The innermost first segment layer and the second segment layer adjacent thereto in a radial direction are twisted using a twisting jig unit including an inner twisting jig and an outer twisting jig, then the twisting jig unit is replaced with another twisting jig unit including an inner twisting jig and an outer twisting jig, and the third segment layer and the fourth segment layer adjacent thereto are twisted, and then the twisting jig unit is replaced with still another twisting jig unit including an inner twisting jig and an outer twisting jig, and the fifth segment layer and the sixth segment layer adjacent thereto are twisted.

A process for assembling a brushless motor-generator includes assembling a rotor formed from two spaced apart rotor portions having magnetic poles that drive magnetic flux circumferentially through the rotor portions and back and forth across an armature airgap formed between the rotor portions. An air core armature is formed by coating a substantially nonmagnetic armature form with a tacky adhesive layer, and winding armature windings into a winding pattern onto the substantially nonmagnetic form using wire made of multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their length when located inside the armature airgap, wherein the strands of said wire are diametrically held together by an outer serve. The winding of the armature form includes sequentially applying pressure to sections of said wire against the tacky adhesive layer.

A process for assembling a brushless motor-generator includes assembling a rotor formed from two spaced apart rotor portions having magnetic poles that drive magnetic flux circumferentially through the rotor portions and back and forth across an armature airgap formed between the rotor portions. An air core armature is formed by coating a substantially nonmagnetic armature form with a tacky adhesive layer, and winding armature windings into a winding pattern onto the substantially nonmagnetic form using wire made of multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their length when located inside the armature airgap, wherein the strands of said wire are diametrically held together by an outer serve. The winding of the armature form includes sequentially applying pressure to sections of said wire against the tacky adhesive layer.

The invention relates to a winding module (2) for a winding device for automatically winding coils for an electric machine, comprising a module structure (20), a needle carriage (24) having a needle (25), wherein the needle carriage (24) is mounted in the module structure (20) such that it can move along a first direction (R). The winding module (2) has a winding material clamping device (240) for clamping the winding material (8), which is designed to secure the winding material (8) against rotation and against shifting along the needle axis (250), wherein the winding material clamping device (240) is arranged in or on the needle carriage (24). The invention also relates to a module frame and a winding device having a module (2) of this type.

A manufacturing device that is used in a manufacturing method for a rotary electric machine is equipped with an insertion roller having an outer circumferential surface configured to contact a coil lead line in such a manner that the coil lead line is inserted into accommodating grooves of an insulator, a roller support section that rotatably supports the insertion roller, and a bending unit that performs a bending process to bend the coil lead line by coming into contact with the coil lead line so as to form a terminal part.

A manufacturing device that is used in a manufacturing method for a rotary electric machine is equipped with an insertion roller having an outer circumferential surface configured to contact a coil lead line in such a manner that the coil lead line is inserted into accommodating grooves of an insulator, a roller support section that rotatably supports the insertion roller, and a bending unit that performs a bending process to bend the coil lead line by coming into contact with the coil lead line so as to form a terminal part.

A stator manufacturing apparatus is equipped with spindles as twisting and bending jigs, an inner guide having a first supply flow path and a suction flow path formed in the interior thereof, and an outer guide having a second supply flow path formed in the interior thereof. Further, the spindles have receiving members in which insertion recesses are formed. Through holes are formed in the receiving members, and the receiving members are formed with lateral holes therein which allow the interiors of the insertion recesses to communicate with each other.

A displacement sensor has a magnetic measuring transducer and at least two sensor units, which are arranged at different positions spaced from each other, the measuring transducer being slidably mounted relative to the sensor units. The measuring transducer is magnetized such that it has a magnetic field which rotates at least partially about an axis of rotation along the measuring transducer, and the axis of rotation of the magnetic field runs parallel to the sliding direction of the measuring transducer. The sensor units are designed to each sense two magnetic measured variables proportionally to the magnetic field strength, both measured variables being sensed by both sensor units.

To enhance process reliability when processing wire ends during the course of a production of a machine element of an electric machine, a positioning and clamping device configured to position and clamp one or several wire ends for further processing during the course of the production of the machine element of the electric machine, comprises a capturing device for capturing and positioning the at least one wire end, wherein the capturing device has at least one oblique guide for the relative positioning of the at least one wire end. Furthermore, a corresponding clamping and positioning method is described.

The invention relates mainly to a method for producing a wound stator (1), including: a step of preparing a phase winding; an insertion step which includes inserting the phase winding into a corresponding series of notches (5) in said stator (1); and an intermediate step of forming lead out wires of the winding (26) each extending between two notches (5) of each series of the inserted phase windings, by applying a first radial force (F1) from an axis (X) of the stator (1) toward the outside of the stator (1), wherein the method also comprises a step of positioning a bearing surface facing at least one notch (5) such as to apply a second radial force (F2) resulting from the application of the first force (F1) from the outside toward the axis (X) of the stator (1).