Abstract: A stator for a rotating electric machine includes a laminated core, and an electrically conductive winding including a winding top layer with electrically conductive top bars, and a winding bottom layer with electrically conductive bottom bars. Each groove of a stator segment of the laminated core has arranged therein a top bar and a bottom bar in adjacent relationship. The top and bottom bars protrude out of the grooves. A connecting element connects a free end of a top bar to a free end of a bottom bar of an adjacent stator segment and includes an inclined section to connect two ends of the connecting element. The ends are angled relative to the inclined section. One end of the connecting element is connected to the free end of the bottom bar and the other end of the connecting element is connected to the free end of the top bar.

Abstract: A coil winding for an electric motor, and systems, components, assemblies, and methods thereof, can comprise turns of a predetermined number of electrically conductive wires on a first side of the coil winding twisted together in a clockwise direction; and turns of the predetermined number of the electrically conductive wires on a second side of the coil winding opposite the first side twisted together in a counterclockwise direction.

Abstract: A modular stator-inverter assembly for an electric machine includes a stator and a traction power inverter module (“TPIM”). The stator includes a stator core having a center axis, an inner diameter (“ID”), an outer diameter (“OD”), and electrical conductors forming stator windings. Stator teeth extending radially toward the center axis from the ID collectively define stator slots occupied by the stator windings. Each adjacent pair of stator teeth defines a respective stator slot. The TPIM delivers a polyphase voltage to the stator windings to generate a predetermined number of stator poles, such that the stator has either two, three, or four of the stator slots per electric phase per stator pole. The stator defines a center cavity and is configured to receive a selected rotor from an inventory of preconfigured machine rotors. The inventory includes multiple synchronous reluctance machine rotors and an induction machine rotor.

Abstract: A stator for an electric machine is fabricated by assembling a core and first and second winding assemblies. The first winding assembly (FWA) is fabricated by a 3D printing process and includes a plurality of U-shaped conductors (hairpins) having respective end-turns arranged in mutually axially-nested relationship to each other to form a ring, and further having two uprights disposed in one of the slots of the core. End-turns connect respective pairs of the uprights and are disposed adjacent to an end surface of the core, distal ends of the uprights projecting axially beyond an opposite end surface of the core. The second winding assembly (SWA) includes a plurality of bridges forming a second ring Opposite ends of each bridge define terminals that mate with ends of the uprights. The SWA further includes an electrically non-conductive casing in which at least one of the bridges is embedded.

Abstract: A strand of a unit coil of an armature coil is transposed by transposition angle 540 degrees in a slot and transposed by a first transposition angle at coil end portions. In the slot, the strand has a change portion in which the change rate of transposition of the strand is changed. An axial-direction middle point of the change portion is located between a position at transposition angle 90 degrees and a position obtained by adding the first transposition angle of the strand to transposition angle 90 degrees.

Abstract: A stator for an electrical rotating machine, in particular for use in a pod drive, includes a laminated stator core having coils. Each coil has a groove portion, a winding overhang portion and a connecting portion. The winding overhang portion is configured as a stator winding overhang board arranged at an end face of the laminated stator core and having an insulating main body and conducting tracks integrated into the insulating main body. Each conducting track is formed by a number of partial conducting tracks that are electrically insulated from each other. Conductors extend in the groove portion, with each conductor formed by a number of partial conductors that are electrically insulated from each other, wherein each of the conductors and an associated one of the conducting tracks of the winding overhang portion are electrically conductively connected in the connecting portion.

Abstract: A continuously transposed conductor (CTC) cable may include a plurality of electrically insulated strands arranged in first and second stacks with the plurality of strands successively transposed between the first and second stacks. The plurality of strands may include at least one strand having a plurality of component strands that are arranged in third and fourth stacks with the plurality of component strands successively transposed between the third and fourth stacks. Each of the components strands may include a conductor and insulation formed at least partially around the conductor.

Abstract: A slot coil 25 is inserted into a slot 23 provided in a stator core 21 and is covered with an insulating material 28. The insulating material 28 has an ear portion 29 on an outer circumferential surface thereof. The slot coil 25 is fixed to the stator core 21 by the ear portion 29 welded to an end surface 21b of the stator core 21.

Abstract: The winding for an electric machine comprises transposed bars having at least four stacks of strands. Couples of stacks of strands define elementary transposed bars. The winding comprises at least two stacks of cooling pipes in each transposed bar, each stack of cooling pipes being arranged between two stacks of strands, and at least one crossover transposed bar in which the sides of the elementary transposed bars are exchanged.

