The invention relates to a method for producing a semi-finished product of a stator (1), wherein the method comprises the following method steps: providing a laminated core (2), wherein the laminated core (2) has a plurality of receiving grooves (5) distributed in a circumferential direction; providing a plurality of conductor elements (3, 4); inserting the conductor elements (3, 4) into at least some of the receiving grooves (5), wherein the conductor elements (3, 4) are inserted into the receiving grooves (5) in such a way that conductor element overhangs (11, 12) of the conductor elements (3, 4) protrude beyond at least one of the axial end faces (7, 8) of the laminated core (2) in the axial direction; bending the conductor element overhangs (11, 12) in the radial direction (22); bending the conductor element overhangs (11, 12) of the conductor elements (3, 4) in the circumferential direction (16, 17).

A coil manufacturing device for manufacturing a coil by rotating a winding core and winding a wire around the rotating winding core, the coil manufacturing device includes a recess formed in the winding core, the recess being configured to suspend the wire wound around the winding core in the recess; and a wire bundling device configured to bundle the wire suspended in the recess.

A rotor cap for an electric generator, e.g., a high-speed turbogenerator, is disclosed, along with a production method for such rotor cap. The rotor cap is at least partially made of fiber-reinforced plastic material. The rotor cap may have cooling fluid passages, e.g., extending in an axial direction, in the area of the fiber-reinforced plastic material.

A coil segment, in particular for a stator coil, wherein the coil segment has a conductor bundle, wherein the conductor bundle has a multiplicity of electrical conductors, wherein the conductor bundle has a form fit, wherein the conductor bundle has at least one cutout for feeding coolant. Furthermore, a method for manufacturing a stator coil, a stator coil having a coil segment according to the present invention, a machine having a stator coil according to the present invention, and a vehicle having a machine according to the present invention.

The invention relates to a method as well as a device for positioned holding of at least one layer (9, 10) of several conductor elements (3, 4) arranged distributed over the circumference of a laminated core (2) and formed as bars in relative position with respect to the laminated core (2) accommodating the conductor elements (3, 4) in each case in a receiving groove (5) extending between a first front face (7) and a second front face (8). For this purpose, all conductor elements (3, 4) of the at least one layer (9, 10) are each acted upon at their end portions (11, 12; 13, 14) protruding beyond the laminated core (2) by at least one pressure element (21, 22), which is adjustable in the radial direction, of a pressure device (20). The laminated core (2) is held in position by a holding device (17).

The invention relates to a method as well as a device (16) for the positioned holding of a laminated core (2) including at least one layer (9, 10) accommodated in the laminated core (2), which layer is made up of several conductor elements (3, 4) arranged spread over the circumference of the laminated core (2) and configured as rods for forming a stator or a rotor of an electric machine. The first front face (7) of the laminated core (2) comes into flush contact with first stop faces (21) of first support elements (20) and the first support elements (20) are readjusted into open spaces between the conductor elements (3, 4). The second stop faces (23) of second support elements (22) then come into flush contact with a second front face (8) of the laminated core (2) and the second support elements (22) are also readjusted into the open spaces between the conductor elements (3, 4). This allows for the laminated core (2) to be held in a positioned manner.

The coil ends in a rotating electric machine are to be made smaller in size. A stator coil 60 inserted into a slot 420 in a stator of a rotating electric machine is formed with segment coils 28 connected to one another. In the stator coil 60, the segment coils 28 each include an insulating coated portion coated with an insulating coating, and a slit 900 or a recess is formed in the insulating coated portion of each of the segment coils 28 at a coil end 140. The slit 900 or the recess is preferably formed between a diagonal conductor portion 28D and a conductor-end straight portion 28E of each segment coil 28.

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).

A stator coil forming method includes a bending step of bending portions of a linear lead wire so as to form bent portions; a cutting step of cutting curve parts of the bent portions thus formed, along a perpendicular plane that is approximately perpendicular to an extending direction of the lead wire so as to form coil segments; a U-shape forming step of bending the coil segments in a U-shape; an assembling step of assembling the coil segments to respective slots of a stator core; a tilting step of tilting both distal ends of the coil segments in a circumferential direction of the stator core so that cut surfaces of the distal ends are oriented toward a central-axis direction of the stator core; and a joining step of joining the distal ends of the coil segments adjacent to each other in a radial direction of the stator core.

Provided is a stator manufacturing method including: inserting a plurality of segment coils into a plurality of slots formed in a stator core; bending arms of the segment coils that protrude from the stator core, in a circumferential direction of the stator core; before or after bending the segment coils in the circumferential direction, directing parallel to each other leading end portions of the segment coils that are adjacent to each other in a radial direction of the stator core; and welding together the leading end portions of the segment coils with the leading end portions directed parallel to each other.