Magneti Marelli S.p.a.

Marelli Europe S.p.a.

Marco Magri

Franco Ciampolini

Francesco Leli

Marzio Lettich

Salvatore Stamato

Vlad Mihai Constandachi

A rotor for a rotary electric machine; the rotor has: a shaft, which is mounted so as to rotate around a rotation axis; a magnetic core, which is arranged around the shaft and consists of a plurality of lamination sheets stacked together; and a pair of end discs, which are arranged around the shaft at the two opposite ends of the magnetic core and are designed to keep the lamination sheets of the magnetic core stacked together; wherein the end discs are designed to have balancing holes, which dynamically balance the rotor around the rotation axis. Each end disc consists of an inner component with an annular shape, which is arranged around the shaft and is made of a first metal material, and of an outer component with an annular shape, which is arranged around the inner component and is made of a second metal material, which is different from the first metal material and is non-magnetic.

Rotor for a rotary electric machine

A method to construct an electric machine provided with: a stator having a magnetic core longitudinally crossed by a plurality of stator slots; a stator winding having a series of rigid bars, which are 'U'-shaped and are inserted through the stator slots defining an entry side, in which the cusps of the 'U'-shaped bars are placed, and an exit side, in which the legs of the &#x201c;U&#x201d;-shaped bars are placed; the construction method comprises the steps of electrically connecting the ends of at least two non-adjacent legs to one another by means of a connection bridge, which is made of a flat plate arranged perpendicular to the central axis of rotation and has, for each leg, a corresponding &#x201c;U&#x201d;-shaped seat, which is suited to receive the end of the leg.

Method to construct an electric machine having a stator winding with rigid bars

A laser welding method to weld two adjacent metal elements of a stator winding with rigid bars for an electric machine; the two metal elements are arranged one beside the other and have respective upper surfaces, which are arranged coplanar to one another and have at least one common edge; in succession, in the direction of the upper surfaces of the two metal elements, a first laser beam is aimed, which is fed along a first welding line, which is perpendicular to the common edge and extends through the common edge itself, and then a second laser beam is aimed, which is fed along a second welding line, which is perpendicular to the common edge and extends through the common edge itself, is parallel to and spaced apart from the first line and has a length that is smaller than the one of the first line.

Laser welding method to weld two adjacent metal elements of a stator winding with rigid bars for an electric machine

An electric machine provided with: a stator having a magnetic core longitudinally crossed by a plurality of stator slots; a stator winding having a series of rigid bars, which are 'U'-shaped and are inserted through the stator slots defining an entry side, in which the cusps of the 'U'-shaped bars are placed, and an exit side, in which the legs of the &#x201c;U&#x201d;-shaped bars are placed; the ends of at least two non-adjacent legs are electrically connected to one another by means of a connection bridge; and an insulating support is provided, which houses the connection bridge, is arranged under the connection bridge and has a plurality of through holes, into which some legs are inserted, which have to pass through the insulating support itself.

Electric machine having a stator winding with rigid bars

An electric machine comprising a stator including at least one stator winding elements that extends from a first to a second end, separate from each other; at least one electrical bridge suitable to electrically connect the separate ends of said stator winding element; at least a support and attachment plate made of electrically insulating material which defines at least one seat suitable to house at least partially, and retain in position, the electrical bridge. The seat is provided with attachment mechanisms which form at least partially a shaped coupling with the at least one electrical bridge, so as to mechanically lock it in position on the support and attachment plate. The seat allows the passage of the ends of the stator winding element and the electrical connection between the latter and the electrical bridge. The seat electrically insulates the electrical bridge from other components of the stator.

Electric machine and related assembly method

Method and station for the construction of a stator winding with rigid bars for a rotary electrical machine; an insulated wire of electrically conductor material and provided on the outside with an insulating layer is unwound from a coil. A final end of the insulated wire is bent in a 'U' shape so as to create a bar having two legs connected to one another by a cusp. The insulated wire is transversely cut to separate the rigid bar from the remaining part of the wire; and the bar is inserted into a stator slot of a magnetic core of a stator. The electrical conductivity is measured between the core and the outer surface of the insulated wire by means of a first electrode electrically and permanently connected to the core of the insulated wire and a second electrode, which rubs against the outer surface of the insulated wire.

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Bologna, Italy

Marco Magri