A coil insertion device includes coil diameter expanders, the coil diameter expanders being configured to insert a coil assembly in a wound state into slots of a stator core by expanding the coil assembly in diameter from inside of the stator core, each of the coil diameter expanders includes: a coil presser that is arranged inside the coil assembly and presses coil end portions of the coil assembly outward from inside to expand the coil end portions in diameter; and a restrictor that is arranged outside the coil assembly, restricts outward movement of the coil end portions expanded in diameter by the coil presser, and sandwiches the coil end portions of the coil assembly inserted in the slots with the coil presser.

A device for deflecting a coil includes a preformed body including a first portion configured as a circular arc to rest on the coil for bending, and a second portion adjoining the first portion and configured as a chord to rest on the coil for bending, wherein the first portion and the second portion are interchangeable.

A stator (1, 10) for an electric motor is disclosed. The stator includes a laminated stator core (2, 11) and a plurality of hairpin-like elements (3, 12) of a metallic material, the plurality of hairpin-like elements having two longitudinal legs (4, 13) and a connecting section (5, 14) between the longitudinal legs (4, 13). The laminated stator core (2, 11) has a plurality of slots (6, 15), wherein each of the longitudinal legs (4, 13) of the hairpin-like elements (3, 12) is received in a slot (6, 15), wherein the connecting sections (5, 14) of the hairpin-like elements (3, 12) form an annular region (7, 16), wherein the hairpin-like elements (3, 12) each define a plane (18, 19) with their two longitudinal legs (4, 13), wherein the connecting section (5, 14) of the respective hairpin-like element (3, 12) is tilted out of the plane (18, 19).

The invention relates to a stator (100) for an electric machine having a stator core (102) and at least one winding (110) which has a winding head (120) protruding axially beyond the stator core (102), wherein the winding head (120) comprises portions of the winding which form reversals of the winding wires, winding connection lines (126) for energizing the winding (110) and at least one radially outwardly arranged first set of winding portions (127) and one radially inwardly arranged second set of winding portions (128) spaced apart from the first set, wherein the portions of the winding connection lines (126) each run in the circumferential direction, do not protrude axially beyond the first (127) and the second (128) sets of winding portions and are arranged radially between and fixed by the first (127) and the second (128) sets of winding portions. The invention also relates to a method for producing such a stator (100) and to an electric machine having such a stator (100).

Disclosed are various embodiments for winding heavy gauge coils of electric machines having fractional concentrated windings including one of more of positioning the middle of a predetermined length of heavy gauge wire in contact with an inclined chamfer in a face of a center projection of a fixture tool, simultaneously bending both ends of the heavy gauge wire in a first direction using the center projection to compete the first turn of the coil, simultaneously bending both ends of the heavy gauge wire in a seconding direction using the center projection to complete a second turn of the coil; continuing to simultaneously bend the heavy gauge wire in the first direction and the seconding direction until the required number of even or odd turns are completed, removing one of the adjoining right-angle faces of the fixture tool; and sliding the coiled heavy gauge wire off of the center projection.

Provided are an alignment method and an alignment device by which, immediately before aligning, the leg parts of adjacent conductors do not interfere with each other. The alignment method, in which by providing a plurality of coil elements (40) in an annular shape and moving the plurality of coil elements (40) in a direction in which the diameter of the annular shape is reduced, the plurality of coil elements (40) are aligned in a state where turn sections (42) provided at substantially apex portions are alternately overlapped, wherein the plurality of coil elements (40) are aligned by moving each of the plurality of coil elements (40) toward an annularly shaped center, and while doing so, rotating the plurality of coil elements about a rotation axis (231e) that is parallel to the central axis (C1) of the annular shape.

The method for manufacturing an armature includes a step of independently pressing pressing-target segment conductors by a plurality of pressing jigs disposed for each of the pressing-target segment conductors, such that the plurality of pressing jigs are movable relative to each other, at least either one of first segment conductors and second segment conductors serving as the pressing-target segment conductors.

A winding head for a stator tooth of an electric motor is provided. A stator core has a first stator flange and a second stator flange that are joined by a stator joint part. The stator core has an I-shaped cross section perpendicular to a longitudinal elongation with a first end and a second end. The winding head is configured to extend the longitudinal elongation at the first end. The winding head has a first winding head flange and a second winding head flange that are joined by a winding head joint part, and the winding head extends at least partially an elongation of a shape of the stator core. The winding head also has a winding hole at the first winding head flange and a winding opening at the winding head joint part. The winding hole and opening are connected by a groove in the winding head joint part.

Various embodiments include a method for twisting a winding head of a stator. The stator has a hollow cylindrical core with a slot on the inner surface extending between the end faces. The method includes positioning two conductors in the slot, so an end section of each conductor extends over the first end face; arranging a winding core with a cam protruding outward on the stator core; and twisting the end section of the first conductor in a peripheral direction, wherein the end section of the first conductor moves over the cam, bending a part of the end section of the first conductor in the radial direction defined by the stator core enlarging a distance between the end section of the first conductor and the end section of the second conductor measured in the radial direction of the stator core.

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.