Abstract: A stator core is formed from a continuous strip of wound sheet stock material, in which the sheet stock material is converted from the sheet stock to a formed material including winding slot cutouts. This strip of formed material is then wound into the stator core, with the winding slot cutouts in the formed material maintained at a substantially constant width throughout most of the radial extent of the resulting winding slots in the finished article. However, one or more of the radially innermost and radially outermost layers may define winding slot cutouts that are wider than the other winding slot cutouts. Where several radial layers are altered in this way, the cutout widths are progressively expanded such that the resulting winding slot has terminal ends with edges that are effectively “radiused” or rounded, thereby protecting windings near the edge of such slots.

Abstract: A generator is provided that includes at least one pole set representing one phase. Each pole set includes a plurality of poles. Only one conductor is turned about the poles of a particular pole set such that only half a single turn is associated to each pole of the particular pole set.

Abstract: In one possible implementation, a method for forming a motor winding is provided which includes compressing a Litz wire to form a compacted Litz wire and forming the winding with the compacted Litz wire. In one possible embodiment, a motor winding is provided that has a high density multi-conductor wire bundle comprises of compacted Litz wire.

Abstract: A rotary electric machine includes a stator having an open slot configuration and a plurality of stator poles with a coil positioned about each stator pole. Each coil has a plurality of electrically conductive wires defining a group of wires and the group of wires is wrapped generally around a stator pole to define a plurality of turns. At least a portion of the group of wires is twisted, and the portion of the group of wires has between approximately 1 and 5 twists per turn. A method of fabricating a stator assembly is also disclosed.

Abstract: Stators (1) for electrical machines, in particular a rotating field machine, such as a motor or generator, in particular for an electric vehicle, wherein a stator (1) has slots separated by stator teeth, into which shaped bars (3, 4), formed from a plurality of individual wires (10), are deployed, characterised in that in each case the two sidewalls of a stator tooth bounding adjacent slots in the region of the shaped bars (3, 4) run essentially parallel to one another.

Abstract: An electric wire includes a conductive portion 11 made of a material having a volume resistivity higher than that of copper, wherein the volume resistivity of the conductive portion is specified so that, in a frequency range in which the electric wire is used, a ratio of AC resistance of the conductive portion 11 to AC resistance of reference copper wire is less than 1.

Abstract: An electric wire includes a conductive portion 11 made of a material having a volume resistivity higher than that of copper, wherein the volume resistivity of the conductive portion is specified so that, in a frequency range in which the electric wire is used, a ratio of AC resistance of the conductive portion 11 to AC resistance of reference copper wire is less than 1.

Abstract: A rotary electric machine includes a stator having an open slot configuration and a plurality of stator poles with a coil positioned about each stator pole. Each coil has a plurality of electrically conductive wires defining a group of wires and the group of wires is wrapped generally around a stator pole to define a plurality of turns. At least a portion of the group of wires is twisted, and the portion of the group of wires has between approximately 1 and 5 twists per turn. A method of fabricating a stator assembly is also disclosed.

Abstract: A rotor coil for a revolving armature includes a strand coil that includes a part arranged in a core slot of the rotor and is composed of a plurality of element wires; and a solid coil welded to an end of the strand coil wherein the end of the strand coil and an end of the solid coil are welded by friction stir welding. A manufacturing method of a rotor coil includes the step of performing friction stir welding wherein the friction stir welding is performed for the butt joint with the end of the strand coil arranged in an advancing side defined by a rotation direction of a tool and with the solid coil arranged in a retreating side.

Abstract: An electric wire includes a conductive portion 11 made of a material having a volume resistivity higher than that of copper, wherein the volume resistivity of the conductive portion is specified so that, in a frequency range in which the electric wire is used, a ratio of AC resistance of the conductive portion 11 to AC resistance of reference copper wire is less than 1.

Abstract: A dynamoelectric device comprises a plurality of armatures arranged circumferentially about an axis, sets of electrically conductive winding members that extend axially through the stack of laminates and are positioned circumferentially between each adjacent pair of the armatures, and first and second layers of end-turn members. Each of the end-turn members of the first axial layer is connected to one of the winding members. Each of the end-turn members of the first axial layer extends clockwise circumferentially from its respective one of the winding members. Each of the end-turn members of the second axial layer is connected to one of the winding members and to each of the end-turn members of the first axial layer of end-turn members. Each of the end-turn members of the second axial layer extends counter-clockwise circumferentially from its respective one of the winding members. The winding members are each formed of litz wire.

