Electric motor
An electric motor may include a rotor assembly including a rotor shaft defining a rotational axis. An electric motor may include a stator assembly including a core, an insulator at least partially covering the core, and a plurality of windings, the insulator defining one of a post that protrudes in an axial direction parallel with the rotational axis or a receptacle in which the post is receivable. An electric motor may include a bus bar assembly including a non-conductive body and a plurality of conductors configured to make an electrical connection between at least two windings of the plurality of windings, the non-conductive body including the other of the post or the receptacle, wherein the receptacle includes at least one of an aperture or a recess, and wherein the post is received within the receptacle to secure the non-conductive body to the insulator.
1 . A method of assembling an electric motor, the method comprising:
providing a rotor assembly including a rotor shaft;
providing a stator assembly including a core, an insulator at least partially covering the core, and a plurality of windings;
providing a bus bar assembly including a non-conductive body and a plurality of conductors;
ultrasonically welding the non-conductive body to the insulator;
making an electrical connection between at least two windings of the plurality of windings and the plurality of conductors; and
inserting a bearing within a bearing pocket of the non-conductive body, wherein the bearing pocket defines an outer circumferential surface, and wherein the insulator includes a coil protector portion having an inner annular surface, and wherein ultrasonically welding the non-conductive body to the insulator produces an ultrasonic weld located where the outer circumferential surface contacts the inner annular surface.
2 . The method of claim 1 , wherein the non-conductive body includes an inboard surface facing toward the insulator, and wherein the insulator includes a coil protector portion having an axially outer surface, and wherein ultrasonically welding the non-conductive body to the insulator produces an ultrasonic weld located where the inboard surface contacts the axially outer surface.