Core slots are provided in an outer circumferential side of a rotor core and extend in an axial direction of a rotor shaft. A rotor conductor is a rod-shaped conductor inserted in each of the slots, and after insertion of the rotor conductor in each slot, a flared portion is formed flaring in a slot-transverse direction, and a propping-apart force occurring between the flared portion and both side wall surfaces of the slot fixes the rotor conductor to the slot. In an inner wall of an outer circumferential side of each slot abutting the flared portion, an unevenness is arranged along the axial direction of the rotor shaft.

A bending-forming jig used in bending and forming a protruding portion of a leg portion of a U-shaped conductor toward a circumferential direction, the protruding portion protruding from an axial end surface of a stator core, the bending-forming jig including a ring portion and a claw portion, the claw portion including a first abutting surface that rises from an axial end surface of the ring portion with the surface directed in the circumferential direction and abuts against a tip portion of the protruding portion from the circumferential direction, and a projecting portion that projects, at a tip end of the claw portion, in the circumferential direction from the abutting surface and abuts against the tip portion of the protruding portion from the axial direction toward the axial end surface of the ring portion.

A stator manufacturing apparatus includes an insertion tool that is insertable into a stator core and being configured to dispose a pair of side parts of a stator coil in two holding grooves. A pressing tool has plate-like pushers arranged to correspond to the positions of the holding grooves. The pressing tool pushes out the side parts of the stator coils and inserts the side parts into the corresponding slots. A pair of shaping tools face coil end parts of the stator coils. A plurality of slits through which the pushers are insertable are provided in a principal surface of each shaping tool. A shaping tool moving unit shapes the coil end parts by pressing the pair of shaping tools in an axial direction with the pushers inserted in each of the corresponding holding grooves.

A stator of a rotary electrical machine has a stator body formed by a stack of metal sheets. The stator body is delimited by inner and outer radial surfaces. Notches in the stator body extend axially. Each notch has a notch base and a notch opening, and the notch opening is on the side of the inner radial surface. A stator winding is supported by the stator body, and the winding has a plurality of winding parts. Each part is accommodated in one of the notches. Each of the notches at the notch opening has a closure element. Each winding par in a notch is retained between the notch base and the closure element. The closure elements are formed by offsetting at least one of the metal sheets of an adjacent notch in the direction of the notch.

Methods and system for creating spacing between insulated stator coils include a spacing device with an expandable container. The expandable container is positioned and expanded between stator coil end portions in order to create a space between the insulated stator coil end portions. Insulating elements are placed in the space created between the stator coil end portions, and the expandable container removed.

A method for manufacturing a wound rotor or stator having more than four poles, preferably a rotor, the rotor or stator having teeth provided with pole shoes. The method includes the following steps, for each pole: (a) producing a partial winding by winding at least one conductor over the portion of the tooth of this pole extending axially along this pole between the pole shoes of this pole and a plane (P.sub.min) at right angles to the axis of the pole and tangential to a pole shoe of an adjacent pole, (b) pushing back the duly produced partial winding towards the base of the tooth, and freeing said portion of the tooth having been used for the winding, and (c) repeating step (a) to produce another partial winding on the duly released portion of tooth.

A stator manufacturing apparatus includes an insertion tool inserted into a stator core, the insertion tool having a plurality of holding grooves formed on an outer periphery, the insertion tool being configured such that a pair of side portions of a stator coil are disposed in two of the holding grooves separated by a predetermined width; and a pressing tool having a plurality of plate-like pushers narrowed toward tips arranged on a pressing body in correspondence with the positions of the plurality of holding grooves of the insertion tool. The pressing tool is configured to push the pairs of side portions of the stator coils inserted in the holding grooves radially outwardly and insert the side portions into the corresponding slots. A recessed groove enabling grippers to be inserted when the stator coil is disposed using the grippers for gripping the pair of side portions is formed on the outer periphery of the insertion tool.

The present invention relates to a method for producing a stator which includes the steps of inserting a stator segment into a former; introducing a coil wire winding into a coil space of the stator segment, and out via a slot which is located in the region between two pole horns; cohesively connecting the turns of the coil at least partially, at least in parts of that region of the coil, which is located outside the slot; and removing the former.

A control device moves a split claw (11) holding a projecting portion (4d) of an eighth-layer coil segment (4) in a counterclockwise direction D1. At this time, the control device moves first to third extended blades (13a) to (13c) in an outward direction D3 so that the projecting portion (4d) of the eighth-layer coil segment (4) is bent in the outward direction D3. Then, the control device moves the first to third extended blades (13a) to (13c) in an inward direction D4. Through the above steps, the projecting portion (4d) of the eighth-layer coil segment (4) is bent in the counterclockwise direction D1 while being bent in the outward direction D3. As a result, a return force tending to return in the inward direction D4 is generated by an elastic deformation force.

A coil end bending jig pushes down a plurality of coil ends of coil segments held by a toric stator core, the plurality of coil ends being arranged on a same circumference. The coil end bending jig includes a plurality of bending units each having a bending tooth that makes contact with a corresponding one of the coil ends, and a guide member having a plurality of guiding slits into which the plurality of bending units is inserted, respectively. The plurality of guiding slits extends from an inner peripheral side of the stator core to an outer peripheral side of the stator core so as not to intersect with each other when viewed from an axial direction of the stator core.