Abstract: An exemplary slot closure arrangement has a sliding block and a pressure piece. At least one spring element is arranged in between them and can be prestressed by at least one attachment, which interacts with the sliding block and the pressure piece, thus creating a prefabricated assembly. Once the slot closure arrangement has been positioned in a slot, the attachment can be mechanically moved from a first position to a second position, which can be monitored, after positioning of the slot closure arrangement, for activation of the spring forces of the at least one spring element.

Abstract: A stator assembly includes a stator core and at least one conductive bundle. The stator core has a first end, a second end, and a plurality of slots extending from the first end to the second end. The conductive bundle includes a plurality of individually insulated conductive wires. At least one portion of the at least one conductive bundle extends from the first end to the second end of one slot of the plurality of slots. The at least one portion is twisted by a predetermined amount within the one slot to minimize a circulatory current along the plurality of individual insulated conductive wires in the at least one portion.

Abstract: A conductor bar for a large, rotating electric machine includes a press-formed conductor loop having a rectangular cross-sectional shape. The conductor loop includes a plurality of identical, helically wound, Roebel transposed, stranded conductors. Each of the stranded conductors includes a cable including a plurality of electrically insulated individual wires, wherein the cross-sectional shape is constant along a length of the conductor bar.

Abstract: An armature winding of an electric rotating machine is provided, which includes at least one armature winding bar composed of a plurality of element wire conductors, wherein the armature winding bar includes an element wire conductor configured to have twisted transposing angles of 180 degrees at one border zone and a middle zone in a winding slot and a twisted transposing angle different from 180 degrees at the other border zone of the winding slot of the element wire conductor.

Abstract: In one possible implementation, a method for forming a motor winding is provided which includes compressing a Litz wire to form a compacted Litz wire and forming the winding with the compacted Litz wire. In one possible embodiment, a motor winding is provided that has a high density multi-conductor wire bundle comprises of compacted Litz wire.

Abstract: A method for reducing leakage currents in an electric machine is described. The method includes positioning a plurality of leakage current shields between windings and teeth of a stator, and coupling at least one of the plurality of leakage current shields to a reference point, wherein an electric potential at the reference point is not earth ground.

Abstract: Sub core sections are arranged at the end portions and the center portion of a stator core, and strand conductors are twisted and transposed by 360 degrees continuously toward the extending direction of winding slot. The length corresponding to transposition pitch 180 degrees of the strand conductors of the stator core is set as one core unit area, the sub core sections including portions whose space factors are different are arranged such that the sum of voltages in the strands induced in the strand conductors in the odd-numbered core unit area from one end portion of the stator core offsets the sum of voltages in the strands induced in the strand conductors in the even-numbered core unit area from the end portion of the core.

Abstract: An armature winding of an electric rotating machine is provided, which includes at least one armature winding bar composed of a plurality of element wire conductors, wherein the armature winding bar includes an element wire conductor configured to have twisted transposing angles of 180 degrees at one border zone and a middle zone in a winding slot and a twisted transposing angle different from 180 degrees at the other border zone of the winding slot of the element wire conductor.

Abstract: Sub core sections are arranged at the end portions and the center portion of a stator core, and strand conductors are twisted and transposed by 360 degrees continuously toward the extending direction of winding slot. The length corresponding to transposition pitch 180 degrees of the strand conductors of the stator core is set as one core unit area, the sub core sections including portions whose space factors are different are arranged such that the sum of voltages in the strands induced in the strand conductors in the odd-numbered core unit area from one end portion of the stator core offsets the sum of voltages in the strands induced in the strand conductors in the even-numbered core unit area from the end portion of the core.

Abstract: A stator assembly includes a stator core and at least one conductive bundle. The stator core has a first end, a second end, and a plurality of slots extending from the first end to the second end. The conductive bundle includes a plurality of individually insulated conductive wires. At least one portion of the at least one conductive bundle extends from the first end to the second end of one slot of the plurality of slots. The at least one portion is twisted by a predetermined amount within the one slot to minimize a circulatory current along the plurality of individual insulated conductive wires in the at least one portion.

Abstract: A stator winding bar comprises a plurality of strands that are transposed in the manner of a Roebel bar in an active part having a prescribed length, the active part being divided into several areas having different lengths arranged one after the other, in each area a transposition of the strands by a prescribed angle magnitude is provided, wherein the crimping distance within each area varies.

Abstract: Sub core sections are arranged at the end portions and the center portion of a stator core, and strand conductors are twisted and transposed by 360 degrees continuously toward the extending direction of winding slot. The length corresponding to transposition pitch 180 degrees of the strand conductors of the stator core is set as one core unit area, the sub core sections including portions whose space factors are different are arranged such that the sum of voltages in the strands induced in the strand conductors in the odd-numbered core unit area from one end portion of the stator core offsets the sum of voltages in the strands induced in the strand conductors in the even-numbered core unit area from the end portion of the core.

