A stator has a stator coil provided on an annular stator core. The stator coil is formed of electrical conductor wires each including an electrical conductor and an insulating coat. Each of the electrical conductor wires has a pair of exposed portions where the electrical conductor is exposed from the insulating coat and a covered portion where the electrical conductor is covered with the insulating coat. The pair of exposed portions are formed respectively at opposite end portions of the electrical conductor wire. The covered portion is formed at other portions of the electrical conductor wire than the end portions. At a coil end part of the stator coil, each corresponding pair of the exposed portions of the electrical conductor wires are welded together and each of the covered portions of the electrical conductor wires includes a coat-removed portion where the insulating coat is locally removed from the covered portion.

A casting coil for a motor assembly, which is formed in a multi-layer structure, includes: a first coil formed to extend in one direction; a second coil bent to extend from an end of the first coil; a third coil bent to extend from an end of the second coil in a direction parallel to the first coil; and a fourth coil bent to extend from an end of the third coil in a direction parallel to the second coil. The first coil, the second coil, the third coil, and the fourth coil form one layer so that a hollow multi-layer structure is formed. A larger magnetic field can be formed by securing a slot filling factor of 50% or more of a stator in the same motor package.

A casting coil for a motor assembly, which is formed in a multi-layer structure, includes: a first coil formed to extend in one direction; a second coil bent to extend from an end of the first coil; a third coil bent to extend from an end of the second coil in a direction parallel to the first coil; and a fourth coil bent to extend from an end of the third coil in a direction parallel to the second coil. The first coil, the second coil, the third coil, and the fourth coil form one layer so that a hollow multi-layer structure is formed. A larger magnetic field can be formed by securing a slot filling factor of 50% or more of a stator in the same motor package.

In a method for mounting a prefabricated form-wound coil or tooth-wound coil on a layered laminated core to form a stator segment or stator, the form-wound coil or tooth-wound coil is insulated with insulation. Laminates are punched and stacked to form partial laminated cores and/or a laminated core, with the partial laminated cores being spaced apart from one another by spacers and forming substantially axially extending open slots of the laminated core. The form-wound coil or tooth-wound coil are radially inserted into the slots such as to embrace a tooth of the laminated core, and a removable auxiliary element is placed at an axial end face of the laminated core to protect the insulation of the form-wound coil or tooth-wound coil as the form-wound coil or tooth-wound coil is radially inserted into the slots. The auxiliary element is radially removed and repositioned on a further tooth of the laminated core.

In a method for mounting a prefabricated form-wound coil or tooth-wound coil on a layered laminated core to form a stator segment or stator, the form-wound coil or tooth-wound coil is insulated with insulation. Laminates are punched and stacked to form partial laminated cores and/or a laminated core, with the partial laminated cores being spaced apart from one another by spacers and forming substantially axially extending open slots of the laminated core. The form-wound coil or tooth-wound coil are radially inserted into the slots such as to embrace a tooth of the laminated core, and a removable auxiliary element is placed at an axial end face of the laminated core to protect the insulation of the form-wound coil or tooth-wound coil as the form-wound coil or tooth-wound coil is radially inserted into the slots. The auxiliary element is radially removed and repositioned on a further tooth of the laminated core.

A system for mounting a motor temperature sensor includes: a hairpin wound stator including a stator core having a plurality of slots, and a plurality of hairpins inserted into the slots of the stator core; and a motor temperature sensor including a sensor element and a sensor housing covering the sensor element, wherein the sensor housing is detachably fitted into one of the plurality of hairpins.

A system for mounting a motor temperature sensor includes: a hairpin wound stator including a stator core having a plurality of slots, and a plurality of hairpins inserted into the slots of the stator core; and a motor temperature sensor including a sensor element and a sensor housing covering the sensor element, wherein the sensor housing is detachably fitted into one of the plurality of hairpins.

A bending unit for bending a bend of a wave winding for a coil winding of an electric machine, having a first holding element for holding a first segment of a wire to be bent, a second holding element for holding a second segment of the wire to be bent and at least one bending mold for bending a transition region of the wire between the first segment and the second segment. The first and the second holding elements are in engagement with each other via at least one mechanical control cam to control a relative pivoting and a relative displacement of the first and the second holding element. Furthermore, a bending device having a plurality of such bending units, a wave winding production apparatus having a plurality of bending units which are synchronized via control cams, and a bending method and a wave winding production method are described.

Stator for an electrical machine, comprising a stator core with stator slots which are formed along an axial direction with respect to a center axis of the stator and are arranged in a manner distributed in a circumferential direction with respect to the center axis, a hairpin winding with a large number of hairpin element arrangements which are arranged in the stator slots and each emerge from the end side of the stator core, and at least one insulation apparatus with a body in which a large number of passage openings which are arranged in a manner distributed in the circumferential direction are formed; wherein a respective hairpin element arrangement passes through one of the passage openings and the insulation apparatus specifies a distance of the hairpin element arrangement from an edge of the stator slot which receives the hairpin element arrangement.

Electric machines, such as motors, may include an armature and a field component, and at least one of the armature or the field component may include a laminated structure having a plurality of slots into which a plurality of conductive elements are positioned. Additionally, a polymeric insulation layer may be formed directly on the laminated structure at least within the plurality of slots.