A widening apparatus for a hairpin-type stator coil is provided to extend a distance between welding portions of hairpin-type stator coils inserted into slots of a stator core, and the widening apparatus includes, a coil support unit installed on a base frame, a tool driving unit installed on the base frame to be vertically movable below the coil support unit, and including a first gear operation part and a second gear operation part, a plurality of lower widening tools operably connected to the first gear operation part, and reciprocally movable along a layer direction of the stator coils, and a plurality of upper widening tools operably connected to the second gear operation part, and configured to be reciprocally movable above the plurality of lower widening tools.

A method and an apparatus for compact insertion of thick wire multiphase pseudo helical wave winding into a ferromagnetic core of an electrical machine, achieving high fill factor of the core slots, resulting in better heat transfer between the winding and the core, low mass and volume, and overall higher efficiency of electrical machine. An apparatus being fully programmable and physically adaptable to wide range of electric machine dimensions, where process is automated, simple, accurate, reliable and quick, while being suitable for mass production.

An apparatus for pre-assembling a winding for an electric machine stator or rotor includes a plurality of hairpins with two legs having non-circular cross-section, a ring including a plurality of slots and an outer containment ring acting in containment along the perimeter of the ring. An inner cam block and an outer cam block, surrounding and radially facing the inner cam block, are arranged opposite to the exit face of the ring. The cams are adapted to be crossed, in use, by the two legs when they cross the ring at the same time; the cams open into a free circular space between the two cam blocks. A method for pre-assembling a winding set for an electric machine stator or rotor is also provided. Hairpins are inserted in sequence in the slots of the apparatus. A finished winding set positioned in the free circular space is obtained by successive rotations of the ring.

A process for making a continuous bar winding (4) for an electric machine is described, comprising: a) a step of providing a template (10) having a template axis (X) and a circular array of slots (11) extended about said template axis (X), said circular array of slots having a number of slots equal to a number of slots of the stator or of the rotor of said electric machine, each slot (11) of said circular array having a first and a second open end face (11A, 11B) which are axially spaced from one another and a third open end face (11C), said third face (11C) being a longitudinal face extended between said first and second end faces (11A, 11B) b) a step of providing a conductive bar (20); c) a step of locking a locking portion (21) of said conductive bar; d) a step of inserting the conductive bar (20) into the slots (11) of said array and shaping the conductive bar (20) so that such conductive bar (20) repeatedly passes through the slots (11) of said array from the side of the first open end faces (11A) to the side of the second open end faces (11B) and vice versa, so that said bar (20) has a plurality of bar portions (20B, 20E, 20H) received in the slots (11) of said array and a plurality of connecting portions (20C, 20D; 20F, 20G) projecting beyond said first and second open end faces (11A, 11B), each of said connecting portions joining a pair of said bar portions (20B, 20E, 20H) received in the slots (11) of said array; in which said step d) comprises: d1) an operation of inserting a first bar portion (20B) of said plurality of bar portions into a respective slot (11) of said circular array of slots (11) through said third face (11C) of such slot (11); d2) an operation of shaping a first connecting portion (20C, 20D) of said plurality of connecting portions (20C, 20D; 20F, 20G); d3) an operation of inserting a second bar portion (20E) of said plurality of bar portions (20B, 20E, 20H) into a further slot (11) of said array, different from the slot (11) into which said first bar portion (20B) has been inserted, through said third face (11C) of the further slot (11); in which said first connecting portion (20C, 20D) joins said first and second bar portions (20B, 20E) projecting beyond the second end faces (11B) of the slots (11) in which said fi

The method and apparatus comprise the following features: —forming coil members (21) by bending an electric conductor (20) externally coated with an outer insulation (20′); wherein the bending is made at predetermined lengths from a reference position (16′), and wherein each one of the coil members (21), when formed, comprises at least one head portion (21′) and leg portions (21″) extending from said at least one head portion (21′); —feeding the electric conductor (20) to accomplish the bending; —cutting the electric conductor (20) to detach a formed coil member (21) from said electric conductor (20); —inserting the leg portions (21″) of the coil members (21) into slots of the stator, so that parts of said leg portions (21″) extend from one end of the stator and the head portions (21′) extend from an opposite end of the stator; —arranging at least one laser beam (13′a, 13′b) to remove the insulation (20′) from predetermined areas (20a, 20b) of the electric conductor (20); —radiating the surface of the electric conductor (20) with said at least one laser beam (13′a, 13′b) situated at a predetermined position (IP, 2P) with respect to the reference position (16′) along the length of the electric conductor (20) being fed, and at a predetermined stage of the bending of a coil member (20).

The invention relates to a method for producing a coil winding (70) for insertion into radially open slots (82) in a rotor or stator (80) of an electrical machine, wherein the coil winding (70) has a wire pack (60) consisting of a number of wires (32), wherein the wires (32) of the wire pack (60) run parallel to one another and are connected to one another in pairs at one end of the wire pack (60), and wherein the coil winding (70) is formed by a flat winding former which can be rotated about an axis of rotation (26). According to the method, the wire pack (60) is fixed on a winding former (26) and winding heads (42) are produced by displacing fixations of the wire pack (60). The winding shaft (26) can be rotated so that, after carrying out the method, a coil winding (70) is present in the form of a wave winding having wires (32) of the wire pack (60) preconnected in pairs at one end. Such a method allows a particularly space-saving coil winding (70) to be produced, which has a particularly high mechanical stability and requires the least amount of installation space in a rotor or stator (80).

A slotless electric motor provides a ferromagnetic yoke that includes laminations of a ferromagnetic material interspersed with a high thermal conductivity nonferromagnetic material to greatly reduce the thermal resistance of this yoke. A thermally conductive coil form provides heat conduction paths on three sides of the coils to this yoke which may in turn attach to a heatsink providing fins that vary angularly along the axis and radius of the heatsink.

This stator manufacturing method includes a step in which one of a skew-forming mechanism portion and a skew-forming jig presses, with the skew-forming jig, the skew-forming mechanism portion having a shape corresponding to the shape of a skew, to form a skew having a bent shape or a curved shape.

A method and an apparatus are provided for manufacturing a stator with a plurality of hairpin conductors. For inserting the hairpin conductors (15, 15) into the slots (11) of a stator core (12) a stator core template (22) is provided. Hairpin conductors (15) are axially inserted into slots (21) of the stator core template (22) such that the hairpin conductor (15) is arranged at a first position (P1) within said slot (21). The hairpin conductor (15) is then moved within said slot (21) to a different position (P2). A complete nest (20) of hairpin conductors (15) formed within the stator core template (22) is then transferred to the stator core (12).

Provided is a segment-core coupled body, including a plurality of segment cores each including a core back and a tooth; and a plurality of coupling portions configured to couple the core backs to one another, wherein the plurality of segment cores and the plurality of coupling portions are each a laminated body of magnetic sheets, wherein the plurality of coupling portions each include: a posture holding portion adjacent to a gap defined between adjacent core backs; a first thin portion configured to couple one corner portion of the adjacent core backs and the posture holding portion; and a second thin portion configured to couple another corner portion of the adjacent core backs and the posture holding portion, and wherein, the posture holding portion projects toward a radially outer side with respect to the adjacent core backs.