A stator manufacturing method that includes a lead wire bending process of inserting a plurality of concentrically wound coils into slots, each of the concentrically wound coils being formed by winding a flat conductive wire for a plurality of turns, each of the slots being formed between every two adjacent teeth extending radially inward from an annular back yoke of a stator core, and bending lead wire portions of the inserted concentrically wound coils projecting in an axial direction from an end surface of the stator core, and a second bending process of bending the lead wire portions using the connection parts as fulcrums so that the lead wire portions approach the end surface of the stator core along the circumferential direction of the stator core after the first bending process.

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 for an electric motor may have a substantially annular shape centered around a central axis and may include a stator core having a plurality of teeth consecutively arranged in a circumferential direction, and a plurality of coils wound around respective teeth of the plurality of teeth. The plurality of coils may be grouped into a plurality of phase groups. The stator may include in association with the respective phase groups: at least one loop wire connecting at least two coils of the respective phase group in series with each other with the at least one loop wire being positioned at a radially inner portion of the stator, and at least two end wires respectively connected to two end coils of the respective phase group. The at least two end wires may be configured to be connected to a power source to energize the coils of the respective phase group.

A method of installing a winding in a stator includes forming a first multi-conductor winding including a first plurality of terminal leads and a second plurality of terminal leads, forming a second multi-conductor winding including a third plurality of terminal leads and a fourth plurality of terminal leads, introducing the first multi-conductor winding into a plurality of stator slots of a stator body, introducing the second multi-conductor winding into the plurality of stator slots of the stator body radially inwardly of the first multi-conductor winding, and connecting the second plurality of terminal leads with the third plurality of terminal leads to form a twelve conductor stator winding.

According to one embodiment, in a stator, bridge parts of seventh coil segments extend in a direction departing from one end surface while being inclined at a predetermined inclination angle from an axial direction of a stator core to the outside of a radial direction. Regarding the bridge parts of the seventh coil segments adjacent to each other in the radial direction of the stator core, when the same cross-sections defined by the radial direction and the axial direction is viewed from a circumferential direction of the stator core, a first inclination angle of the bridge part positioned relatively in an inner side of the radial direction is smaller than a second inclination angle of the bridge part positioned relatively in an outer side of the radial direction.

An active part of an electric machine includes a plurality of coils, each having a sub-conductor. The coils are formed by windings of the sub-conductors thereof. The windings of a coil each have a predetermined winding length. In addition, the active part has a carrier part, in the grooves of which, the coils are arranged. The coils have a winding head region which projects from an end surface of the carrier part. The coils are also arranged in the form of a tiered winding. At least one of the coils has a V-shaped cross-section in the winding head region, as a result of an arrangement of its sub-conductor.

Rotating electric machine provided with an axis X. The machine comprises a front part and a rear part. The machine comprises a rotor of axis X comprising two axial end surfaces, each provided with fan blades. The axial surfaces located on the side of the front part and on the side of the rear part. A stator comprises a stator body having slots. The stator comprises a winding installed in the slots and forming a front winding head and a rear winding head. The rotor and the stator are placed in a casing. The front winding head completely masks the blades of the axial surface located on the front side of the machine, along a direction perpendicular to axis X.

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.

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.

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.