Connection module for a bar wound stator assembly and method of manufacturing a bar wound stator assembly

A method of manufacturing a stator assembly for an electrical device, the method comprising:

• forming a stator core to define a plurality of slots that extend along a longitudinal axis and are angularly spaced about the longitudinal axis;
• positioning a plurality of bar conductors within the plurality of slots to define at least one winding set that defines multiple phases and defines a first pole pair having a first pole and a second pole, wherein each of the bar conductors include an identical span;
• positioning a connection module relative to the stator core to span across the first pole pair, wherein the connection module includes a plurality of electrical jumpers, with each jumper oriented in a pre-determined orientation relative to the stator core to electrically engage at least two pre-determined bar conductors;
• and
• electrically connecting each of the electrical jumpers to the at least two pre-determined bar conductors to complete each phase of the winding set and to interconnect each of the multiple phases in a pre-determined connection configuration.

An electric device comprising:

• a housing;
• a rotor assembly rotatably supported by the housing;
• and
• a stator assembly supported by and positionally fixed relative to the housing, with the rotor assembly rotatable relative to the stator assembly about a longitudinal axis, the stator assembly including:
• a stator core extending along a longitudinal axis between a first axial end and a second axial end and defining a plurality of slots extending along the longitudinal axis and angularly spaced about the longitudinal axis;
• a plurality of bar conductors, each having an identical span and positioned within the slots to define at least one winding set defining multiple phases, and further defining a first pole pair having a first pole and a second pole;
• a connection module coupled to the stator core at one of the first axial end and the second axial end of the stator core and spanning across the first pole pair of the winding set, wherein the connection module is configured to connect each of the bar conductors of each phase of the first pole pair to complete each phase, and to interconnect each of the multiple phases in a pre-determined connection configuration;
• wherein the connection module includes an electrically non-conductive substrate supporting a plurality of electrical jumpers;
• wherein each of the electrical jumpers is oriented on the substrate in a pre-determined orientation relative to the stator core to electrically engage at least two pre-determined bar conductors;
• wherein the connection module includes a flexible lead coupled to the substrate and oriented on the substrate in a pre-determined orientation relative to the stator core to electrically engage a pre-determined bar conductor associated with each different phase of the winding set;
• wherein the connection module includes a connection jumper coupled to the substrate and oriented on the substrate in a pre-determined orientation relative to the stator core to electrically connect the phases of the winding set in a pre-determined connection configuration;
• and
• wherein the connection module includes a plurality of insulators attached to and supported by the substrate, wherein the insulators extend from the substrate radially toward the longitudinal axis, and extend axially along the longitudinal axis, with each of the insulators oriented on the substrate in a pre-determined orientation relative to the stator core to electrically insulate between two adjacent bar conductors.