Abstract: Sub core sections are arranged at the end portions and the center portion of a stator core, and strand conductors are twisted and transposed by 360 degrees continuously toward the extending direction of winding slot. The length corresponding to transposition pitch 180 degrees of the strand conductors of the stator core is set as one core unit area, the sub core sections including portions whose space factors are different are arranged such that the sum of voltages in the strands induced in the strand conductors in the odd-numbered core unit area from one end portion of the stator core offsets the sum of voltages in the strands induced in the strand conductors in the even-numbered core unit area from the end portion of the core.

Abstract: A conformable layer (14) for inhibiting electrical discharge between vent tubes (16) and strands (12) in an inner-cooled coil (5). The conformable layer comprises a resistive inner core (24) and a conductive strip (20) wrapped in a conductive outer wrap (26). The conductive strip (20) is electrically connected to the strands (12) at one end of the coil (5) and left to electrically float at the other end. In this configuration, the conformable layer (14) reduces voltage buildup between the vent tubes (16) and the strands (12) to help prevent electrical damage to the coil (5).

Abstract: An armature winding of an electric rotating machine is provided, which includes at least one armature winding bar composed of a plurality of element wire conductors, wherein the armature winding bar includes an element wire conductor configured to have twisted transposing angles of 180 degrees at one border zone and a middle zone in a winding slot and a twisted transposing angle different from 180 degrees at the other border zone of the winding slot of the element wire conductor.

Abstract: An armature winding includes a plurality of strand groups each having strands transposed and bound in at least two rows and multiple tiers, and a main insulator for covering the strand group. The strands belonging to a strand group on one side of a central strand group has a cross-sectional area smaller than that of the control strand group, and the strands belonging to the strand group on the other side of the central strand group has a cross-sectional area larger than that of the central strand group.

Abstract: A method for producing a conductor bar including transposed stranded conductors for a large, rotating electric machine. The method includes a first step of cabling a plurality of electrically insulated individual wires to form a plurality of identical stranded conductors having an essentially circular cross section. In a second step the stranded conductors are helically wound around a winding spindle in the manner of a Roebel transposition so as to form a conductor loop, wherein the winding has a profile adapted to a final cross sectional shape of the conductor bar. In a third step, the winding spindle removed from the conductor loop. In a fourth step, the conductor loop undergoes a press-forming procedure that gives it the final cross sectional shape, especially, for example, a rectangular shape.

Abstract: An electromagnetic device includes a plurality of coils formed by winding conductors. At least some of the conductors are constructed by stacking conductor constructional elements so that an eddy current generated by a leakage flux linked to the conductor is divided. An outer insulating member is disposed on an outer circumferential surface of the conductor stack for electrically insulating the conductor stack from another member. An inner insulating member whose thickness is smaller than a thickness of the outer insulating member is disposed between the conductor constructional elements adjoining to each other in the same conductor stack.

Abstract: Sub core sections are arranged at the end portions and the center portion of a stator core, and strand conductors are twisted and transposed by 360 degrees continuously toward the extending direction of winding slot. The length corresponding to transposition pitch 180 degrees of the strand conductors of the stator core is set as one core unit area, the sub core sections including portions whose space factors are different are arranged such that the sum of voltages in the strands induced in the strand conductors in the odd-numbered core unit area from one end portion of the stator core offsets the sum of voltages in the strands induced in the strand conductors in the even-numbered core unit area from the end portion of the core.

Abstract: In a stator winding bar for an electrical machine without end winding transposition and with transposition in the active part of 450°, the middle part of the active part, in order to compensate the external fields acting in the region of the end windings and inducing circulating currents, has a length that is greater than ¾ of the total length of the active part.

Abstract: A stator for a power generation system and associated methods are provided. The stator preferably includes a plurality of high voltage stator coils. Each of the plurality of high voltage stator coils preferably includes a plurality of metal strands, a plurality of vent members positioned adjacent the plurality of metal strands, and compact voltage grading means contacting each of the plurality of vent members and the plurality of metal strands for grading voltage between the vent members and the metal strands to thereby prevent an overvoltage condition. The present invention also provides a method of grading voltage between internal vent members and conductive strands of a high voltage coil of a power generation system. The method preferably includes connecting conductive portions of each of a plurality of internal vent members to a plurality of conductive strands of a high voltage coil.

