Remy Inc.

Remy International, Inc.

Christopher Congdon

David A Fulton

Wei Cai

Ronald Dale Gentry

Richard A Van Sickle

A method for simultaneously brazing adjacent conductor joints comprises the steps of arranging at least two pair of conductor joints in a row placing a brazing compound between the pairs of joints desired to be electrically connected placing a conductive spacer between the pairs not to be brazed and passing an electrical current through the row of conductors until the brazing compound melts joining the conductor joints. The spacer can then be removed thereby maintaining the proper spacing between the pairs of brazed conductor joints. The multiple rows of conductor joints can be arranged adjacent one another so that they can be moved between brazing electrodes sequentially thereby allowing a continuous brazing operation of multiple rows of conductor joints. The brazing compound may be a continuous ribbon of brazing compound which extends between the multiple rows of conductor joints.

Method for simultaneous resistance brazing of adjacent conductor joints

An electric machine having multi-set rectangular copper hairpin windings comprises a stator having a plurality of partially closed stator slots. A first winding set and a second winding set are positioned in the stator slots. The first winding set and the second winding set are connected by adjacent leg ends. According to a first embodiment, conductor layers in alternate slots alternate between different phases. The conductor layers in the remaining slots are all of the same phase. Hairpins having unequal length legs are used to implement the first embodiment. According to a second embodiment, conductor layers in alternate slots include one phase for the first winding set and another phase for the second winding set. The conductor layers in the remaining slots are all of the same phase. Hairpins having equal length legs are used to implement the second embodiment.

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Fishers, IN, United States of America

Christopher Congdon