes a stator with an iron core having a plurality of slots and a stator winding configured by connecting a plurality of segment conductors each formed by a rectangular wire including an end portion and an insulating film; and a rotator that faces the stator through a gap, wherein the conductor includes a portion coated with the insulating film and a peel-off portion from which the insulating film is peeled off and has a cross-section smaller than the coated portion, the segment conductor and another segment conductor are bonded to each other outside the slots so as to bring at least parts of the peel-off portions as bonding faces into contact with each other, at least one segment conductor of the bonded segment conductors includes a straight portion that is formed in a linear shape in an axial direction and an arc portion.

Abstract: An example electric machine includes a stator disposed about an axis having a plurality of slots. The electric machine also includes a plurality of windings each having a first portion and a second portion. At least two of the plurality of windings are at least partially disposed within each of the plurality of slots. At least one of the first portion or second portion of at least one of the plurality of windings of each slot includes a first exposed end with a surface having a plurality of grooves, the surface in contact with a second exposed end of at least one other winding of the same slot. The first exposed end and second exposed end form a joint between the plurality of windings. A braze material is dispersed in a plurality of grooves disposed between the first exposed end and the second exposed end.

Abstract: The invention comprises a modular electric machine comprising a modular stator having a plurality of stator teeth and windings and a modular rotor comprising a plurality of modular magnetic elements for electromagnetic interaction with stator teeth. The invention further comprises a method of control of a modular electric machine.

Abstract: The present invention provides a coil end structure of a rotating electric machine which is able to miniaturize the coil end structure without having an insulation coating of a flat wire being affected. A coil segment 4 is composed of a plurality of flat wires. A surface of each flat wire confronting another in a slot 2a (legs 41 and 41) is identical to the surface confronting the other at a coil end (head 42).

Abstract: A motor having a rotor and a stator is disclosed. The rotor is a consequent-pole rotor having a rotor core, a plurality of magnets, and a plurality of salient poles. The stator includes a stator core and multiphase coils. Each coil is wound about the teeth by distributed winding, in such a manner as to wind two or more consecutive teeth in single winding. The opening degree each of salient pole opposed to the distal ends of the teeth is set greater than or equal to twice the opening angle of the distal end of each tooth.

Abstract: A system for completing an electrical circuit includes first and second base contacts electrically isolated from each other, each having a magnetic portion secured thereto, each magnetic portion having an opposite polarity, and each of said base contacts electrically connected to an electrical lead for transmitting an electrical signal through said base contacts. The system also includes first and second mating contacts electrically isolated from each other, each having a magnetic portion of opposite polarity secured thereto.

Abstract: A stator for an electric motor includes first and second rows of conductors arranged concentrically around an axis inside a steel core. Each conductor includes a linking end. The stator also includes a first dielectric shim ring arranged between the two rows of conductors. Each conductor of the first row is bent in either a clockwise or a counter-clockwise direction relative to the axis and each conductor of the second row is bent in the opposite direction. The linking end of each conductor of the first row is attached to the linking end of an adjacent conductor of the second row after the conductors are bent. The first shim ring separates the first and second rows of conductors when the conductors are being bent, and is also at least partially disposed between the first and second rows of conductors when the linking ends are being attached.

Abstract: Embodiments of the invention provide an electric machine module including a stator assembly. The stator assembly includes a stator core comprising a plurality of slots. Conductors can be at least partially disposed within the slots. The conductors can include leg portions and can be positioned so that at least some of the slots include a first leg portion, a second leg portion, a third leg portion, and a fourth leg portion. The stator assembly can include first clearance apertures defined by between circumferentially adjacent first leg portions, second clearance apertures that can be defined between circumferentially adjacent second leg portions, third clearance apertures that can be defined between circumferentially adjacent third leg portions, and fourth clearance apertures that can be defined between circumferentially adjacent fourth leg portions. In some embodiments, the second and third clearance apertures can comprise a greater circumferential size relative to the first and fourth clearance apertures.