Abstract: A high voltage generator armature bar (10) that exhibits improved performance by forming one or more of its conductive components from a conductive material that uses a tin oxide-based composition as a conductive filler. The armature bar (10) is of the type having one or more tiers of conductor strands (12), strand insulation (14), conductive internal grading (20), groundwall insulation (22), conductive slot armoring (24), and preferably a transposition filler (18). The conductive internal grading (20), the conductive slot armoring (24) and/or the transposition filler (18) contain a conductive filler of antimony-doped tin oxide that may constitute the entire conductive filler, or can be present as a shell on the filler particles.

Abstract: A winding element for an electrical machine, in particular a turbogenerator, includes an electrically conductive conductor configuration for carrying an electric current, an insulating layer surrounding the conductor configuration and a protective configuration surrounding the insulating layer. The protective configuration includes an isolating layer disposed like a helix, and an at least slightly electrically conductive contact layer likewise disposed like a helix and overlapping itself. The contact layer traverses or passes through the isolating layer from an inner side facing the insulating layer to an outer side facing away from the insulating layer. A winding assembly for an electrical machine includes an electrically conductive winding support and a winding element circumferentially surrounded and electrically contacted by the winding support.

Abstract: A tapered electrode with a rounded tab portion and a grading electrode is disclosed for minimizing the concentration of current flow to localized areas of the electrode. The tapered electrode comprises a base portion and a tab portion with a rounded end. The grading electrode comprises areas of varying width and relative resistance which operate to grade current flow away from the terminal portion of the tapered electrode tab.

Abstract: The asynchronous discoidal electric motor has stator (1A, 1B) windings (13) and radial rotor bars (2) embedded in notches (11, 22) opened by a very narrow slit (11, 21). These slits (11, 21) and notches (12, 22) may be machined electrochemically using a wire. Application to asynchronous discoidal electric motors with winding embedded in the stator and with a cartwheel structure on the rotor.

Abstract: Winding bars of AC machines include a multiplicity of mutually electrically insulated conductor elements, which are transposed according to the Roebel principle. The conductor elements in the two end clip sections and in the active part section are transposed with one another.In order to achieve virtually perfect field compensation in the winding overhang, the conductor elements in the two end clip sections have a transposition of between 60.degree. and 120.degree.. In the active part section, either an incomplete transposition is provided, i.e. the transposition in the active part section is uniform and less than 360.degree., or, given a complete 360.degree. transposition in the active part section a void, i.e. a nontransposed section, is provided in the center of the active part, while the transposition in the active part section outside this nontransposed section is a uniform 180.degree. transposition.

Abstract: The stator winding of an electrical machine comprises conductor elements which are spaced apart from one another, are electrically insulated from one another and are surrounded over their entire length by common main insulation. The cavities, which are caused by the arrangement on both bar narrow sides of the conductor elements and the main insulation, are filled with an electrically semiconductive compound which, for its part, is covered by an electrically semiconductive strip. In order to provide a smooth bar surface, the electrically semiconductive strip is composed of a fiber-reinforced plastic, which has incisions on alternate sides of the narrow sides of the conductor bar oriented transversely with respect to the bar's longitudinal direction; these incisions are deeper than half the strip width and have a cut width which is on the order of magnitude of the strip thickness.

Abstract: An electric machine having a stator winding which is impregnated by total immersion. The bar ends of the stator winding have soldering lugs which are insulated from one another and with respect to grounded housing parts. In order to simplify the assembly of the soldering lug insulation and at the same time to improve heat transfer, the soldering lugs are surrounded on all sides by a deformable insulating material with is pervious to impregnating resin. The insulating material is fixed by means of a shrinkable fabric which is likewise pervious to the impregnating resin. The insulation and shrinkable fabric are impregnated and cured at the same time as the winding insulation.

Abstract: Stator bars for dynamoelectric machines are covered with an electrically conductive tape formed of a fabric support sheet carrying an electrically conductive polymeric binder system comprised of carbon particles dispersed in a polymeric matrix. The carbon particles are preferably selected from carbon black and/or graphite, and are present in the polymeric binder system in an amount of at least 5 percent by weight, based on the weight of the binder system. Low tip-up values of less than 0.025% and increased high voltage breakdown strengths of at least 700 VPM are obtained.

Abstract: A small motor having a two-pole permanent-magnet rotor and a U-shaped laminated stator having a pair of limbs with end portions that form magnetic poles for the rotor. The limbs carry alternately energized exciter coils including three nested winding layers arranged in two winding groups, of which the outer winding layer and the inner winding layer of the first limb and the second limb, respectively, and the central winding layer of the second limb and the first limb, respectively, are connected in series with one another.